THE MODERNISATION OF HISTORIC WELDING PRACTICES: SWR+HYPERFILL

THE MODERNISATION OF HISTORIC WELDING PRACTICES: SWR (SPOOL WELDING ROBOT) +HYPERFILL

Innovative welding automation technologies, like Novarc’s SWR+HyperFill, are modernising historic welding practices, allowing pipe fabrication shops to realise higher performance and productivity, while improving their bottom line.

SWR+HyperFill was launched after extensive independent research on welding productivity, costs, quality and efficiencies, which found that substantial productivity improvements in deposition rate, deposition efficiency, and duty cycle, compared to the baseline processes, were consistently achieved.

Essentially, Novarc’s SWR+HyperFill option expands the capabilities of the company’s collaborative Spool Welding Robot (SWR) designed to collaborate with operators to automate the pipe welding process.

SWR+HyperFill is a highly efficient, fully-integrated dual torch system that uses Lincoln Electric’s patented twin-wire GMAW solution, HyperFill, to maximise productivity and profitability allowing fabrication shops to expand the capabilities of the SWR. The system increases heavy fabrication productivity by increasing weld deposition rates while delivering excellent weld quality.

SWR+HyperFill uses the Lincoln STT GMAW process on the root, and twin wire (HyperFill) on fill and cap passes, and it can be used on carbon steel pressure pipes or vessels with 0.5” - 2” thickness and as low as 6” in diameter. The system also has the flexibility of using root to cap GMAW or seamlessly switching to FCAW or MCAW for the fill and cap passes.

Pipe fabrication shops using Novarc’s technology see production increases of up to 12x for stainless steel and 5x for carbon steel.

Snapshot of SWR+HyperFill Benefits for Pipe Shops • Higher deposition rates and efficiencies, reducing welding times and material handling costs compared to using the sub-arc process • Higher production rates (lb/hr) by streamlining and simplifying production, increasing efficiency and reducing costs • Excellent weld quality • Increase Factored Diameter Inches (FDI) to 350500 per shift on carbon steel pipes • Meet ASME Section IX and B31.3 WPS qualification requirements • Achieve high toughness test results down to -45℃

The expanded capabilities of SWR+HyperFill is excellent news for the world of tube and pipe, knowing that stainless steel and pipe welding is crucial to several industries and manufacturing processes.

Novarc’s welding automation technology has revolutionised the manufacturing processes and is a productivity game changer for pipe fabrication shops serving the shipbuilding, building construction, oil and gas, and offshore industries.

Novarc’s Spool Welding Robot works collaboratively with welders to allow junior welders to do the work that could previously only be performed by more senior welders, increasing productivity, weld quality and welder ergonomics.

RECENT CHANGES TO GUIDANCE NOTES

Weld Australia’s Guidance Notes have been updated recently. Some of the changes are noted below. All our Guidance Notes are available via the website, free of charge for Weld Australia members.

Weld Australia Guidance Note TGN-SW03 - Welding Electrical Safety Revised in 2021, this Technical Guidance Note contains the pop-out guide and form Welding electric shock injury and electrocution report form referenced within Weld Australia’s Technical Note 22 Welding Electrical Safety. It is designed to be read in conjunction with the Technical Note, and, to assist users in its application when investigating welding current related electric shocks or electrocutions. Weld Australia Guidance Note TGN-SW04 - Welding Safety - Audit Checklist Published ion 2022, this Technical Guidance Note assists users to identify hazards associated with welding and its allied processes. It draws upon the recommendations of a range of Weld Australia’s Technical Notes and Technical Guidance Notes and is presented in the format of a self-audit form. It may be particularly useful when identifying hazards associated with welding and related activities, and where additional control measures may be required.

Weld Australia Guidance Note TGN-SW07 - Health and Safety in Welding - Guides and Forms Revised and published in 2021, this Technical Guidance Notes reproduces the guides and forms presented in Weld Australia’s Technical Note 7 and Technical Note 22.

CAREER IN METAL FABRICATION & WELDING?

NON-ACCREDITED COURSES

Introduction to Welding (24 Hours) Hobbyist Course (8 hours)

ACCREDITED COURSES

Cert 3 in Engineering – Fabrication Trade (MEM30305/30319) Construction Induction White Card (CPCCWHS1001)

AS1796 Pressure Tickets 1-9 Short Courses

MEM05012 – Perform Manual Metal Arc Welding (100 hours) MEM05017 – Weld Using Gas Metal Arc Welding (100 hours) MEM05047 – Weld Using Flux Core Arc Welding (100 hours)

MEM05019 – Weld Using Gas Tungsten Gas Arc Welding

(100 hours)

CONTACT US

69 Melbourne Road, Riverstone, NSW 2765 Phone: (02) 9627 6237 Email: academy@fabinox.com.au Website: www.fabinoxweldingacademy.com.au

WHY US?

• Practical Training: Our school boasts 13 training bays with the latest high-tech welding machines and fume extraction units • Theoretical Training: Our classrooms have been designed to create a friendly

Weld Connect | June 2022 7interactive environment for learning • Virtual Reality / Real-Weld Training: We have acquired some of the most modern and up-to-date visual reality machines, to enhance our students learning.

ONLINE WHITE CARD TRAINING

SafeWork NSW accredited for general construction induction (White Card) training. BOOK NOW!

WANT TO DISCOVER HOW WELD AUSTRALIA CAN SUPPORT YOU THROUGH MEMBERSHIP?

Questions? Queries? Wondering how Weld Australia can help support your business, staff or career progression?

Contact Michelle Bignold (National Manager, Sales & Marketing, Weld Australia) on m.bignold@ weldaustralia.com.au to set up a 30 minute Zoom chat. Michelle will take you through the ways that Weld Australia can help.

A reminder that your Weld Australia membership must be renewed before 30 June in order to remain active. So, if you haven’t already renewed yours for this year, now is the time!

If you’re not sure if you have renewed for this year, or you want to renew now, log into the Member Portal or contact us on membership@weldaustralia.com.au

JOB BOARD

The Weld Australia Job Board reaches not only our member base, but the wider welding community - a much more targeted market than one of the big job boards. If you’re looking for someone with industry relevance (like welding knowledge or experience), why not look in the place where those kinds of people gather already?

ADVERTISE NOW

Weld Australia would like to welcome the following new members who have joined over in the last month.

INDIVIDUAL MEMBERS • Rylee Jemson-Ledger • Zac Townsend • Ryan Mommsen • Martin Wong • Cameron Camp • Benny Xu • Shane Atta-Singh • Bradley Coleman • Indiana Gould • James Hurle • Andrew Bryant • Bryan McCrystal • Jarrad Hansen • Ryan Chappell • Brian Curtin • Richie Mazurkiewicz • Stephen Varley • Bill Cudera • Kerry Raumati

STUDENT MEMBERS • Jaxon Donhardt • Emma Argent Butler • Kouger Shiner • Jaliyah Wanganeen • Charlie Kessey • Toryn Christensen • Jedda Baxter

Weld Australia membership is an investment in the success of your career or your business. We will help you increase your income, decrease your costs and give you a competitive advantage over companies or people who aren’t members.

JOIN WELD AUSTRALIA TODAY

Take advantage of our advertising packages. With a multi-channel marketing approach, you can reach as big an audience as possible. Plus, Weld Australia members get a significant discount on all our advertising rates.

Diamond Package: $6,000 If you have a ground-breaking story to tell, or a brand new product or service to launch, take advantage of our ‘Diamond Package’ for maximum impact and exposure: 1. Australian Welding: 1 x full page inside cover ad 2. Weld Connect: 1 x third of a page front cover ad 3. Weekly Wrap-Up: 1 x right-hand sidebar advert (420px x 250px) in 4 x editions 4. 3 x social media posts

Gold Package: $5,000 Our ‘Gold Package’ provides great value for money, as well as fantastic impact and exposure: 1. Australian Welding: 1 x full back cover advert 2. Weld Connect: 1 x back cover advert 3. Weekly Wrap-Up: 1 x right-hand sidebar advert (420px x 250px) in 3 x editions 4. 2 x social media posts

Silver Package: $4,000

Our ‘Silver Package’ provides great value for money, as well as great impact and exposure: 1. Australian Welding: 1 x full page advert 2. Weld Connect: 1 x full page advert 3. Weekly Wrap-Up: 1 x right-hand sidebar advert (420px x 250px) in 2 x editions 4. 1 x social media post

DOWNLOAD THE MEDIA KIT

Our Audience Our publications reach the players who make the decisions in the welding, fabrication and industrial industries—those people with the authority to choose, purchase and recommend your products and services. Our audience is continually growing year-on-year. In 2020-2021, Weld Australia saw a 50% growth in its audience across all distribution streams. Our audience includes: • Welding, fabrication and manufacturing industry professionals and top decision-makers at the

C-suite level • Welding, fabrication and manufacturing small-tomedium business owners and managers • Apprentices employed throughout the welding, fabrication and industrial sectors • Educational institutions, including a range of researchers and academics • Innovators throughout all of Australia’s industrial and manufacturing sectors • All Weld Australia members

Audience Location

Audience Job Role

Operations

Engineering

Quality Assurance

Business Development Sales & Marketing

Education

Other

Social Media Audience

Three Day Course

Need to use ASME Section IX? Learn how to minimise cost and maximise qualifcation usefulness.

The ASME code is the American Society of Mechanical Engineers (ASME) standard that regulates the design, development and construction of boilers and pressure vessels. ASME Section IX specifies the requirements for the qualification of welders and the welding procedure specifications. This three day course will give participants a working knowledge of ASME Section IX, including how to comply with its requirements.

Who Should Attend?

This course is intended for people who are involved in writing and qualifying welding and brazing procedure specifications, qualifying welders, brazers and operators, reviewing suppliers procedures, auditing or reviewing in-house procedures and qualifications and estimating jobs which impose the requirements of Section IX.

Welding Engineers, quality assurance personnel, auditors, testing laboratory personnel, maintenance personnel and jurisdictional inspection personnel will find this course interesting, exciting and beneficial.

Course Details

Perth

Date: 16, 17 & 18 November 2022 Venue: Novotel Perth, 388 Murray Street, Perth Room: TBA Registration first day: 7:30am Course time: 8:00am – 5:00pm

Brisbane

Date: 22, 23 and 24 November 2022 Venue: Novotel Brisbane, 38 Cordelia Street, Brisbane Room: Musgrove Room Registration first day: 7:30am Course Time: 8:00am – 5:00pm

REGISTER FOR PERTH Course Overview

A review of the welding processes and variables, and basic steel welding metallurgy will be conducted to provide all participants with sufficient background in welding technology to interpret and understand Section IX. The mechanics of using Section IX and how to address its requirements will be explained in a simple, straightforward manner.

Emphasis will be placed on writing welding procedures so that they contribute positively to the manufacturing process and on qualifying procedures in a cost-effective manner. The requirements for welders and operators will be examined with particular emphasis on minimising the cost and maximising the usefulness of qualifications.

Time will be provided to address individual participant’s problems and concerns. Attendees will receive copies of the course notes covering the course’s content. Attendees must bring a copy of the current edition of Section IX. Multiple choice tests will be given for each section.

Cost

Early Bird Rate:

• Weld Australia Members: $3,610 inc GST • Non Weld Australia Members: $3,810 inc GST

Rate After 1 September 2022:

• Weld Australia Members: $3,760 inc GST • Non Weld Australia Members: $3,960 inc GST

Please note: in order for the course to go ahead in two locations, minimum attendee numbers must be reached.

COSTS & ECONOMICS OF WELDING Tuesday 14 June at 6:00pm (AEDT)

Every year, welding manufacturing operations lose millions of dollars in profits due to the improper calculation of costs and inefficient welding practices. This session will help you avoid the pitfalls and help your business stay out of the red, including: • Highlight how to identify and manage production to reduce expenses and ensure quality control. • Explain how to calculate the costs of welding by weight of the deposited metal and give some tips and techniques for cost estimation. • Discuss the main factors influencing weld costs to highlight where it is possible to optimise the welding process and save money. • Use real business case examples to highlight the costs of welding and how to optimise.

REGISTER NOW

THE DEFENCE INDUSTRY GROUP Tuesday 5 July at 11:00am (AEST)

Weld Australia’s Industry Networks collaborate to engineer innovative solutions that enhance safety, manage risk, reduce cost, and optimise operating efficiency. As a result of COVID and a certain amount of industry turbulence, the Weld Australia Defence Industry Network experienced a hiatus. It’s now back and bigger and better than before.

The Defence Industry Network will focus on companies who are either already operating in the defence supply chain or have ambitions of joining it. Our aim is to ensure that contractual commitments to Australian Industry Content and Indigenous Participation are honoured.

REGISTER NOW

TECHNOLOGY EVENING IN MACKAY Tuesday 14 June at 4:30pm (AEDT)

Visit BOC Mackay’s centre of welding and enjoy an evening of innovative technology to launch Weld Australia’s newly formed Mackay Committee. The event will be co-hosted by BOC, Independent Welding Supplies, Diverseco and the Mackay Manufacturing Hub. Hear from Geoff Crittenden (CEO, Weld Australia) who will open the event, followed by a panel of welding industry experts ready to deliver an interactive, engaging demonstration featuring welding cobots, EWM welders, EWM Xnet, and Soldamatic augmented reality welding simulators. This is a great opportunity to see how the latest in welding technology can make a difference to your productivity. Ask your questions to a host of industry experts in a relaxed environment, with drinks and nibbles plus giveaways on the night.

REGISTER NOW

INTRODUCTION TO K-TIG Thursday 4 August at 12:00 noon (AEST)

K-TIG is a highly refined, keyhole variation of GTAW both with or without filler. It excels in Austenitic Stainless Steels, Carbon steels, Titanium, Zirconium, Duplex and Super Duplex, Nickel, Monel, Inconel and Hastelloy. It delivers an average time saving of 90% on suitable applications, and is able to perform singlepass full penetration butt welds in materials up to 12mm thick.

This presentation will include close up look at the K-TIG process, with a practical demonstration of the system and how it can be applied in both piping and pressure vessel applications. It will be delivered by Bill Kelly (Chief Technical Officer, K-TIG) who has over 20 years’ experience in the fabrication and welding industry as a qualified fabricator and welder.

REGISTER NOW

INVEST IN THE SUCCESS OF YOUR BUSINESS: DEFENCE INDUSTRY NETWORK

Weld Australia’s Industry Networks collaborate to engineer innovative solutions that enhance safety, manage risk, reduce cost, and optimise operating efficiency.

As a result of COVID and a certain amount of industry turbulence, the Weld Australia Defence Industry Network experienced a hiatus. It’s now back—bigger and better than before. The Defence Industry Network will focus on companies who are either already operating in the defence supply chain, or have ambitions of joining it. Our aim is to ensure that contractual commitments to Australian Industry Content and Indigenous Participation are honoured.

Membership of the Defence Industry Network will be free of charge for all Weld Australia Premium Corporate Members.

Weld Australia will organise and facilitate all meetings, with agendas and areas of interest driven by members. Areas of Proprietary or Confidential Information will be recognised and appropriately managed by all participants.

Further Information For details, contact: Andrew Davies (Manager Technical Industry Networks) on 0438 428 966 or a.davies@weldaustralia.com.au

Interested in Joining? Weld Australia is proposing an initial online meeting to determine the level of interest and possible agenda items. Event details: • Date: 5 July 2022 • Time: 11am – 12pm AEST • Venue: Online Zoom

REGISTER NOW BENEFITS FOR INDUSTRY

WELDING VISION TECHNOLOGY EVENT

WELDING VISION TECHNOLOGY EVENT

Weld Australia recently hosted a Welding Vision Technology Event. Attendees learnt how Xiris Weld Cameras are being applied in industry and in welder training. The webinar covered topics such as: an introduction to weld cameras; weld monitoring software innovation and integrations; using weld cameras in welder education, metal process research, and industrial processes; and innovation via thermal analysis.

This session was presented by Xiris Automation. Weld Australia has partnered with Xiris Automation to bring their weld cameras to Australia. Xiris helps manufacturers detect, recognise, and interpret quality defects in manufactured goods. For further information, contact Michelle Bignold (National Manager, Sales and Marketing, Weld Australia) on m.bignold@weldaustralia.com.au or 0437 106 726, or visit: xiris.com. The INDO PACIFIC 2022 International Maritime Exposition featured the largest exhibitor turnout in the event’s 20 year history. It is believed to be the largest defence industry event ever held in Australia, after a record number of participating exhibitor companies presented at the event at Sydney’s International Convention Centre in early May.

In all INDO PACIFIC 2022 had more than 25,000 visitor attendances across the three days, and 736 participating exhibitor companies from 23 countries—a 12% increase on 2019. Weld Australia was one of these exhibitors.

The exhibition space was 11% larger than the previous record set in 2019, and there were over 70 symposia and presentations. More than 40 nations were represented, with 39 Chief of Navy Counterparts or their representative from around the world in attendance.

Justin Giddings, CEO of INDO PACIFIC 2022 organiser AMDA Foundation, said INDO PACIFIC 2022 comprehensively achieved its goal of bringing the maritime and defence communities together.

“This was my first INDO PACIFIC, and it was overwhelming to see the support of not only Navy, but also the exhibitors, sponsors and visitors,” Giddings said.

“From Day One there was a hum of activity in the halls that continued for the entire event. INDO PACIFIC was delayed from 2021 because of COVID, and it was clear that industry is very happy to be talking face-to-face again, so the vibe on the floor was electric. We thank the Royal Australian Navy for its commitment and engagement with INDO PACIFIC 2022, and for its service to the nation.”

Weld Australia’s stand at Indo Pacific 2022.

WELD AUSTRALIA’S NEW WOLLONGONG OFFICE AND WORKSHOP

Weld Australia recently moved into a new office in Wollongong. With our Training department expanding rapidly to meet the ever growing industry demand, we needed larger office space.

We also took the opportunity to find premises with a small workshop facility, as well as classroom space to deliver training courses. The workshop facilities will enable us to film practical welding demonstrations for use in our training courses.

The classroom space is already proving popular. We have already delivered a Welding Supervisor AS 1796 Certificate 10 training course, and plan to deliver the next International Welding Inspector - Basic (IWI-B) course as well. The feedback from students has been really positive so far. MANUFACTURING HUB EVENT: AS/NZS ISO 3834: HELPING SECURE THE FUTURE OF AUSTRALIA’S WELDING INDUSTRY

Throughout May, Weld Australia delivered a three-part workshop for the Mackay Manufacturing Hub on The Benefits of AS/NZS ISO 3834 Certification. Paolo Corronca (National Manager Engineering), Victor Blain (Engineering Team Manager) and Ross O’Bryan (Welding Engineer) all facilitated the training.

Many companies across the world are certified to ISO 9001 for their quality management systems. However, where a special process such as fusion welding is used, ISO 9001 fails to demonstrate the specialist capability required by a company to manufacture products according to the necessary quality standard.

Certification to AS/NZS ISO 3834 helps businesses operate more efficiently, improving client satisfaction. AS/NZS ISO 3834 certification increases the likelihood of global supply chain opportunities and repeat business, bolstering profitability.

Certification helps Australian businesses demonstrate their ability to deliver a compliant, superior quality fusion welded product on time and to budget.

The feedback received from all attendees has been very positive.

SUCCESSFUL AUDITS AND WELDER QUALIFICATIONS ACROSS AUSTRALIA

Ross O’Bryan (Welding Engineer, Weld Australia) recently performed several successful surveillance audits for AS/NZS ISO 3834.2 Quality requirements for fusion welding of metallic materials. These audits were undertaken for Fabinox and Ashflex Holdings.

Based in Riverstone, New South Wales, Fabinox specialises in structural and architectural steelwork, pressure piping, tanks, vessels, chutes and hoppers, and safety access products like balustrades, handrails, stairs and bollards. They can also deliver a range of quality testing services, as well as transport and erection. Fabinox is also an RTO, offering a Certificate III in Engineering Fabrication and Welding. Their school boasts 13 training bays with the latest high tech welding machines and fume extraction units, and their classrooms have been designed to create a friendly interactive environment for learning.

Ashflex Holdings is an Australian company formed in 1995. Today the company employs a team of 10 people and operates from a modern, well equipped 2,000m2 workshop in Prestons, Sydney. A fabrication and erection company, Ashflex specialises in pressure piping and structural steel as well as repair of pumps, pressure vessels and various process equipment.

The Fabinox team. L to R: David Lortan (General Manager), Edgar Naidoo (Operations Manager), Vernon August (QHSE and Fabinox Welding Academy Head Teacher), and Reece Carter (QC Inspector / RWC). Frontline Manufacturing’s welding bays.

JAG welder, Ronnie Lovey, was qualified to AS/NZS ISO 9606-1.

Ross also undertook welder qualification in accordance with AS/NZS ISO 9606-1 at JAG Welding. Welder Ronnie Lovey (pictured above) was qualified for horizontal butt welds with supplementary fillet welds.

JAG Welding is a privately owned and operated company with over 22 years experience providing steel fabrication services to south east Queensland businesses. As well as working with mild and galvanized steel, JAG Welding has extensive experience working with structural stainless steel and aluminium. Significant investments in leading edge technologies have allowed JAG to continue providing efficient, responsive and quality services to their customers, and highly competitive pricing.

Questions? Queries? Need Help?

02 8748 0100 or qnc@weldaustralia.com.au