PIM Metals December 23 - January 24 by ASTAC

PIM METALS INCORPORATING IMT

NEWS

VOLUME 2 l ISSUE 12 l DECEMBER 2023/JANUARY 2024

WELDING

LASERS

PRODUCTS

NEWS

25 Years State of the Art

PIM Metals December 2023/January 2024

COMMENT/IN THIS NEWS ISSUE

COMMENT

IN THIS ISSUE

elcome to the December issue of PIM Metals, unlike the normal comment from us we have to update you our readers as to our position going forwards. As an independently owned magazine, we have to rely on advertising revenues to continue being able to both print and mail the magazine around the world. Having spent the past 12 months monitoring all our costs, we have made the decision to cease printing the magazine for the foreseeable future. This has been far from an easy decision and one we did not rush into. Having published our first issue in 2008, we have seen a significant shift in advertisers spending precious budgets in non-verified circulation media. All however is not lost; we will continue to post news and articles on Process Industry Match - https://www. processindustrymatch.com And the specific Metals tab. We would now urge all our readers to register via the website and the sign-up link - https://confirmsubscription. com/h/j/86D90E68BEB59364 , this way you will be kept as as up to date as possible with what’s new in the Metals production and processing industry. All that is now left for me to say, is may I wish you all a great Christmas and prosperous 2024. Vince Maynard, Publisher Email: imtmagazine@virginmedia.com

PM, Rishi Sunak, visits North Yorkshire Pipeline Pigging Specialist iNPIPE PRODUCTS

thyssenkrupp Steel

thyssenkrupp Steel enhances know-how in electric mobility and higher strengh steels

PUBLISHER & EDITORIAL DIRECTOR Vince Maynard KVJ Enterprises, Tralee, Hillcrest Road, Edenbridge, Kent, TN8 6JS, UK

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ABB

LASERS

EVENTS

ABB publishes new report examining primary steel decarbonization pathways & spotlights global innovation

WELDING

Fit for the future thanks to smart robot welding technology

Cover picture: ABB News p.7

VOLUME 2, NUMBER 12 – DECEMBER 23/JANAURY 2024 Contact information

NEWS

Making it’s mark: Gripple reports ‘significant benefits’ of using Nukon Fibre Laser

PRODUCTS

Steel mill reaps rewards from adopting NSK bearings

The Who’s Who of the international wire, cable, tube & pipe industries in Düsseldorf

PIM Metals December 2023/January 2024

NEWS

Prime Minister, Rishi Sunak, visits North Yorkshire Pipeline Pigging Specialist iNPIPE PRODUCTS

rime Minister, Rishi Sunak, Visits North Yorkshire Pipeline Pigging Specialist iNPIPE PRODUCTS One of the UK’s leading manufacturers and suppliers of pigging products – North Yorkshire based iNPIPE PRODUCTS - welcomed MP for Richmond (Yorks) and Prime Minister Rishi Sunak for a visit. The visit comes almost 10 years since the Prime Minister last visited the iNPIPE business - before becoming an MP. It also provided an opportunity to support one of the largest single employers in his Richmond (Yorks) constituency. The company’s growth has increased employment opportunities for apprentices in a successful, expanding engineering company with almost 12% of the workforce now being made up by their apprenticeship programme. The visit comes on the back of one of the most successful periods to date for iNPIPE PRODUCTS, which has seen the company invest in a new service centre in Aberdeen and grow its global customer base. As part of the visit, the Prime Minister met the six apprentices based at iNPIPE’s Brompton-onSwale facility, near Richmond, North Yorkshire, spoke to all members of staff and received a full tour of the company’s six-acre site, including the foam shop, where the Prime Minister viewed some of the latest foam pig technology manufactured by the business and used for pipeline cleaning, de-watering

Prime Minister Rishi Sunak pictured with MD of iNPIPE PRODUCTS, Simon Bell. and swabbing. The visit also provided the management team with the opportunity to talk through their continued strategy for growth which has seen the business export 70% of its turnover worldwide. Speaking about the visit, Simon Bell, MD at iNPIPE PRODUCTS said: “We are very proud to have been visited by the Prime Minister and were hugely privileged to welcome him to our premises. “Everyone at iNPIPE PRODUCTS is extremely proud of the business and the success that we have all worked so hard to achieve during what will be our 40th year of trading next year. Our consistently strong performance is coupled with a strong internal culture with many of our team having been with us for 25 years or more. “Our success – recognised

PIM Metals December 2023/January 2024

by the Prime Minister choosing iNPIPE as the company to reinforce government support for British industries exporting our products & services worldwide – is reflected in the continued commitment and loyalty of our team, all of whom have played an enormous part in making iNPIPE the successful business that it is today.” Mr Sunak said: “I welcomed the opportunity to return to iNPIPE – a world-class manufacturing and design business in my constituency. “It’s commitment to innovation and quality of manufacture has led to worldwide success anchored in the workforce here in North Yorkshire. “I was particularly pleased to see the company’s commitment to growing its own team through its longstanding commitment to an apprenticeship programme which already has seen young

people develop into senior roles in the company.” iNPIPE PRODUCTS is a world leader in the design, manufacture, supply and hire of pipeline pigging, maintenance and testing products across the oil and gas, petrochem, powergen, mining, nuclear, water and food processing industries. Formed in 1984, the business will be celebrating 40 years of trading next year, employs 68 members of staff including 8 apprentices – across its Brompton-on-Swale and Aberdeen sites and works with many of the world’s largest brands across Europe, the Middle East, North America, South America and Asia. For further information contact: Jane Gatiss Scarab4 Email: jane.gatiss@ scarab4.com Tel: 0844 800 2686/ 07540 786 836

NEWS

ALFED report analyses impact of international conflict on UK extrusions market

LFED, the aluminium federation, has launched the second report in a series of research papers analysing the impact of international conflict on the UK aluminium industry. Developed in partnership with CRU International Ltd, the document specifically explores aluminium extrusions and the changing face of the import market. With the objective of protecting the UK’s thriving aluminium supply chain, supporting domestic production and minimising the effects of geopolitical issues, the report provides extensive analysis into themes including post-COVID market recovery, the reasoning behind weakening industrial activity and the continued implications of the Russia/ Ukraine war. Alongside analysing changing market trends, the document breaks down the past four years of extrusion import volume data by month, as well

as detailing the rapid rise of imports from ‘Group A’ countries Vs. material from China. Tom Jones, chief executive officer of ALFED, commented: “Following the initial shock of COVID-19 on aluminium extrusion imports, the market is indeed recovering but is still yet to return to pre-2020 levels. During this time, the origins of material destined for UK shores have changed significantly. “Previously, China was the number one exporter to the UK market but, in recent times, volumes from other countries have risen fast. This trend has been further accelerated by the impacts of global conflict, with territories including Spain, Malaysia, Poland, Greece, India and Romania now comprising the lion’s share. “Our latest report investigates the changing

face of the import market, analysing trends, challenges and opportunities. It’s fair to suggest that this report is a hugely important resource for any business involved in the UK aluminium supply chain and I’d implore industry professionals to take the time to read it in further detail.” “Impacts to UK aluminium extrusion imports following Russia/ Ukraine war” is available for members to download via the ALFED website. To become a member of ALFED, or to learn

more about its pioneering work fostering innovation, promoting best practice and championing the interest of the UK’s aluminium industry, visit www. alfed.org.uk.

Corinth Pipeworks is awarded major contract for OMV Petrom’s Neptun Deep in the Black Sea Corinth Pipeworks, as subcontractor of Sumitomo Corporation Europe Limited, will manufacture and supply approximately 160km of longitudinally submerged arc-welded steel pipes (LSAW) for the development of an offshore natural gas pipeline for OMV Petrom’s Neptun Deep project in the Black Sea. A major contract valued between EUR 100 and

150 million. The Neptun Deep Block in the Black Sea has an area of 7,500 square km and is located at a distance of about 160 km from the shore of Romania, in water depths up to 1,000 meters. Neptun Deep is the largest natural gas project in the Romanian Black Sea and the first deepwater offshore project in Romania. The 30-inch pipeline will

be manufactured at Corinth Pipeworks’ facilities and will include external anticorrosion coating and internal flow efficiency lining, applied at the same location as pipe manufacturing at Thisvi, Greece. Corinth Pipeworks has a comprehensive portfolio of products and solutions to supply and deliver challenging, current and future offshore

development projects, using the latest welded linepipe technology. “We are particularly delighted to be awarded this major project by Sumitomo Corporation Europe Limited, a trusted partner of OMV Petrom, the largest integrated energy company in Southern and Eastern Europe”, stated Ilias Bekiros, General Manager of Corinth Pipeworks.

PIM Metals December 2023/January 2024

NEWS

Konecranes secures 16-crane order to support environmentally sustainable scrap metal recycling rebar mill in Arkansas Konecranes will provide 16 cranes to Hybar, an environmentally sustainable scrap metal recycling and steel production company in the United States. These cranes, including ladle, charge, rolling mill, and shipping bay cranes, will be instrumental in supporting Hybar’s steel rebar production. The order was won in September 2023, with deliveries scheduled in 2024 and early 2025.

ybar’s first mill is currently being built to produce a full complement of high-yielding rebar for large industrial projects. Once operational, Hybar expects its greenhouse gas emissions to be the lowest among all North American steel producers, and likely the lowest in the world’s steel making community. Furthermore, it will be directly connected to an adjacent solar panel field to tap renewable energy. For this transformative initiative, Konecranes will deliver a diverse array of heavy-duty cranes that are engineered to withstand challenging conditions including high temperatures and dust. The cranes offer unique features and technology tailored to Hybar’s specific needs. For example, two Shipping Cranes are equipped with specialized magnets for the efficient handling of spooled rebar coils and long flat bundles, and two ladle/ charge cranes come equipped with operator cabins designed for optimal visibility, ensuring safe and precise handling of molten metal. “The team at Konecranes understands the complexities of moving steel,” said Ari Levy, Hybar’s Chief Financial Officer. “They also share our dedication to operational efficiency, environmental stewardship and, above all else, safety.” “Hybar’s commitment to

A Konecranes ladle crane in action. reducing carbon emissions aligns very well with our sustainability approach, which makes this order for high-quality steel mill cranes that support Hybar’s financial and environmental initiatives a perfect fit for both companies,” said Juergen Gieske, VP of Process Cranes Sales, AME, Konecranes.

PIM Metals December 2023/January 2024

A strong focus on customers and commitment to business growth and continuous improvement make Konecranes a lifting industry leader. This is underpinned by investments in digitalization and technology, plus our work to make material flows more efficient with solutions that

decarbonize the economy and advance circularity and safety. Further information: Tanja Wilson, Communications Director, Industrial Service & Equipment E: tanja.wilson@konecranes.com M: +971 56 4141878 media@konecranes.com

Precision Inline Profile Measurement • Full profile measurement • Surface fault detection • 3D image analysis

Family owned since 1957, Zumbach is a global leader in the industry. Driven by innovation and experience. We are here for you and ready to build the future together. www.zumbach.com • sales@zumbach.ch

NEWS

Magnetic Analysis Corp. announces new CEO

agnetic Analysis Corp., a global leader in instruments and systems for the nondestructive testing of metals, is pleased to announce the appointment of Daniel Lawrence as President and Chief Executive Officer effective November 6th, 2023. Just the fifth leader in MAC’s 95-year history, Dan will succeed President Dudley Boden, who announced his intent to retire in June, 2024. Dudley will remain a Director of MAC and will assist in the transition. Dan comes to MAC from his current role as General Manager of the Optical Components Business of MKS Instruments in Franklin, MA. Previously,

Daniel Lawrence President and Chief Executive Officer Dan was a Vice President and General Manager of the Stellite, Conforma Clad and Advanced Materials Systems businesses within Kennametal and spent a decade as a Division Vice President and Business Unit Manager for the Precitech and

TMC business units within AMETEK. Early in his career, Dan received management and executive training at both Danaher and GE. Dan received his BS and MS in Chemical Engineering from Clarkson University, studied law at Boston University and received an MBA from Southern New Hampshire University. Robert Gould, Chairman of the Board of Directors, commented, “Dan comes to MAC at an exciting time. We emerged from the pandemic stronger than we were at the start and currently enjoy one of the largest order books in our company’s history. We are confident that Dan can help us build on our solid foundations and accelerate our growth.

At the same time, I would like to express our grateful appreciation for the steady stewardship that Dudley Boden has provided as President over the past seven years and the contributions he has made over his entire 22- year career at MAC.” Magnetic Analysis Corporation (MAC®), headquartered in Elmsford, NY, USA, with manufacturing facilities in Boardman, OH and Östersund, Sweden, has been advancing the science and technology of non-destructive testing for 95 years.

50th Anniversary Offer

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PIM Metals December 2023/January 2024

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NEWS

Primetals Technologies selects ABB electric arc furnace equipment for hydrogen-powered steel project

BB is providing an ABB ArcSave® electromagnetic stirrer (EMS) to one of the leading German steel producers Salzgitter Flachstahl GmbH. The equipment will optimize the metallurgical performance of a new electric arc furnace (EAF) provided by Primetals Technologies, which is the first step in the SALCOS® program to transform the steelmaking process from coal-based to hydrogen-based. The steelmaker has a target to produce virtually CO₂-free steel at its plant in Salzgitter, Lower Saxony, Germany, by 2033, and to achieve this it is

replacing existing blast furnaces and converters with three EAFs and two direct reduction plants. Utilizing hydrogen, Salzgitter is expected to reduce CO₂ emissions by 95 percent. The developments align with International Energy Agency (IEA) reports that state hydrogen and hydrogen-based fuels can play an important role in the decarbonization of sectors where emissions are hard to abate and alternative solutions are either unavailable or difficult to implement, such as heavy industry and long-distance transport. Salzgitter has signed a contract with original equipment manufacturer (OEM) Primetals Technologies for the Ultimate Furnace. This EAF with a tapping

weight of 220 tons and an annual capacity of 1.9 million tons of steel will begin the SALCOS conversion. The EAF Ultimate is part of the electric steelmaking portfolio at Primetals Technologies, offering short tap-to-tap times, fully automated operation and advanced control systems. ABB ArcSave will optimize metallurgical conditions in the EAF, resulting in higher productivity, lower costs and more efficient use of resources including electrical energy. “With SALCOS we are pioneers

in the decarbonization of steel production,” said Ulrich Grethe, Head of Steel Production at Salzgitter. “With the electric arc furnace from Primetals, we are relying on an established technology that is further optimized by the electromagnetic stirrer from ABB.” ABB ArcSave is a unique, patented and proven EMS technology designed to improve metallurgical conditions and optimize operation of EAF. Installed on some of the world’s largest arc furnaces and on over 165 projects globally, ArcSave can help reduce the carbon footprint of both existing operations and greenfield projects. Commissioning is expected in 2025. “Resource and energy efficiency mean many steelmakers are switching to electric arc furnaces, which have lower environmental impacts than other steelmaking routes such as blast furnaces,” said Zaeim Mehraban, Global Head of Sales, ABB Metallurgy. “ArcSave enables safer, more consistent and efficient arc furnace operation and therefore contributes to sustainability as well as financial goals. It is great to be collaborating with major steel industry player Primetals Technologies on Salzgitter’s significant low CO₂ steelmaking project.” Requiring no contact with the bottom of the EAF, ArcSave enhances stirring during the melting of large scrap items, reducing stratification via forced convection. This improves EAF

PIM Metals December 2023/January 2024

NEWS

operation by homogenizing temperature distribution and chemical composition, while speeding scrap and ferroalloy melting compared with natural convection alone.

Typically, ABB’s patented ArcSave technology can improve yield by around one percent, with productivity improvements of between five and seven percent. The solution also reduces

PIM Metals December 2023/January 2024

consumption of electrical energy by three to five percent as well as use of process additions such as alloys and lime, and other consumables such as electrodes. Salzgitter has an annual

capacity of seven million tons of crude steel with 25,000 employees worldwide in 150 national and international subsidiaries and associated companies.

thyssenkruppNEWS Steel

thyssenkrupp Steel enhances know-how in electric mobility and higher strengh steels

thyssenkrupp Steel strengthens its expertise in electric mobility and higher-strength steels with completion of the new double reversing stand in Bochum

hyssenkrupp Steel is continuing with the consistent implementation of its Steel Strategy 20-30 and has now completed another major project. The new double reversing stand (DRG) can be used above all to produce higher-performance steels for electric mobility, as well as other high-strength grades. The location on Essener Strasse in Bochum will be expanded into a center of excellence for electric mobility by 2025. In addition to the now completed unit, an annealing and isolating line (GIL) and an electrical steel inspection line (EBIL) are being built there. The total investment at the site amounts to about EUR 300 million. Dr. Heike Denecke-Arnold, Chief Operations Officer at thyssenkrupp Steel: “The investment in the new double reversing stand is a clear signal for the future of the Bochum site. Among other things, we want to significantly strengthen our expertise in higher-strength steels and electric mobility. In this way, we can differentiate

ourselves even more consistently through the quality of our products, and consequently we can satisfy the ever-increasing and demanding requirements for premium electrical steel. With even thinner highly silicized sheets, for example, we can help to further increase the energy efficiency and thus the performance of electric motors.” This places increased demands on cold rolling technology. The new double reversing stand is a design developed by equipment builder Primetals Technologies and meets the highest standards

in the industry. It satisfies the exacting requirements of thyssenkrupp Steel and significantly improves the capabilities of the Bochum site for non-grain-oriented electrical steel. Reversing rolling processes can be used to produce particularly thin materials with significant flatness and the narrowest thickness tolerances. This is particularly important for sheets used in electric motors and generators, for example for wind turbines, because it can minimize core losses. The DRG will also boost the Bochum location’s capabilities in higher-strength products for the automotive industry, which are used in the chassis area and in safety-relevant components. The investment thus focuses on economical lightweight

construction for the automotive industry. thyssenkrupp Steel is already a leading global supplier of non-grain-oriented electrical steel under the brand names powercore® and powercore® Traction supplied to energy producers, the automotive industry and home appliance manufacturers worldwide. Electrical steel strips with a thickness of less than 0.35 millimeters can only be rolled efficiently and in high quality on reversing stands such as the new DRG due to high material requirements. The technology used ensures a stable rolling operation with very thin and hard strips. This avoids faults in the material and ensures significantly improved product quality for customers overall. The completion of the new double reversing stand is also a good signal for Bochum as an industrial center. Bochum’s mayor Thomas Eiskirch: “The completion of this multi-million Euro facility is very good news for the 2500 people who work for thyssenkrupp Steel at this site, and also for the city of Bochum. It secures future jobs and, with the establishment of the center of excellence for electric mobility, consolidates Bochum’s position as an important steel location.”

Technical data of the double reversing stand Design: 2 housings, stand configuration – 6 Hi Hyper UniversalCrown-Mill Length: 60 m

Height: Up to 11 m

Strip widths max.: 1570 millimeters

Strip thickness min.: 0.2 millimeters

Standard capacity p.a.: approx. 475,000 t/a (depending on portfolio) PIM Metals December 2023/January 2024

WELDING ABB

ABB publishes new report examining primary steel decarbonization pathways and spotlights global innovation

BB is today launching a new report that considers carbon capture, hydrogen and electrochemistry as routes to decarbonizing primary steel production. It spotlights innovative new technology developments and approaches in Brazil, China, India, Sweden and the US – the countries that are leading the way towards fossilfree steel. It includes insights from leading steel manufacturers SSAB, Tata Steel and Aperam, as well as experts from the American Association for Iron and Steel

Technology and ABB. The new ABB report named ‘What does the journey to fossil-free steel look like? How to achieve a sustainable future’ discusses decarbonization challenges including cost, the complexity in transitioning to lower carbon technologies and access to hydrogen, clean electricity, high grade iron-ore and fossil-free carbon and lime. Current steel production is carbon and energy intensive and classified as one of the six ‘hard to abate’ sectors. Globally, the steel industry is responsible for an

estimated 8 percent of the world’s energy demand and generates between 7 percent to 9 percent of CO2 emissions – most of which are from burning fossil fuels, according to various sources including the recent International Energy Agency (IEA) Iron and Steel Technology Roadmap. To meet the criteria set out in the United Nations Paris Agreement on climate change and limit the global temperature increase to below 1.5 °C compared with pre-industrial levels, the steel industry must achieve a target of net zero emissions by

2050. This will require radical transformation, especially in context of global steel demand which is projected to rise 30 percent by the same date. The ABB report spotlights fossilfree steel innovation in five steel producing markets. These include: l the Hydrogen Breakthrough Ironmaking Technology (HYBRIT) piloted in Sweden by steelmaker SSAB, state-owned iron ore miner LKAB, and state-owned energy company Vattenfall to make steel using green hydrogen and fossil-free

The ABB report presents actions that steel producers can make now to reduce carbon in the short and medium term. Image ABB 10

PIM Metals December 2023/January 2024

WELDING ABB

The largest steel producers in the world understand the role they play in global decarbonization and are taking action today. Image Adobe Stock electricity using the high grade iron ore from the LKAB mines instead of coking coals; l the ResponsibleSteel™ industry association-backed Aperam, which has interests in stainless steel and agriculture, and the use of charcoal produced from its own 100,000 hectares of FSC®-certified forests in Brazil as a renewable substitute for coal-based coke in steelmaking to significantly reduce CO2 and entirely eradicate the use of extractive coal; l the HIsarna process by Tata Steel in India which uses a powdered form of the raw ore material instead of processed ores such as coke, sinter or pellets to make liquid pig iron and can reduce emissions by up to 20 percent compared with the traditional Blast FurnaceBasic Oxygen Furnace (BF-BOF) method. “Digitalization is not only intrinsic to collaboration between entities but to optimizing the use of resources and energy

management, and in providing the traceability required to keep organizations accountable to emissions targets,” said Shiva Sander Tavallaey, Senior Principal Scientist at ABB Corporate Research Center. The ABB report presents actions that steel producers can make now to reduce carbon in the short and medium term as well as steps to take with industry suppliers and partners to work together towards a fossil-free steel future. “Regulatory, commercial, and social drivers are accelerating the journey to decarbonize steel,” said Frederik Esterhuizen, Global Business Line Manager for Metals at ABB. “But to address the core challenges set out in ABB’s report and phase out fossil fuels, the steel industry will need powerful, integrated solutions and must collaborate at every level of the global steel supply chain in order to succeed.” “A digital, autonomous and fossil-free steel industry is possible through partnership. ABB is taking an approach of

To meet the criteria set out in the United Nations Paris Agreement on climate change and limit the global temperature increase to below 1.5 °C compared with preindustrial levels, the steel industry must achieve a target of net zero emissions by 2050

partnership and collaboration to integrate innovative technology with ABB’s existing portfolio for the steel industry. Initiatives from around the world show that the industry is committed to a sustainable future, with several promising developments in the works. Through innovation and partnership, a green steel future

is an achievable reality.” To view the ABB report: ‘What does the journey to fossil-free steel look like? How to achieve a sustainable future’ visit https:// new.abb.com/metals/what-doesthe-journey-to-fossil-free-steellook-like ABB’s Process Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs – from supplying energy, water and materials, to producing goods and transporting them to market. With its ~20,000 employees, leading technology and service expertise, ABB Process Automation helps customers in process, hybrid and maritime industries improve performance and safety of operations, enabling a more sustainable and resource-efficient future. go.abb/processautomation For more information please contact: Media Relations Chris Brand Phone: +44 (0) 7523919978 Email: chris.g.brand@gb.abb.com

PIM Metals December 2023/January 2024

WELDING

Fit for the future thanks to smart robot welding technology

ursuing progress and innovation in consultation with the customer, trendsetting Austrian company Anton Paar manufactures highprecision measuring devices for a wide range of industries. Its dedicated research, engineering, and production teams aspire to keep pushing the boundaries of what’s possible. Today, Anton Paar GmbH is the world leader in density and concentration measurement, rheometry, and the analysis of dissolved CO2. A growing shortage of skilled workers and ever-increasing quantities call for intelligent production solutions, so the company invested in a latestgeneration robotic welding cell. Up until now, all components of the measuring and control devices Anton Paar produces in Graz, Austria have been welded by hand. This was because robotic welding systems were deemed uneconomical for small batch sizes between one and 400 pieces. Ongoing sales growth, the increasing shortage of skilled workers in the domestic job market, and innovative robot technologies—which now make automated welding economically

Programming welding sequences and simulation using Fronius Pathfinder Anton Paar GmbH, says, “The shortage of skilled workers and ever-increasing quantities call for new solutions in production. The new robotic welding cell represents a huge step towards automation of our manufacturing. If we were to weld our process sensors manually like before, we would encounter huge difficulties achieving the planned quantities in the coming years.”

viable even for small batch sizes—prompted the high-tech company to invest in a modern robotic welding system. The measurement and control specialists at Anton Paar were looking for flexibility all along the line, combined with a high degree of cost effectiveness. This meant flexibility in terms of the number, shape, and size of the components, in their positioning, and in the use of different welding processes. Dominik Santner, COO at

Autonomous welding and a broad range of components

CMT welding of countercoolers on the tilt-turn positioner, with pallet repository in the background

From the outset, the emphasis has been on system autonomy for the experts at Anton Paar. Once set up, the welding system needed to be able to process a complete order from start to finish in a single pass. For example, welding a batch of different objects such as oscillator housings, main carriers, or countercoolers. And the system had to be able to do this completely independently and without the intervention of welding specialists.

PIM Metals December 2023/January 2024

Dominik Santner A range of factors made designing the system especially challenging for engineering and programming teams, including components of various shapes, weights, and sizes, different gripping, positioning, and storage possibilities, the option to use two different welding processes (TIG and MIG/MAG) on a single component, as well as the use of forming gas to protect the components against tarnishing, which is necessary for cylindrical bodies. “We were looking for a reliable partner who was very similar to us in terms of precision and quality. We wanted someone

WELDING NEW PRODUCTS

Robotic welding cell: TIG welding is performed on so-called main carriers; handling robot positions the pallet with components who would really listen to us, respond to our preferences, and propose sustainable solutions. A partner that would give us a competitive edge for years to come,” explains Daniel Moik, department manager for joining technologies. “Fronius International met these criteria for a sustainable partnership. In close cooperation with our technicians, the welding automation team developed a robotic welding cell that meets our requirements in every respect. On top of that, Fronius is ready to work with us to evolve the system and adapt it to new needs.”

Synonymous with efficiency: Fronius Pathfinder At Anton Paar, new welds are programmed offline—away from the welding system—rather than directly on the system, as is often the case. Rather than stopping ongoing welding work, welding continues during programming, increasing productivity. The welding technicians create the conditions for this by importing the CAD data of the measuring device components to be welded into the Fronius Pathfinder®. Various joining scenarios are then tested and welding sequences are defined and optimized in the course of simulations.

Starting points, work angles of the welding torches, torch offsets in the corner areas, and all reorientations of the welding robot are all taken into account during these simulations. Pathfinder identifies instances where the robot range is exceeded, known as axis limits. By the software operators correcting the storage location of the workpiece and positioning it within arm’s length of the welding robot, potential collisions between the torch and various component edges are avoided at an early stage.

Sources of errors are identified in good time If the track needs to be corrected, the affected teach points can be easily moved by dragging and dropping them. When the approach to the component needs to be changed, the specialists simply press “Reset.” The virtual robot then moves to the home position to start a new approach run. Under real-life conditions, operators would have to complete the time-consuming process of retracting the robot, moving it to the home position with the robot controller, and restarting the teaching process. By opting for the Pathfinder offline programming and simulation software, the experts at Anton

Handling robot: Fully automated removal of components and clamping devices from the pallet rack

Paar not only gain valuable time for welding work but also identify sources of error ahead of time. Once a welding program has been set up in Pathfinder, it is translated by a so-called postprocessor into the specific code of the Fanuc welding robot. It can then be transferred to the welding system via data transfer using a LAN connection, for example. A key feature that provides effective support for production planning as a whole is the “Determination of cycle time” function, which includes welding speeds as well as gas pre-flow and end crater filling times. Compared to teaching with the robot controller, Pathfinder can achieve a time savings of up to 90%, depending on the component geometry and welding requirements.

Customized for Anton Paar Anton Paar has access to custom workflows for welding its many different components, including the three main workflows, which are a prime example of the incredible flexibility in the range of components. Workflow 1: The components are welded on the turn-tilt positioner. A pallet loaded with components is removed from the pallet rack and temporarily stored on a pallet storage table. The handling robot

then attaches a suitable gripper for picking up components, with six different ones being kept in what is known as a gripper station. Equipped with the gripper, the handling robot picks up the components and fixes them in a component-specific clamping device, which is already installed on the manipulator. The robot always removes one component at a time, which is then joined and returned to the pallet. Workflow 2: The components are welded directly on the pallets, with the handling robot transporting the pallets from the pallet rack and positioning them in front of the welding robot. The handling and welding robots can then perform coordinated movements together during the welding process, enabling them to weld not just simple seam geometries but complex ones as well. Workflow 3: The components are removed individually, positioned by the handling robot, and move in sync with the welding robot during welding. This is called “coordinated motion.”

Making sure the system knows what to do In addition to the innovative Fronius welding technology,

PIM Metals December 2023/January 2024

WELDING

controls, tool center point (TCP) measurement, torch cleaning station, and enclosure, the robotic welding system consists of seven core modules that collaborate on the basis of software control. These consist of a handling robot, a welding robot, a turn-tilt positioner with forming gas unit, a pallet store with two racks, a gripper station, a torch changing system, and a pallet repository inside the system. The following steps are required in order for those modules to interact precisely during the working cycles. First, pallets and components are created together in the HMI-T21 RS system controls, which are provided with four important pieces of information by the relevant welding specialist: (1) the pallet type and (2) the type, (3) the number, and (4) the position of the components on the pallet—for example, how many main carriers or oscillator housings are located in which position on which pallet. If it is an offset pallet, the component position is calculated on the basis of the so-called offset distances between the components, with the first component assuming the master position. For example, an offset might be 200 mm on the y-coordinate and +200 mm on the x-coordinate. The pallets manufactured by Anton Paar consist of perforated plates that are centimeters thick and function as a plug-in system. They are located in a pallet store consisting of two racks and are designed to accommodate each of the different workpieces, with the receiving and depositing positions of individual components often varying depending on the nature of the component and the gripper of the handling robot. The robot controller contains a hierarchically superordinate robot program for each workflow type. This is where the welding 14

Daniel Moik programs created with Pathfinder are stored. If a pallet for Workflow 2 is created on the HMI (components are welded directly on the pallet), the robot controller filters the corresponding robot welding programs, and Anton Paar’s welding specialist can conveniently choose between all the programs that are available for Workflow 2 and assign the right one to the pallet. There is also the option to not only use a single welding program but also create an entire work sequence. For example, a TIG program can be created for a pallet, followed by a MAG program (e.g., CMT) in the same sequence. In this case, the robotic welding system would execute both programs one after the other and automatically change the welding process. In addition, the experts at Anton Paar can insert certain special steps into the HMI process. For instance, the system knows the special “Turn component” step, which can be used between the

two welding processes (TIG and CMT) if necessary. If a specific gripper is required for pallet handling, as described in Workflow 1, the system operator must select it in the system. As previously mentioned, there are a total of six different grippers available, all of which are kept in a gripper station.

Teaching gripping and depositing positions The conventional handling sequence itself—picking up the pallet, positioning it for welding, transporting it back, and depositing it—is a standard program and requires no intervention from the operator. This is referred to in the field as an “encapsulated” function. Only the gripping positions have to be specified. If a new component is “moved in” and not recognized by one of the depositing or receiving stations, the automatic run pauses. The welding specialist is prompted to start a teaching process with the robot controller—the Fanuc iPendant—and receives stepby-step instructions from the system software. Based on this, the system “learns” the required gripping/depositing position for the relevant station (e.g., for the clipboard). This position is stored in a register and is available for the handling process from that

point on. The automatic run can then continue to the next station. If the component is also unknown there, this position must also be taught. Once all the stations have been worked through as described, the handling robot transports all other identical components through the system automatically, without interruption. If a pallet should have seven components but there are only three components on it, this is no issue for the system. It detects an “empty grip” and automatically moves to the next component position.

Custom-made: the teach pallet In addition to the standard offset assignment, which favors simple component shapes, Anton Paar wanted to be able to deposit up to 30 metal components at any point on a pallet. Fronius responded by creating the “Teach pallet” function. Selecting this function makes it possible to separately teach the position of each component on the pallet. “These two versions, offset and teach pallet, offer us maximum flexibility in component placement,” explains Dr. Ingo Riemenschneider, department manager for production automation. “It doesn’t always make sense for us to define component positions using offset distances. We have to fix some components in different orientations because of their complex shapes.”

As precise as on the first day—even after months

Oscillator housings are welded on pallets using the CMT process; coordinated movement sequences of handling and welding robots

PIM Metals December 2023/January 2024

When the welding specialists want to start a welding process, they use their handheld scanner to scan the item number on the component data sheet. “If the system detects the item number and thus the component, it knows about the

WELDING NEW PRODUCTS

handling and welding process and starts operation. Everything is controlled via the HMI-T21 RS. The system stores which gripper and which device are needed for each of the components,” explains Riemenschneider. “The same applies to the argon flushing time during forming and the seam time. The system also knows whether and what data is required for process data recording.” Months later, the robotic welding cell is still just as precise as on the first day, and the weld seam is perfectly positioned in the same place. This can also be attributed to the fact that Anton Paar manufactures the components with micrometer precision and joins them with an exemplary level of quality.

Components can be turned multiple times—even during forming The turn-tilt positioner has a media conduit for four flowthrough lines, two for air and two for argon, and can transmit up to 32 input-output signals (IOs). It is made of plastic and was produced by Anton Paar using 3D printing. If components need to be formed, the handling robot first retrieves the required clamping device from the pallet rack and clamps it on the manipulator with the help of a special clamping system. From that point on, both the air lines for the pneumatic cylinders and the gas lines for flushing with argon are connected. The electrical signals are now also transmitted by the clamping device. The handling robot then positions the components and the system sends the signal for clamping. Forming can now be carried out, followed by welding. The system is designed in such a way that the components can be turned several times on a single clamping device. “It is important to us that all processes and properties

CMT welding, handling robot moves the component into position that were implemented in the system are open in terms of their repeatability. The matter of whether a turning process is carried out once or a hundred times has to be irrelevant from the perspective of the system. Given that the complexity of our components is constantly changing, we and the experts at Fronius put a lot of energy into making the processes as unrestricted as possible,” notes Riemenschneider.

Residual oxygen measurement made by Anton Paar When forming on the tilt-turn positioner, the residual oxygen in the component is measured with the company’s own Oxy 5100 measuring device. It carries out drift-free measurement of the dissolved oxygen in the gas stream in real time during the entire welding process. Normally, the component is fixed between two sections of a line. The forming gas flows in on one side, on the supply line, and out again as a flow of exhaust gas on the other side, where the residual oxygen content is measured. This procedure would be counterproductive for the automated welding process, as the robot would have to take the extra step of inserting and removing an exhaust gas hose during each welding process. The

decision was therefore made to place the measuring device in the supply line. As soon as the device reports that the desired residual oxygen content has been reached, welding is started, taking into account a time delay for the time it takes the argon gas to flow through the component. This period is needed to ensure that the required residual oxygen content is not exceeded. The time it takes for the component to be completely filled—the time delay—is determined for each of the components based on a manual measurement and stored in the system. If the component comes up again, the controller can access the values and respond accordingly.

At the apex of welding technology It was particularly important for Anton Paar’s welding specialists to be able to combine two welding processes for a component—for example, TIG for welding the root pass and MAG for welding the final run. However, the final choice of welding method depends on the welding calculations and the required resistance of the individual components. “Our welding tests are the deciding factor in whether we use special processes such as CMT (cold metal transfer), PMC

(pulse multi control), or LSC (low spatter control). The process we then decide on depends on the wall thickness of the component, on the type of weld, for example square butt or fillet weld, and on the required welding depths and micrographs,” Moik explains. “We need about six or seven tests before we go into series production. If the heat input would be too great due to the nature of the material, the CMT ‘cold’ welding process is of course suitable. If we want to boost productivity by increasing the welding speed, we look at PMC. If welding needs to be particularly low spatter, LSC might be a good choice, primarily because this prevents expensive rework.” The welding data is recorded in the HMI. If the welding specialist finds a fault during the visual inspection, they can check the welding data record to see whether there have been any deviations from the limit values. Every component is subjected to a visual inspection (VI) as a matter of principle, and every tenth component undergoes a color penetration test (PT). This method can be used to detect cracks, pores, and lack of fusion of down to 1 µm. The PT-tested metal components are regularly subjected to micrographs at the end of the test cycle. The innovative Fronius processes, a system concept that is both intelligent and flexible, and the ongoing potential to continue developing the robotic welding system ensure that Anton Paar’s sensitive, high-precision measuring devices will have perfect weld seams for years to come. The company’s welders simultaneously benefit from increased safety and protection of their health as they are shielded from the arc and its emissions by the enclosure and extraction system.

PIM Metals December 2023/January 2024

NEW PRODUCTS LASERS

Making it’s mark: Gripple reports ‘significant benefits’ of using Nukon Fibre Laser Investing in a Nukon 2D fibre laser machine from Nukon Lasers UK brings significant vertical integration, product development and sustainable manufacturing benefits to Gripple – a world-leading manufacturer of wire joining, tensioning and suspension systems.

little over 12 months since the installation of a new Nukon 2D flat sheet metal fibre laser machine at its recently opened, netzero-certified Norfolk Bridge manufacturing site in Sheffield, UK, Gripple reports considerable benefits from the purchase of the machine. With increasing global sales for its Fast Trak® bracket systems for mechanical and electrical service suspension, a desire to equip its Ideas & Innovation team with greater opportunities for new product development, and a drive to further reduce its carbon footprint through greater vertical integration, Gripple took delivery

of a new Nukon 2D fibre laser machine at its Norfolk Bridge facility in 2022. The machine, a Nukon Eco 315 4kW model, was supplied by Nukon Lasers UK – the exclusive UK and Ireland distributor for Nukon’s 2D fibre laser, 3D fibre laser and fibre laser tube cutting technologies, and the sister company of UKbased tube bending machinery specialists, Unison Ltd. Built in Europe, Nukon’s fibre laser machines offer highly accessible power and performance, and are equipped with solid state American-made nLIGHT fibre lasers as standard. After considering a number of fibre laser machine manufacturers,

From left: Steve Haddrell and Alan Pickering – Nukon Lasers UK; Claire Tunnard – Gripple. 16

PIM Metals December 2023/January 2024

Gripple shortlisted Nukon and another leading brand. With the high levels of product quality and capability provided by Nukon machines never in doubt, it was the commitment shown by Nukon Lasers UK’s sales director, Steve Haddrell, into fully understanding Gripple’s laser-cutting requirements, that secured the sale. At Gripple’s Norfolk Bridge site, production surrounds the manufacture of the company’s Fast Trak® bracket systems, as well as solutions for the OLE rail industry and utility solar applications. For this type of work, Gripple typically uses CNC-controlled punch machines, with tooling specific to individual

customer requirements. However, with an Ideas & Innovation team continually looking to provide new solutions to the challenges faced by customers, and a companywide drive to bring even more production in house through a vertically integrated supply chain, it wasn’t long before the new Nukon fibre laser began making its mark. “Following installation, our Nukon fibre laser machine quickly gained a key role in the cost-effective manufacture of our OSHPD OPA-2123-10 seismic bracing and blast protection systems – brackets developed for some of the most demanding environments in the world,” comments Claire Tunnard,

NEW PRODUCTS LASERS

production manager at Gripple’s 21,000 sq. ft. Norfolk Bridge site. “The machine is also being used to produce components for our lightweight, easily transported solar cable hangers ¬– suspended routing systems that are significantly faster to install than traditional underground solar cabling. The ease of programming, speed, accuracy and flexibility of the machine are also providing our Ideas & Innovation team with exciting opportunities for new product development. Added to that, the Nukon fibre laser is being used to produce components for the manufacture of machine tools that will be based at other Gripple sites.”

Net zero by 2030 “Investing in equipment such as the Nukon fibre laser also supports our enterprise-wide

goal of becoming totally net zero by 2030,” adds Claire Tunnard. “We use local component providers whenever possible, for a minimal carbon footprint, with the additional security of manufacturing as many components as possible for our suspension systems in house. This dual source approach ensures security of supply and helps immensely with quality control.”

Significant savings from cutting with air From the outset, Gripple’s manufacturing team was impressed with the Nukon laser’s build quality, performance and precise cut. “Nukon Lasers UK has shared a wealth of advice and technical knowledge with us, including specific production processes and the most cost-effective

gas to use depending on the material being cut. For example, our solar cable hangers are cut exclusively using compressed air – an essentially free medium,” says Claire Tunnard. By largely cutting with compressed air, rather than costly nitrogen gas, which looks set to remain at historically high prices, Gripple is also benefiting from significant savings which, in turn, assist it in remaining competitive. In terms of reliability, Gripple reports that the Nukon machine has been trouble-free. Nukon Lasers UK’s Steve Haddrell adds: “At the end of the day, for us, it is all about supporting the customer, whether it’s advising on the best fibre laser machine for their needs, achieving a particular finish, or using a particular gas – and all with the highest levels of aftersales service as standard.

We have worked closely with Gripple since day one and will continue to do so. Our UK service and support teams are never more than a phone call or short drive away, and we also have the added support of the incredibly helpful and approachable teams at Nukon’s European HQ.” The Nukon Eco 315 4kW 2D fibre laser machine purchased by Gripple was specially developed for organisations wishing to add value to in-house manufactured products, and for subcontractors either starting out in 2D laser cutting or with demanding flat sheet metal cutting requirements. Nukon Eco machines offer high-spec features including advanced Lantek Expert CAD/CAM nesting software and American-made nLIGHT fibre lasers, with CutLine Adaptive Beam Shaping.

Gain the cutting edge. • • • •

2D, 3D and tube fibre laser cutting machines from Europe Accessible high power and high performance American-made nLIGHT fibre lasers Advanced Lantek CAD/CAM nesting software

• From the exclusive Nukon distributors for the UK and Ireland

nukonlasers.co.uk PIM Metals December 2023/January 2024

NEW PRODUCTS

Steel mill reaps rewards from adopting NSK bearings

NSK TF series bearings offer outstanding toughness and longevity in harsh operating conditions thanks to superior resistance against wear, seizure and heat

hen a steel mill was experiencing regular failures of the bearings on its pilger mill, the plant turned to the expertise and experience of NSK for a robust and economic solution. By recommending bearings with 200% more life than the units they replaced, NSK provided the mill with annual savings of €159,933. To identify the root cause of the issue, NSK’s engineering team performed a technical

PIM Metals December 2023/January 2024

application analysis, discovering that the main problems were severe operating conditions exacerbated by high loads and inadequate lubrication. Armed with this information, NSK was able to propose a special spherical roller bearing with optimised internal design that took advantage of the company’s proprietary Super Tough (STF) steel. Durability, even in extreme operating environments is a critical criterion for steel mill bearings. The reliable, uninterrupted performance of

rolling components that endure heavy loads and high heat amid water and scale is vital to realising and accelerating production capacities. NSK bearings made from STF or TF steel offer outstanding toughness in harsh operating conditions, providing long service life and superior resistance against wear, seizure, and heat. A trial at the steel mill showed that the new bearings offered double the operating life. Reductions in production downtime, maintenance labour,

replacement bearings and other material replacements led to annual costs savings of €159,933 for the steel mill. NSK offers a complete product line for steel mill processes, with long-life and highly reliable bearings supporting improved productivity and lower maintenance costs. Bearings are available to cope with heavy/ shock loads and vibration, as well as operating speeds that range from extremely slow to very high, coupled with rapid acceleration and deceleration.

EVENTS

The Who’s Who of the international wire, cable, tube & pipe industries in Düsseldorf: Who will be exhibiting in April 2024?

photo: Messe Düsseldorf/ctillmann)

he sector looks to Düsseldorf with anticipation, where the global No. 1 trade fairs for the wire, cable, tube & pipe industries will be staged from 15 to 19 April 2024. With immediate effect all exhibiting firms are live at www. wire-tradefair.com, Exhibitors & Products 2024 and www. tube-tradefair.com, Exhibitors & Products 2024 presenting their products and trends on the Internet portals. In five months that time will have come and the industries will meet at Düsseldorf Exhibition Centre. What makes it special: #Sustainability and #Energy Efficiency are even more in focus than in 2022. Daily ecoMetal trails touring the exhibition halls are

aimed at convincing visitors of exhibitors’ novel, clean production methods. Trend forums, expert meetings and themed pavilions for stainless steel, hydrogen, other regenerative energy carriers, separating and cutting, plastic pipes & tubes and finished products for Fastener & Spring

Making Technologies will be in focus. Community building comes care of the daily After-Work Chill Meetings in the outdoor spaces and entrance Nord – here exhibitors can also meet their customers after trade fair hours over drinks and tasty Düsseldorf canapés.

Ranges on display at wire 2024 wire will be staged in exhibition halls 9 to 17 in 2024. It will be as big as ever, occupying some 66,900 square metres of exhibition space. With 1,026 exhibitors from 60 countries it will even surpass pre-pandemic levels. On show will be machinery and equipment for the manufacture and processing of wire, finished products at Fasteners & Springs, tools and auxiliaries for process engineering, materials, glass fibre technologies, special wires and cable as well as innovations from sensor, control and testing technology. In addition to wire and cable machinery producers, wire and cable products and glass fibre technologies, impressive wire mesh welding machines will be displayed in Hall 17. These pose logistics with particular challenges because thick cables have to be laid and connected

PIM Metals December 2023/January 2024

photo: Messe Düsseldorf/ctillmann)

EVENTS

in the supply ducts to transport the electric power this heavy machinery requires for its live operations.

Fastener & Spring Making Technologies and their finished products in Hall 16

registered. They will occupy a total of 49,600 square metres’ exhibition space in Halls 1 to 7.1. #Tube 2024 presents the entire process chain of the tube & pipe industry – in a focused and compact array: machinery

Here the complete value chain for fasteners and springs can be found: from raw materials, machinery and equipment to fasteners, connectors and industrial springs. This once again makes #wire Düsseldorf 2024 a highly topical information and order platform for the producers, dealers and buyers of screws, brackets, construction components and fittings, all types of springs and wire bending parts.

Ranges on display at Tube 2024 Tube also enjoys excellent booking levels. So far, 768 exhibitors from 49 countries have 20

PIM Metals December 2023/January 2024

International satellites in booming markets of the future Over a time span of almost 40 years wire and Tube Düsseldorf have developed into the leading trade fairs for their industries –

now also “giving birth” to satellite events on the #Wire, #Cable and #Tubes & Pipes themes. In their regions, they are the market leaders and drivers for the local industries and boast high growth potential. Satellites in Turkey, Egypt, Mexico, China, Thailand and India now already form an integral part of the growing portfolio of the Metal and Flow Technologies made by Messe Düsseldorf. Press contact for wire/Tube 2024: Petra Hartmann-Bresgen M.A. Ulrike Osahon Phone: +49 (0)211/4560-541/992 Fax: +49 (0)211/4560-87 541 E-Mail: HartmannP@messeduesseldorf.de

photo: Messe Düsseldorf/ctillmann)

and equipment for manufacturing pipes and tubes, finishing and processing of pipes & tubes as well as raw materials, plastic pipes, tube products and accessories, used machinery, tools for process engineering, auxiliaries, sensor technology, control, measuring and testing technology all form part of the extensive ranges. This line-up is complemented by tube & pipe, pipeline, OCTG technology and profile trading.

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11–12 SEPTEMBER 20246NEC

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x250+ Supply Chain Exhibitors x5,000+ visitors x120+ Speakers x50+ Seminars x4 Theatres

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