Welding BLOG
GeKa Seamless Flux Cored Wires
What is Seamless Flux Cored Wire?Flux Cored Wires can be produced in two different ways as seamed and seamless. Seamed cored wires are produced by first rolling/forming the steel strip into a "U" shape in the forming machine as in the production of welded pipes and then putting the powder-mix “core” into it and then closing it into a pipe form and drawing it. On the other hand, seamless cored wires are produced by filling the core into a previously formed steel pipe and drawing it to the desired end-product diameter. With the advancement of technology, a faster and more efficient seamless cored wire production process has been developed. In this method, the core is filled into the U-shaped strip as in the production of seamed cored wires, then the strip is rolled into a circular form and the edges are welded seamlessly with a laser beam. Since there is no gap in the seamless cored wires, contrary to the seamed cored wires, the risk of moisture absorption of the core is automatically eliminated. TYPES OF FLUXCORED WELDING WIREWhat are the advantages of Seamless Cored Wire?In Seamless Cored Wires, the risk of hydrogen-induced cracks is minimized as the seamless design prevents re-absorption of moisture. Since seamless cored wires have very low moisture contents in the core and it is virtually impossible to pick up moisture under normal storage and operation conditions, the need for special vacuum packaging is eliminated.Another advantage of Seamless Cored Wires is the possibility of copper coating. Copper coating protects the wire surface against corrosion, prevents friction in the passage through the liner and contact tip during welding and greatly enhances wire feedability. Finally, thanks to the copper coating, the electrical resistance between the wire and the contact tip is considerably low, resulting in a much more stable arc, cooler contact tip and nozzle, thus in turn, reducing nozzle wear and cooling requirements.Since the production of Laser Welded Seamless Flux Cored Wire requires a distinct technology, knowledge, know-how and experience, the number of companies in the world that can offer products with premium quality still is very limited. Gedik Welding is proud to be the only leading and pioneering company in this field in Turkey and has taken its prestigious position in global competition to a higher level.
GeKaWeldSim Realistic Welding Experience
GeKaWeldSim Welding simulators based on Virtual or Augmented reality (VR or AR) system are systems that provide an extremely close to reality welding experience consisting of welding machine, welding mask, welding table, welding electrode holders in original shapes and weights, MIG / MAG and TIG torches. The systems, which can simulate the welds made in different welding methods one-to-one, detect and analyze the errors made during welding, are especially preferred for training purposes in educational institutions and industrial enterprises that want to train welders.Since there is no consumption of consumables and main materials to be welded in welding simulators, training costs are minimized, while occupational safety risks that may occur during training are eliminated.With Welding Simulators, Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW-GTAW), Flux Cored Arc Welding (FCAW) processes can be simulated in full detail. Parameters such as feed speed, feed angle, working angle, arc length distance, position, distance between the contact nozzle and the workpiece can be monitored live on the analysis screen, while welding defects such as insufficient penetration, slag inclusion, burning groove, porosity, poor drop placement, excessive convexity / concavity, incorrect weld size, excessive spatter can be monitored and reported together with their location on the seam, providing a detailed performance analysis.
Smart choice for Underwater
SMART CHOICE FOR UNDERWATER In recent years, more than 50 percent of developed oil deposits and natural gas pipelines are located under the sea, increasing offshore development to develop and exploit mineral resources. Underwater welding plays a special role in the maintenance and repair of modern offshore installations, pipelines and ships. The large amount of underwater structures used in oil and gas production and the increasing intensity of maritime transportation constitute the technological cornerstone of economic development and strategic issues. Gedik Welding has produced Turkey's first domestic underwater welding electrodes as a product of its long years of knowledge and experience in the welding industry. These electrodes have been designed and formulated to produce welding metal with unrivaled, high-performance standards in the field for structural underwater wet welding in all sectors, including offshore oil and gas pipelines, commercial vessels, coastal industries and nuclear facilities. It is available for assembly and repair welding in water depths up to 20 m for offshore and harbor construction, shipbuilding and underwater engineering.Meets Class A Source CriteriaMetal arc welding with covered electrodes with rutile character is the most common underwater welding method used. GeKa UW E7014 is a rutile covered electrode developed for underwater welding with a waterproof coating. AWS A5.35/A5.35M: 2015 standard requirement and AWS D3.6M:2017 Class A quality level. A premium underwater welding electrode with excellent properties that fulfills the "Class A" welding criterion in all positions for both inside fillet and butt welds of pipe and sheet joints according to the international AWS D3.6M:2017 standard. The electrode consists of a specially formulated high efficiency rutile coating that offers a continuous weld seam.Waterproof CoatingThe electrode cover needs to be protected from the water environment by a waterproof coating. In order for underwater welding electrodes to provide high quality weld metal, the waterproof coating is expected to prevent moisture from penetrating the electrode cover, while at the same time allowing it to burn without undue interference with metal transfer. The waterproof coating protects the electrode cover from water and moisture. It also provides the highest level of protection against physical damage to the electrodes, while providing electrical protection for the diver underwater. The soft breakable electrode tip prevents contact of the electrode cover with water, even if it has to remain underwater until welding. Thus, the electrode continues to retain its rutile cover properties during welding. GeKa UW E7014 electrodes are comfortable to use in both fresh and salt water, perform exceptionally well in any position and are specially designed to produce high quality welds at different depths on a variety of carbon steels. With its outstanding user-friendly features and enabling long working times underwater, GeKa UW E7014 is destined to become the electrode of choice for professional welders worldwide. More stable burning and less spatter during welding than other underwater welding electrodes. Easy slag cleaning for the welder. The electrode is easy to re-ignite and the molten metal deposition rate is highly efficient and excellent seam appearance is achieved.Effective and fast solutionInternational interests to develop and exploit the oceans and their mineral resources have allowed the development of offshore gas and oil fields, offshore construction and hence underwater resource development. Underwater welding has been used for construction and maintenance work, but mostly for temporary repair work. Failure of parts underwater can be caused by collisions of ships, unexpected accidents or corrosion. Underwater welding is an effective and fast solution as it can be done immediately after the accident without the need to remove the structure from the water. Underwater welding is also applied in the manufacture of large ships and offshore structures that do not fit into the dock. Underwater welding is also applied to the installation and maintenance of pipelines. GeKa UW E7014 electrodes are available in Ø3,20 and Ø4,00mm. Welding should be performed in accordance with the parameters specified in the catalog.Protective equipment and diving equipment in accordance with occupational safety rules must be used before all stages of use. The most important issue in underwater welding is the availability of welding and welding safety equipment. Due to the high safety risks, great importance and responsibility for carrying out these activities lies with trained human resources, including surface divers and the organizational team. GeKa UW E7014 electrodes are designed to be used in all positions, even for less experienced divers. At the same time, in the hands of more experienced divers, welding can be performed allowing a friendly, controllable arc characteristic. Welding pliers and torches should be as insulating as possible, allowing as little current to escape as possible. Attention should be paid to the angle and height of the grip in welding due to the effect of pressure under water. Attention should be paid to the applicability and accuracy of welding positions.
Laser Welding Technology: Fast, Efficient and Environmentally Friendly
Fast and Efficient: The Power of Laser Welding Technology!Laser welding technology, which is rapidly increasing in use due to its fast and efficient compared to conventional welding methods, enables welding and cutting with low heat input and minimal deformation.Easy to Use, No Professional Knowledge Required: Laser Welding AdvantagesIt is very easy to use and eliminates the need to be an experienced welder as it does not require professional knowledge and experience to weld. The fact that it is much faster than traditional welding methods is one of its salient features.Environmentally Friendly and Energy Efficient: The Environmental Contribution of Laser WeldingThe laser's photoelectric conversion efficiency results in up to 30% less energy consumption and is therefore environmentally friendly. Thanks to the very low heat input in the laser welding process, penetrating, deformation-free and resistant welds can be obtained even in the thinnest materials.Fiber laser welding machines, which are available in our product range with 3 different power options as GeKaLaser 1000, GeKaLaser 1500, GeKaLaser 2000, offer the possibility of cutting and cleaning as well as joining various materials such as unalloyed steel, stainless steel, aluminum, copper, brass with the 3IN1 feature, while eliminating additional labor costs as there is no need for leveling and grinding processes after welding with continuous welding mode.Precise Solutions for Different SectorsOur GeKaLaser Laser Welding machines offer precise solutions in many applications and sectors such as industrial kitchen manufacturing, furniture shelf and scaffolding manufacturing, machinery manufacturing, railing and window manufacturing, advertising and lighting sector, automotive, medical, aviation sector.
Brazing with Oxy Gas Flame
What is Brazing, How Is It Done?The joining of different or same type metals with a heat source using an additional solder alloy that melts above 450 °C is called brazing. The joining process takes place with the metallurgical bond formed by the transfer of atoms called diffusion between the additive metal and the metals to be combined.Where is Brazing Used?The brazing process allows the economical joining of different types of materials with different cross-sectional thicknesses. Therefore, it is preferred in many sectors such as automotive, white goods, aviation and space industry, heating-ventilation, gas armatures production, food sector, and medicine sector. It is also widely used in pipe connections carrying oil, air and fuel where impermeability is important.In brazing joints, in the metals to be joined, unlike welding, melting does not occur. Since there is no significant change in the crystal structure of the material, the homogeneity of the internal structure of the metal is preserved. As the brazing temperature is above 450 °C and lower than the melting temperatures of the soldered metals, deformations caused by high temperatures do not occur in the welded joints.The molten metal solidifies by spreading between the parts to be brazed by capillary action (with capillary tube forces). It is recommended that in order to take advantage of the capillary effect, the spacing of the parts to be brazed should be set between 0.05-0.5 mm. In larger soldering intervals, the capillary effect cannot be benefited from. All elements that will prevent the attachment and flow of the additive metal between the material surfaces to be joined should be removed before the brazing process. Elements such as oil, rust, and paint on the material surface cleaned by brush, sandpaper or suitable chemical methods should be taken to the brazing process without waiting for too long.When the brazing process of the surface-cleaned materials is started, oxide formation starts on the surfaces due to the heat. Fluxes are used to prevent and clean this oxide formation. Fluxes melt 50 °C before the operating temperature, increasing the fluidity of the additive metal while cleaning the oxide.The selection of fluxes that prepare the melt joint zone for brazing before the filler metal is made according to the filler metal. While GeKaTec FLUX F-SH1 fluxes are used for the use of silver alloy brazing rods, it will be appropriate that GeKaTec FLUX F-LH1 fluxes are preferred for brazing aluminum and its alloys. The selection of these related fluxes is determined by the melting temperatures of the materials to be brazed.Self-flux coated brazing rods such as GeKaTec L-Ag20 FC or GeKaTec L-Ag40 FC provide convenience to the user in practice. In addition, since GeKaTec S5 brazing rods, which are frequently preferred, have very high fluidity, they can be used without flux in joining copper to copper.In the selection of the additive metal, it is desired that the melting point of the main metal be at least 200 °C higher than the melting point of the additive metal. Color compatibility can also appear to us as an important criterion in the selection of additional filler materials that are expected to match the mechanical properties of the main material to be brazed.Flame Types in Oxy-Gas Flame BrazingNeutral Flame: It is the type of flame in which the ratios of combustible gas (acetylene) and oxygen are equal. It is generally preferred for brazing metals such as steel and copper.Carburizing Flame: Flames with high flammable gas ratio are called carburizing flames. Its burning is calmer. Its flame cone is longer than normal flame. It is preferred in brazing of cast irons, in order to prevent oxygen content in brazing of aluminum and its alloys, the surface of which is easily oxidized.Oxidizing Flame: It is the type of flame with high oxygen ratio. Its burning is harsh. The highest temperature values are reached in this type of flame. It is used for brazing brass having zinc evaporation problem.
Tungsten Electrode Selection
What is Tungsten Electrode?Tungsten electrodes, which ensure the welding process on the workpiece by carrying the current required for arc formation, stand out among the components in TIG welding. The selection of tungsten electrodes, which vary in current carrying capacity, arc characteristics, service life, re-ignition performance with different alloys, is important for welding performance.Where Is Tungsten Electrode Used?Tungsten electrodes, which are indispensable components of TIG welding, can be used for TIG welding of unalloyed and low alloyed materials, stainless and aluminum, depending on their types. Parameters such as the type of material to be welded and the type of current to be used in welding are important in their selection.Tungsten Electrode Types and their PropertiesGreen (Pure) Tungsten ElectrodesWhile unalloyed, pure tungsten electrodes have advantages over other types of tungsten electrodes in terms of cost, they are used especially in TIG welding of aluminum and magnesium alloys. These electrodes with high arc stability are used with AC current.Gray (2% Cerium Alloy) Tungsten ElectrodesCerium alloy electrodes are particularly used for welding unalloyed and stainless steels. It can be used in both DC and AC current type. While it is more preferred to be used in DC current, it has approximately 35% more current carrying capacity than pure tungsten electrodes in AC current.Although its service life is long, its ignition and re-ignition performance is quite high.It is not radioactive. Therefore, it is more environmentally friendly than Thorium alloy tungsten electrodes.Gold (1.5% Lanthanum Alloy) and Blue (2% Lanthanum Alloy) Tungsten ElectrodesLanthanum alloy tungsten electrodes, which provide very high performance especially at low current values, are called Gold and Blue Tungsten Electrodes according to the amount of lanthanum they contain. Lanthanum alloy tungsten electrodes are not radioactive. Their service life is long and their re-ignition performance is high.Lanthanum alloy tungsten electrodes, which are good for use in automation welding, are suitable for use in both AC and DC currents. It is preferred for welding of unalloyed and stainless steels.Red Tungsten (2% Thorium Alloy) ElectrodesWhile it has a very high current loading capacity thanks to the thorium it contains and is highly resistant to oxidation and pollution. They are easy to ignite and form a more stable arc.Thorium alloy electrodes contain a low amount of radioactive material. It is important for users to pay attention to the points in the SDS form of the product.They are mainly used with DC current. Their service life is long. It is generally preferred for welding carbon steels and stainless steels.
Welding of Tool Steels
What are Tool Steels, What are their Types?Tool steels are steels with high hardness, toughness or high temperature resistance used in shaping a wide variety of materials by processes such as machining, cutting, drilling, pressing, casting, and forging. It is divided into four groups as cold work tool steels, hot work tool steels, plastic tool steels, and high-speed tool steels:Cold Work Tool Steels: Tool steels used in applications below 200 °C are in this group. Abrasion wear is often encountered on tools. The hard wear resistant carbides required for steels are usually provided with chromium, molybdenum, vanadium, and tungsten. Threading tools, scissor knives, cutting tools, bolt head forging tools, and deep drawing tools can be given as examples to this group.Hot Work Tool Steels: They are tool steels used at temperatures above 200 °C. High temperature resistance is provided by elements such as molybdenum, tungsten, and vanadium. Forging dies, forging tools, casting dies, continuous casting rolls, hot cutting blades, and hammering dies, can be given as examples for hot work tool steels.High Speed Tool Steels: They are tool steels that can remove chips by maintaining their hardness even at high temperatures, in a way that the end of the tool will be hot. In addition to adding elements such as tungsten, molybdenum, and vanadium chromium to the material, hot rolling and special heat treatment suitable for the material should be applied for homogeneous distribution of carbides in order to give the material the desired strength at high temperatures. Cutting and drilling tools that maintain their hardness even at 600 °C can be given as an example for this group.Plastic Work Tool Steels: They are generally used in shaping plastics by injection, extrusion, blowing, and pressing techniques. Compared to other tool steels, they have higher corrosion resistance, polishability, and patterning capabilities. They contain alloying elements such as chromium, manganese, molybdenum, nickel, vanadium, and aluminum.How to Perform the Welding of Tool Steels?Steels containing more than 0.2 percent carbon have low welding capability. Welding of tool steels with a carbon ratio of 0.8 - 1.5% is a very difficult process due to the high risk of cracking. Hence, repair and maintenance welding are applied in tool steels rather than joining. Welding is mainly applied in processes such as hard facing applications of worn surfaces and repair of cracks, except for the joint welds made for the revision of the mold due to the design change and the obligation of combining the prepared parts into a mold.Preliminary Preparation: It is important to control and prepare beforehand the surface of the part before the welding application of the tool steels. Surface cleanliness should be checked and factors such as oil and dirt have to be cleaned before application. Whether there are cracks on the surface of the part or not should be examined visually or with a penetrant test and, if there is any crack formation, it must in any case be cleaned by intervening before welding. “U” welding end should be preferred in welding end design.Preheat: It is important to preheat before welding. Preheating reduces the risk of warping and cracking by reducing the cooling rate. The preheating temperature should be below the tempering temperature of the tool steel and 50-100 °C above the martensitic transformation temperature of the weld metal to be used. During welding, the weld zone should always be kept within this temperature range. Preheating temperature is recommended as 200-300 °C for tool steels made of low alloy steels, 300-400 °C for tool steels made of high alloy steels, 400-600 °C for hot work tool steels, and 400-500 °C for high-speed tool steels. Heating should be slow and homogeneous. The recommended heating rate is 50 °C/hour.Welding Application and Selection of the Filler Material In the welding of tool steels, attempts must be made to keep the heat input low. Welding methods with low heat input such as TIG should be preferred, and if electric arc welding is to be applied, electrodes with as small diameter as possible should be used. It is recommended to weld by using minimum voltage and current parameters in all welding methods.After each pass, the slag cleaning should be performed carefully and lightly hammered while the seam is hot. Slow cooling of the seam after welding is important.Sharp corners and edges should not be allowed to form after welding. Crater formation should be prevented at the end of welding.In hard filling applications that require multiple passes, the number of passes should not exceed 3. Buffer welding can be applied between the base material and the hard filling application.GeKatec 229 SUPER electrodes can be used for buffer welding or GeKa Elox SG 312 MIG or TIG wires for gas metal arc welding applications.In tool steel welding applications, the chemical composition of the tool steel, the heat treatment condition, and the desired hardness value if hard filling is to be applied, play an important role in the selection of the filling material. In normalized tool steels, the chemical composition of the filler material is desired to be the same as that of the tool steel, while in hardened tool steels, the properties such as hardness and temperature resistance of the weld metal are expected to be similar.While GekaTec Tool 60 electrode is used in hard filling applications of cold work tool steels, very satisfactory results are obtained with GeKatec Tool 55 SG and GeKatec Tool 60 SG arc welding wires and rods. The welding filler of GekaTec Tool 60 electrode and GeKatec Tool 60 SG arc welding wires and rods are in the structure of speed steel and are also preferred in hard filling applications of high-speed steels. GeKatec Tool 45 SG welding wire, which is used in filler welding of hot work tool steels, provides very good resistance to abrasion and impact at high temperatures.
Cored Wire Uses and Advantages
What is cored wire and what are its uses? The use of cored wires, which are produced by forming steel strips into a pipe form and filling them with various chemicals in powder form, is becoming widespread in many sectors fast. The use of cored wire for different methods such as joining, hard facing, repair, and maintenance welding has begun to prevent the use of solid wire and electrodes.So, why are cored wires, which have relatively higher prices, started to be preferred more than traditional methods? Let us try to scrutinize the prominent features of the method such as the advantages it provides in reducing the total production costs, the quality of the weld and weld metal deposition rate.Advantages of Cored Wire Compared to Solid Arc Welding WiresThe higher weld metal deposition rates provided by cored wires compared to solid wires directly affect manufacturing times. Low burr formation despite high deposition rate reduces the labor costs required for burr cleaning after manufacturing. In addition, the cored wires, which provide larger droplet weld metal transfer, provide excellent penetration for the weld surface sidewalls.One of the most important advantages of cored wires over solid wires is that they allow welding in all positions. Penetration welds can be carried out at high welding speeds with the use of cored wire, even in processes where the control of the weld pool is difficult, such as overhead and vertical welding positions.Advantages of Core Wires Compared to Covered ElectrodesThe cored wire technology, which has rapidly replaced the use of welding electrodes, stands out particularly with its production speed and efficiency advantages. In the welding electrode application, the stops that occur at the end of each electrode due to the nature of the work are eliminated by the mechanized cored wire welding method used with a gas metal arc welding machine.The unusable waste that occurs at the end of the electrode while welding with the electrode is also a negative point for production efficiency.As the weld metal deposition capability of cored wires is better than electrodes, it is understandable that it is a natural process for core wire technology to replace the use of electrodes, considering the advantages it provides in view of production efficiency and speed.Flexibility to Intervene with Formulation according to NeedsCore wires can offer solutions by applying different formulations by the manufacturer to meet the needs of the material to be welded. In particular, the low welding capabilities of high alloy solid gas arc welding wires can be eliminated with the use of cored wire with suitable formulations.Improvements in weld quality and advantages in mechanical values of the weld metal should not be overlooked with appropriate formulations.DeoxidationWhile the cleanliness of the material to be welded directly affects the quality of the weld, we often encounter situations where the surface cleaning process cannot be performed 100% due to the additional labor costs and the dynamics of the production that competes with time, particularly in project-based works. It is possible by means of using cored wire to remove the elements that cause problems such as pores and cracks, which adversely affect the weld quality, like oil, rust, and dirt remaining on the material, from the weld pool by trapping them in the welding slag, especially thanks to the deoxidizing chemicals in the cored wire.Other Important Advantages and Applications of Cored WireThe protective atmosphere created by the core material during welding ensures that cored wires are preferred in sectors where open air welding is required, such as the shipyard and construction sector. Especially gas-free, self-protected types of cored wires minimize gas consumption costs and eliminate the negative impacts of open-air working conditions that adversely affect the weld pool. Core wires such as Hardcor 65 O, Hardcor 63 O are frequently preferred in hard filling applications.GeKa Elcor R 71 rutile type cored welding wires, which are used with CO2 gas as a shielding gas, provide production efficiency with their high melting capacity and the possibility of welding in any position at high current intensities. GeKa Elcor R 71, which is frequently preferred especially in shipyards, steel construction, and machinery manufacturing, stands out with its low hydrogen level (H5). Thanks to the low hydrogen content in the weld seam, cracks due to hydrogen can be prevented. Thanks to the CO2 gas, which has a lower cost compared to the mixed gas, savings in shielding gas costs are achieved.Gedik Welding, which has a wide range of cored wire products according to the variety of materials to be welded and welding method, continues its studies to develop new products in line with customer needs.
Difference Between Acetylene and Propane
What is the Difference Between Acetylene and Propane Cutting, Which Cut is More Advantageous?Acetylene and propane gases, which are frequently preferred in cutting, welding, and annealing works together with oxygen as flammable gas, have different advantages and disadvantages when compared to each other. In both of them, it is important to use the right equipment in order to get healthy results in terms of quality, cost, and efficiency.Before scrutinizing acetylene and propane gases in comparison with their results such as quality, cost, performance, it is necessary to briefly provide information about questions such as what acetylene gas is, what propane gas is, what is it for, what are the areas of use.Although acetylene (C₂H₂) is a triple bond carrying hydrocarbon, it is not toxic but acts as an asphyxiant at high concentrations. It is a very flammable and combustible gas. It is used in cutting and welding works. Acetylene is passed through hot copper pipes and a substance called benzene is obtained. Benzene is used as a raw material in the production of many organic substances. It is also widely used in the production of plastics in the chemical industry.Propane (C3H8) is a colorless gas composed of carbon and hydrogen. It is used as a flammable gas in welding and cutting works as in acetylene gas. Liquid petroleum gas (LPG) contains lots of propane. In industry and our daily life, it is also used as a fuel in forklifts and many buses, as a tube in homes, in kitchens, and in generators to provide electricity.Cutting processWhen the flame temperatures are compared, we see that the oxy-acetylene flame reaches higher temperature values than the oxy-propane flame.Oxy-Acetylene:3100°COxy-Propane: 2800°CNevertheless, when the two mixture gases are examined as heating value, the fact that the heating value of the flame formed by oxy-propane gas is higher attracts attention.Oxy-Propane: 95,758 KJ/m³Oxy-Acetylene: 54,772 KJ/m³The higher flame temperature of oxy-acetylene is not sufficient for it to be preferred over oxy-propane alone. The high focused heat release capacity of oxy-acetylene gas allows it to cut holes faster. Cutting thin sheets can be made more practically with oxy-acetylene.Higher heating value of propane gas provides an advantage in cutting thick-sectioned parts. The area under the influence of heat is narrower than the cutting process with oxy-acetylene. The fact that the flame focus is lower than the acetylene gas reduces the risk of wearing off the edges by melting during cutting. Edge cutting quality is higher than oxy-acetylene. Oxy-propane gas is often preferred particularly in shipyards where thick-section parts are used.Welding ProcessOxy-propane is not preferred much in oxy-gas welding. The structure of the oxy-acetylene flame allows welding to be performed by cleaning the surface of the material to be welded and creating a suitable shielding gas. Oxy-propane gas can be used in a soldering process. However, the use of oxy-acetylene gas generally gives better quality results in a soldering process.Annealing ProcessWhile acetylene gas creates a hotter flame, the fact that the propane gas creates a flame at a higher temperature as a result of its high calorific value, and the use of oxy-propane is preferred as it increases the annealing efficiency.Acetylene and Propane Cost DifferencesThe amount of oxygen needed by propane gas to react with oxygen gas to form a flame is higher than that of acetylene. While 1 liter of acetylene gas can react with approximately 1 liter of oxygen gas, 1 liter of propane gas reacts with approximately 4 liters of oxygen gas and creates a flame. Hence, the oxygen gas consumption is about 4 times higher when propane is used.The cost of propane gas is lower than acetylene gas. As the usage cost of which gas is more advantageous may vary depending on the place and purpose of use, the practical calculation of gas consumption in the production processes will give the most accurate result. However, the use of oxy-propane gas generally brings along lower costs.SafetySince acetylene gas is an unstable and unbalanced gas, it is suitable for being separated into its components. Therefore, when it is compressed with a pressure of more than 2.5 atmospheres in the free state and its temperature increases, the carbon and hydrogen in its composition start to decompose. At the same time, it explodes by increasing its pressure 11 times without ignition and combustion. As a result, pressures higher than 1.5 atmospheres are not permitted in acetylene production devices.The result of this situation should not be perceived to mean that propane gas is a safer gas than acetylene. While acetylene gas is lighter than air, as a result of the fact that propane gas's specific gravity is heavier than air, any propane leak in a confined space can precipitate onto the floor and cause poisoning. If propane gas does not receive enough oxygen while reacting with oxygen gas, incomplete combustion may occur, giving carbon monoxide to the environment and posing a risk of poisoning.Both gases become flammable and explosive as a result of their compounds with air and oxygen at certain rates. Flame check valves must be used for work safety.In both methods of cutting acetylene and propane, it is important to use the right equipment to obtain healthy results in terms of quality, cost, and efficiency. To examine our products in detail, you can review the Gekamac Gas Fixtures product page.
What is Additive Manufacturing (WAAM)
Elements such as a clean environment, low cost, speed in production and raw material savings have led to the emergence of the method in the industry under the names "3D-Printing" or "Additive Manufacturing." Additive manufacturing is based on the principle of creating (mainly using welding technology) a geometric structure by stacking the raw material in the form of layers without removing machining, as opposed to traditional machining methods."Wire Arc Additive Manufacturing - WAAM," which is one of the additive manufacturing methods, is the most suitable additive manufacturing method for low production costs, high deposition rates, and the production of fast and large parts. The name WAAM is given to the production of parts with robotic welding technology according to the 3D drawing of the part to be produced using welding wire. In our content, the details of the question of what is additive manufacturing, which is one of the topics that are a matter of curiosity in the sector, are included.Other additive manufacturing methods generally use metal powder instead of welding wire, and laser beam or electron beam as arc welding. Since there is still no strong metal powder production technology in our country, additive production using powder has to be entirely dependent on abroad. Another disadvantage of these powders imported from abroad is that they have high cost.Advantages of Additive Manufacturing (WAAM)Unlike traditional subtractive methods, the WAAM method is based on a layer-by-layer part production approach. Thanks to this, the material is collected only in the required dimensions and close to its final shape, and the material is saved. With the WAAM method, metallic parts can be produced on a larger scale than powder-based additive manufacturing methods. As the robot arm used in the process has more mobility as it can reach, it allows the production of large and complex parts that cannot be produced by powder-based methods.The WAAM process is a method that also allows for personalized production. It reduces production investment costs for manufacturers with a varying product range. It also provides cost savings in mold design and workmanship as no special gauge/mold tools are needed during the production phase. It provides efficiency by reducing labor and time. Because it is also used in repair maintenance and repair works, it also makes it possible to manufacture spare parts fast. The welding wire used as a feed material in the WAAM process is cheaper and has higher accessibility than the metal powders used in powder-based methods. As the WAAM process is a resource-based method, it consists of cheaper and ready-made equipment compared to other methods. The surface treatments in the WAAM process are relatively less compared to other additive manufacturing methods, and it enables the production of the parts desired to be produced with the closest versions to their final state.Uses of Additive ManufacturingAdditive manufacturing method can be used in many fields, particularly in aviation and space, automotive, maritime, oil & gas, and renewable energy sectors.Innovative ApplicationsIstanbul Gedik University Welding Technology Application and Research Center and Gedik Welding R&D Center conduct joint R&D studies on innovative applications of WAAM Technology. Dr. Uğur Gürol, Welding Technology Application & Research Center and Gedik Test Center Manager, says that this knowledge of Gedik Welding, which can develop and produce welding wires with different characteristics used in WAAM Technology in accordance with WAAM and apply them with a robotic system, has a strategic importance for the technology in question.Gürol said, “The welding wire (as solid or cored wire) required for WAAM is made suitable for this technology by making the necessary improvements. The GeKa WAAM Product Catalogue and system will be presented to the market at the SCHWEISSES & SCHNEIDEN Fair to be held in Germany soon.”Within the scope of WAAM projects carried out in partnership with Gedik Welding R&D Center and Istanbul Gedik University with this purpose, the first parts have been produced successfully by using solid and cored welding wires and a welding robot. At the same time, he stated that these studies are supported by national and international projects.Future TargesThe R&D studies conducted at Gedik Kaynak R&D Center are aimed at producing this technology with the welding technology of “Bi-Material;” that is, complex parts containing more than one material. The additive manufacturing method carried out using two different materials in the future manufacturing sector is particularly important for the defense industry. In this field, it was aimed to create a product by using two different materials (for example, low alloy welding wire and stainless welding wire) in the additive manufacturing method in the Gedik Kaynak R&D center, and the results of the studies were turned into scientific articles and published in "The International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry” (3D-PTC2021).
We are attending SCHWEISSES & SCHNEIDEN
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