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.

The above indicates 6 cents/lb metal energy cost for deposition with a 450A welder.

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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]
+*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 know into fesibility of [[MIG Casting]] engine blocks.