Processes

Laser tube-cutting system

The new TruLaser Tube 7000 laser-cutting system from Trumpf Inc. processes tubes inside a tunnel-like safety enclosure and then, depending on size, moves them forward to the brush table or ejects them to a parts container behind the machine. The laser-cutting system features heavy-duty drives engineered for heavy tubes, a broad chucking range and a high degree of flexibility. This new machine can process tubes up to 30-ft long and can handle a maximum weight of 496 lb. The system's 0.6- to 10-in. clamping range, and with up to 3.6 kw of laser power, it is good for a wide range of applications.

The company said that compared with conventional processes like sawing, drilling or milling, a TruLaser Tube 7000 machine can boost productivity significantly. One example of a productivity enhancement is the short set-up time when changing programs. Nearly all of the adjustments depend on profile specifics. Values that have to be entered at the machine and the loading unit can easily be handled by the parts program. The self-centering chucking jaws do not need to be changed and the rollers that provide support and lateral guidance for the tubing automatically adjust to the diameter. The integrated scrap container in the feed station is emptied without operator intervention.

The machine's FocusLine function automatically adapts the laser focal position to the material type and thickness. Its software independently adjusts to the focus parameters given in the technology table, eliminating any set-up effort. Also new is the slender cutting head with a 6 in. lens and new style clutch, designed for flexibility and process safety.

When combined with the LoadMaster Tube that has a tube magazine that can hold up to 8,000 lb of raw material, the TruLaser Tube 7000 can be fully automated. Its pivoting feed support holds a number of tubes and keeps them at constant orientation. The loading unit performs a feasibility test to compare the tube geometry with the parts program. Special profiles and small batches can be fed by a conveyor section. The LoadMaster Tube measures the pipe length and adjusts the position of the grippers accordingly.

The TruLaser Tube 7000 also works with a new version of TruTops Tube software to make sophisticated processing strategies available. With this new software, complex tube designs can be fabricated more easily, precisely and reliably. It is now possible, for example, to position one 3D tube on another instead of designing and programming individual tubes. This saves time since parameters such as length, width, height, wall thickness and spacing between cut-outs can readily be modified to generate any number of variations.

Aluminum welding system

Miller Electric Mfg. Co. has introduced its AlumaFeed Synergic Aluminum Welding System for high-volume, high arc-on time industrial aluminum applications requiring conventional MIG and pulsed MIG welding outputs. Designed for simplicity, experienced MIG welders require no learning curve to understand system controls, and novice welders can make production-quality pulsed MIG welds within hours using the system's synergic control and the Profile Pulse output.

The AlumaFeed System consists of the AlumaPower 350 MPa synergic power supply — an 80-lb inverter with an output of 5 to 425 amps/10 to 38 v and built-in programs for 4000 and 5000 Series aluminum — the lightweight XR AlumaFeed wire feeder/control module (42.5 lb) and the XR-Aluma-Pro or XR-Pistol Grip gun available as air- and water-cooled models in 25- or 30-ft length options. The system is designed for MIG aluminum applications only, eliminating unneeded controls and complexity that can lead to unintended errors.

With optional extension cords, an operator can take the wire feeder up to 100 ft away from the power source, providing an extended reach that improves production efficiency when welding inside hulls or tanks, or maneuvering around large weldments.

Equipment

Abrasive belt machines for Coated and Scotch-Brite belts

The Dynastraight series of portable air-powered abrasive tools from Dynabrade Inc. have an ergonomic, lightweight composite housing that reduces tool vibration and is thermal-insulated to prevent cold air transmission to the operator. Applications include paint and rust removal, refining before final finishing, medium and fine grain finishing and final finishing.

Available in power ratings from 0.4 to 1 hp, these tools work well with abrasive-impregnated, non-woven nylon products, coated abrasive flap wheels, buffs and Scotch-Brite abrasive belts mounted on Dynacushion inflatable pneumatic wheels. Operators can use the inflatable pneumatic wheel for finishing work surfaces of virtually any shape, contour or material including finishing stainless steel and other metals.

The USA-made machines work on a variety of materials including stainless steel, aluminum, carbon steel, copper, brass, plastic, fiberglass, composites, wood and much more. The straight-line tools feature high-quality air motors ranging in speed from 950 to 18,000 rpm. The tools also feature an adjustable speed air motor and a standard muffler, which reduces noise levels in the workplace.

Trimmable flap disc for hard metals

Weiler Corp. has introduced its Saber Tooth ceramic flap disc that provides cool, fast-cutting action on hard-to-grind metals, such as stainless steel, resulting in lower grinding and finishing costs. Due to the aggressive, self-sharpening ceramic grain, the flap disc has a fast cut rate and long life. In addition, it has a specially formulated grinding aid that prevents dulling and glazing. This allows for “cool cutting”, thereby protecting high-value parts from heat discoloration.

Designed to work with hard, heat sensitive materials such as stainless steel, Inconel and titanium, the Saber Tooth flap disc grinds and finishes in one step, resulting in fewer changeovers and increased productivity. It is good for weld blending, grinding, deburring, deflashing, surface finishing or edge chamfering on hard metals.

The standard angled style phenolic backed Saber Tooth ceramic flap disc is available in 4-½ in. and 7 in. sizes. In addition, Weiler provides the only ceramic trimmable backed disc in the marketplace. The 4-½-in. trimmable Saber Tooth's design enables an operator to reduce the diameter of the backing to extend disc life. The trimmable backing also provides high flexibility, enabling access to hard-to-reach areas. The performance-engineered non-marking trimmable backing will not damage the work-piece, resulting in less re-work and scrap.

Consumables

Stick electrodes for boiler tube repairs

Hobart Brothers has introduced its Hobart Boilermaker family of low alloy stick electrodes to meet the challenges of tough boiler tube repairs and minimize weld rejects on these critical applications. The family, which includes Boilermaker 18 (AWS E7018, E7018-1), Boilermaker 18A1 (E7018-A1), Boilermaker B2 (E8018-B2) and Boilermaker B3 (E9018-B3) stick electrodes, has been formulated to provide X-ray quality welds with no starting or stopping porosity.

The stick electrodes accommodate a wide variety of welding styles and also provide several distinct characteristics such as low spatter levels and an easily removed slag to reduce downtime for post-weld cleaning and minimize the need for rework. The company said the products' excellent bead wash and reliable arc starts and stops ensure good weld quality with no porosity. Boilermaker stick electrodes burn evenly, especially when welding pick-ups on the tube sides, making them especially forgiving for welding operators to use.

Because the Boilermaker stick electrodes operate from 75 to 90 amps, they can be used to weld on both thin- and heavy-walled boiler tubes without burn-through, saving time and lowering costs for changing stick electrodes.

Boilermaker B2 electrodes are available in 0.0937-in. diameter 12-inch lengths allowing welding operators to bend the electrode to fit in tight spaces common to boiler tube repairs and also allowing for non-stop welding, again lessening the chance of starting and stopping porosity. All of the other Boilermaker products are available in 0.0937- and 0.125-in. diameters in 14-in. industry standard lengths.