Read Full Story
Print Summary
Share Summary
Article Summary
Wheel Manufacturer Eliminates Spatter
- Eliminating spatter eliminates pinholes and quality problems
- Unique CSC process reduces heat affected zone, increases tensile strength
- Travel speed increases 25 percent, wire consumption decreases
- Energy-efficient XMT inverter reduces utility bill by $1,000/year
- Hobart wire in ROBOPAK container improves feedability, inventory management
Customer Testimonial
“We know the weld has a stronger tensile strength than the parent material. This is attributed to the minimal heat-affected zone of the CSC process.”
— Harlan Janssen, quality/engineering supervisor, Carlisle Tire & Wheel Company
Application
MIG welding of quality commercial, recreational, utility tires and wheels.
Key Business Issue
- Application of anti-spatter spray caused weld quality issues, which in turn affected productivity
Challenge(s)
- Selecting a GMAW process that would eliminated spatter in a fixed (hard) automated welding application
- Gaining operator trust during the process change
Previous System & Process
- Standard short circuit MIG welding
New Solution
- Miller XMT 350 CC/CV inverters paired with a Jetline CSC controllers
- BR6 copper-coated filler wire in Recyclable ROBOPAK containers from Hobart Brothers.
Results
- Weld quality improved. “Enhancing our welding process to increase our competitiveness is just one small example of the Carlisle continuous improvement philosophy.”
—Richard Kohl, Carlisle operations manager - Problems associated with anti-spatter eliminated. “We often had too much or not enough anti-spatter solution. With too little, spatter would stick to the wheels. With too much, pinholes would form in the weld, which would then have to be repaired. The pinholes also caused problems with painting.”
—Doug Karlin, Carlisle production engineer - Increased tensile strength. “We can apply enough pressure to deform the hub and crush it like a soda can and even then, the weld won't break.”
—Harlan Janssen, Carlisle quality/engineering supervisor - Energy savings. “The XMT 350 is 28 percent more power-efficient, which amounts to energy savings of $1,000 a year.”
—Doug Karlin, Carlisle production engineer - Reduced reject rates. “The ROBOPAK 950 reduced reject rates. Previously, we had to apply wire straighteners to remove the cast. With the ROBOPAK, the wire is straighter so it makes better contact.”
—Harlan Janssen, Carlisle quality/engineering supervisor
