Welder Deposition Rate: Difference between revisions
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=Data Points= | |||
*450A MIG with 1/16" wire gets 17 lb/hr. [https://www.esabna.com/euweb/awtc/lesson9_13.htm] | *450A MIG with 1/16" wire gets 17 lb/hr. [https://www.esabna.com/euweb/awtc/lesson9_13.htm] | ||
*Submerged arc welding is limited to flat horiz surfaces due to need to cover with flux, but gets 40 PPH rate (Pounds Per Hour) [https://www.thefabricator.com/thewelder/article/arcwelding/improving-deposition-rates-with-submerged-arc-welding] | |||
*This gets us to make about 1-2 heavy duty sprockets for tractor drive | *This gets us to make about 1-2 heavy duty sprockets for tractor drive | ||
*This gets us know into fesibility of [[MIG Casting]] engine blocks. | *This gets us know into fesibility of [[MIG Casting]] engine blocks. | ||
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*With 5 welders and 50kW - we have 80 lb/hour deposition rate of finished parts. | *With 5 welders and 50kW - we have 80 lb/hour deposition rate of finished parts. | ||
*This lends itself to robot arm automation in due time. | *This lends itself to robot arm automation in due time. | ||
=Calculations= | |||
*The above indicates 6 cents/lb metal energy cost for deposition with a 450A welder. | |||
=Links= | |||
*[[GMAW Deposition Rate]] | |||
*[[Weld Deposition Rate]] | |||
*[[Welder Deposition Rate]] | |||
Latest revision as of 01:17, 22 November 2023
Data Points
- 450A MIG with 1/16" wire gets 17 lb/hr. [1]
- Submerged arc welding is limited to flat horiz surfaces due to need to cover with flux, but gets 40 PPH rate (Pounds Per Hour) [2]
- This gets us to make about 1-2 heavy duty sprockets for tractor drive
- This gets us know into fesibility of MIG Casting engine blocks.
- This is a low skill process, allowing further opportunity in Extreme Manufacturing starting with scrap steel. This upgrades the need for wire drawing to produce welding wire.
- Disadvantage: this requires 2x the energy over casting or hot rolling - because an extra step is needed to melt the feedstock fully. Quenching in water can possibly reclaim energy of water for space heating.
- Using multiple welders at the same time in the Extreme Manufacturing scenario allows for the quickest way to cast complexity - 5 minutes per 1 lb part such as a small coupler. This is the amount of time to just turn on an induction furnace for regular casting.
- With 5 welders and 50kW - we have 80 lb/hour deposition rate of finished parts.
- This lends itself to robot arm automation in due time.
Calculations
- The above indicates 6 cents/lb metal energy cost for deposition with a 450A welder.