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RMD and Pro-Pulse Cuts Welding Time in Half, Eliminates Rework for Mechanical Contractor
- Welding time is cut in half
- Rework, which could be as high as 10%, is now non-existent.
- Weld quality is uniform and identical, even between welders of different skill levels
- Processes are easy to learn. New welders get up to speed quickly
Customer Testimonial
“Now, it's hard to tell one welder from another. The new technologies level the playing field between our less- and more-experienced welders. Customers think we've fully automated the process because the welds look uniform and identical, and I have a huge amount of confidence in every weld we make.”
— Mike Mackintosh, production and design manager, Bel-Aire Mechanical
Application
- Root and fill passes on carbon steel pipe
Key Business Issue
- Increasing productivity
- Reducing weld costs
Challenge
- Finding an alternative to Stick and MIG processes that increase productivity and provides the quality demanded by customers.
Previous System & Process
- Stick and traditional MIG
New Solution
- RMD™ (Regulated Metal Deposition) for root pass.
- Pro-Pulse™ advanced pulsed MIG process optimized for fill and cap passes.
Results
- Doubled production. As part of redesigning its pipe welding operations, Bel-Aire adopted RMD and ProPulse. Combined with better pipe preparation and improved workflow this allowed them to double pipe-welding production. On a six-inch joint, time has decreased by 50%.
- Improved quality. The new processes leveled the playing field between the less- and more-experienced welders. Customers think the process has been automated because of the consistently high weld quality.
- No rework. "Rework is now almost nonexistent. People are going to look at that and ask, 'Is it possible?' but it's true. I can now put an estimate together and not have to consider rework in the equation. Rework due to weld quality is no longer a factor."
— Mike Mackintosh, production and design manager, Bel-Aire Mechanical
