Mündersbach, Germany, 23 November 2011

Trade discovers innovative welding processes

This year's annual meeting of the metal-working sector produced an "aha" experience among many of those attending. At the Metal Construction Congress in Koblenz at the beginning of November, many guests were surprised to learn how much work, and therewith also money, they could save through using highly innovative welding processes. "The reaction to our talks and presentations provided recognition for our commitment", is how Susanne Szczesny-Oßing, Managing Director of the EWM Hightec Welding GmbH, sums it up. The largest German manufacturer of welding technology had played a key role in shaping the programme of the event in its role as primary sponsor.
"The potentials for our customers in the trade are massive, especially as many businesses are still operating with traditional technology", explains Szczesny-Oßing. It is still customary in the trade and in smaller medium-sized enterprises to carry out welding using MMA and MIG/MAG standard processes. The low-splatter pulsed arc, which entails considerable saving in reworking, tends to be the exception according to the many conversations which took place at EWM's stand and around the Congress. EWM's innovative welding processes also largely involved exploring unknown territory for this target group. Interest in the first item on the programme had already been heightened, moreover, by the fact that 61 of the 250 participants at the Metal Construction Congress had already visited the EWM Technology Centre at the Mündersbach headquarters.
"Our guests were visibly impressed by the possibilities afforded by modern welding technology", Szczesny-Oßing is pleased to say. Attention was particularly focused on the "forceArc", "coldArc" and flux cored wire welding processes developed by EWM. While welding with "forceArc" saves layers, and therefore also time, material and costs, "coldArc" partially replaces typical TIG applications such as the welding of visible seams and pipes. Flux cored wire welding is also said to be a particularly economical alternative to MMA welding, especially when working outdoors is involved.
The participants learnt how efficient these welding technologies are in practical applications from presentations given after the visit to EWM. Dieter Kocab, who works as an Assistant to the company management in the area of process optimisation for end customers, demonstrated the ways in which efficiency could be increased during welding while simultaneously improving the quality of the outcomes. Presentations by EWM customers Manitowoc, Meiser and Plauen Stahl confirmed the potential for increasing productivity by providing detailed insights into their production processes.
Jan Schönweiß, IWS (International Welding Specialist) welding expert in the Meiser Group, which specialises in manufacturing gratings and staircases, reported having made considerable efficiency gains through the use of "forceArc": "As well as saving shielding gas, energy and welding consumables, we save around 50 per cent as regards welding time and seam preparation." The powerful and focused arc also helps to produce a perfect backing run during welding in the same operation.
The same experience was reported by welding engineer Jörg Neudel, Director of Work Preparation at Plauen Stahl, one of the leading companies in building, bridge and plant construction: "We now only have to weld certain seams from just one side, while the backing run is formed of its own accord during this." Using "forceArc" means a root-side drop-through can be achieved, which is not possible with MIG/MAG standard welding. "Using focused EWM technology saves us lots of time and allows us to design the joining process mores surely, which in turn means we can achieve a leap in quality."
Manitowoc Cranes, manufacturers of mobile and telescopic cranes, presented a further advantage. Adjustments in constructing the welding point and reducing the seam volume, while at the same time providing welding seams from one side, mean the manufacturing period can be considerably reduced. A weld pool backing and the gouging of the seam is now no longer required with the one-sided welding seam.
These examples drawn from practice and experiencing the innovative welding technologies for themselves were real eye-openers for quite a few guests. The Metal Construction Congress provided a new experience for EWM in this respect as well. "If it has succeeded in revealing to the participants from the metal-working trade new opportunities for being able to work more efficiently, then the Metal Construction Congress has fulfilled its purpose."

250 participants visited the meeting of the metal-working sector in Koblenz sponsored by EWM. The central theme of the Metal Construction Congress was welding. The presentations by the largest German manufacturer in the field, EWM, and their customers produced a real "aha" experience and awakened great interest among many guests. Visitors were just as impressed by the performance capability and quality of highly innovative welding processes shown as by their economical efficiency.

Around a quarter of the congress participants visited Mündersbach in the Westerwald region prior to the actual programme starting in Koblenz. Divided up into three groups, they got to know EWM Hightec Welding, which operates from there as an established leader in technology. Managing Director Susanne Szczesny-Oßing introduced the guests to the modern world of welding and presented EWM's history of successes.

Experiencing high-tech live: In the EWM Technology Centre, the company presented its highly innovative "forceArc" and "coldArc" welding processes as well as flux cored wire welding. This made a particular impact on those guests who until then had been working with traditional welding processes. Looking into the arc by means of a high-speed camera and an automatic welding stand also proved to be fascinating.

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