The Xiris Blog

How to Detect Scarf Tool Wear on a Tube Mill

Posted by Cameron Serles on Thursday, December 13, 2018 @ 11:00 AM

During tube production, immediately after the tube has been welded and before any further in-line processing is done, the weld bead must be scarfed off the tube. Scarfing is the process whereby the weld bead is cut off with a knife, or scarfing tool.  Unfortunately, if the scarfing tool is not done properly, the tube may not meet end user customer specifications because of a rough surface left behind by the scarf tool.  The result can be the primary contributor to creating a leak path on a compression fitting.

Using a surface profiling tool such as the Xiris WI2000, the scarf defect measurement can be used to detect how well the scarfing tool is cutting the weld bead and indicate the amount of scarf tool wear. 

Scarf tool wear describes the gradual failure condition of a scarf cutting tool on a tube mill as a result of ongoing use.  It can occur either as flank wear in which the portion of the scarf tool in contact with the welded tube erodes over time sometimes causing a ridge to be left behind in the scarf zone; or as crater wear, in which contact with chips of weld bead erodes the rake face of the tool causing an uneven cut surface; or a cluster of weld bead material building up on the face of the tool causing it to dredge a groove in the scarf zone. These conditions are somewhat normal for tool wear, and they do not seriously degrade the use of the scarf tool until it becomes serious enough to cause a scarf tool cutting edge failure that may be a concern for a potential leak path for the tube in its final use.

The scarf defect measurement on the WI2000 looks for any significant deviations in surface height above or below the ideal scarf surface.  The Scarf Defect will detect the absolute value of the largest defect on the scarf surface.  Any significant amount of scarf tool wear could reduce the specifications and performance of the final tube, especially for some automotive applications where tight assembly requirements or a smooth, scratch free surface is required.

Scarf Defect_2017-01

The Definition of a Scarf Tool Wear: The scarf plane can be defined as the straight line drawn between the left and right scarf edges.  Any detected features above or below the scarf plane, are measured as a scarf defect.  The actual amount of wear is defined as the distance from the scarf plane measured perpendicularly to the scarf plane.

If you have any questions about our profile inspections for tube and pipe, please feel free to contact us. 

 

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Topics: tube mill, tubedefects, WI-2000p, defects, tube, pipe, scarfing, bead height, Tube and Pipe welding, quality control

The Quality Challenge in Metal Additive Manufacturing

Posted by Magda Paszko on Thursday, November 29, 2018 @ 10:30 AM

Product manufacturers in industries such as aerospace, defense, and healthcare have no room for error in their manufacturing processes—the product liability is too high with human lives at stake. The need for the strictest quality control and quality assurance poses substantial challenges for these manufacturers as they migrate some product manufacturing to use Metal Additive Manufacturing (AM).

Manufacturers of precision parts are attracted to metal AM because it allows the production of intricate, free-form components directly from CAD—making the production of these parts more feasible than with conventional machining. In addition, Metal AM parts often end up being lighter and stronger than parts made with traditional subtractive machining processes.

A primary obstacle to the widespread use of Metal AM is the difficulty of implementing effective quality control and qualifying parts for the end users. Because of the random nature of material deposition in AM processes, parts must be continually monitored during production rather than being tested after completion to ensure cost effective production.

However, a powerful tool for this quality control and quality assurance has been developed— High Dynamic Range ( HDR) cameras. These cameras can be used in-process to monitor multiple parameters and enable the real-time adjustments required for Metal AM to be successfully productive.

Metal AM-043399-edited
Image captured by a Xiris XVC 1000 HDR Camera

For manufacturers that want to adopt Metal AM, investing in HDR camera technology will be a major step in overcoming the challenges of consistent part quality. The technology is available now, and early adopters stand to gain a significant competitive advantage.

To learn more about HDR camera technology and how it can help your company achieve the quality control and quality assurance necessary to make Metal AM a winning solution, download our whitepaper, Ensuring Quality in Metal Additive Manufacturing.

 

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Topics: XVC Weld Camera, weld camera, additive manufacturing, Metal AM

Reflecting on Fall 2018 Trade Shows

Posted by Magda Paszko on Thursday, November 15, 2018 @ 08:35 AM

The experience of a trade show is quite difficult to put into words; regardless of whether you are an exhibitor or an attendee, the level of energy, engagement, and excitement associated with a show is indescribable. Here at Xiris Automation, we are quite familiar with the trade show process, but this doesn’t make the events any less exciting. The last couple of months have been no exception as we traveled the world to meet customers and faced the hustle and bustle of EuroBLECH and FABTECH.

EuroBLECH

EuroBLECH is the largest trade exhibition for the sheet metal working industry and it is valued by top industry professionals from all over the world.[i] This year, the show ran from October 23rd to the 26th in Hanover, Germany and highlighted the theme of Stepping into the Digital Reality. The show attracted over 56,000 visitors from all around the world[ii] and gave us the opportunity to connect with clients from new regions. We showcased our weld cameras and weld inspection systems and were very impressed with the level in interest in the XVC 1000e welding camera.

Xiris Team at Euroblech 2018

This show also doubled as our first opportunity to introduce Michael Staiger to our European market. As business in Europe continues to grow, Michael joined our team as the new European Service Technician in order to better meet the needs of our customers. Based out of the Xiris Automation GmbH office just outside of Duesseldorf, Germany, Michael will be responsible for installation, calibration, and training for all new Xiris customers, as well as servicing and repair work of Xiris equipment across Europe. Not only was EuroBLECH the perfect opportunity to introduce Michael to our connections worldwide, but it also conveniently demonstrated the scope of our business. 

Introducing Michael Staiger

FABTECH

About one week after coming back from Germany, we headed to Atlanta, Georgia for FABTECH 2018. FABTECH is North America’s largest metal forming, fabricating, welding and finishing event[iii] and our team was very excited to get in touch with our North American market. The show took place at the Georgia World Congress Center and was open to the public from November 6th to the 8th.

Xiris Booth at Fabtech 2018

This year, our booth was bigger and better than ever before as we showcased the capabilities of our HDR welding cameras through demo videos of numerous applications. We also had over 20 cameras on the floor with trusted industry partners including: Lincoln Electric, Hobart Brothers, Cloos Welding, Gullco, Abicor Binzel, Arcrite Automation and Bug-O, big thank you to those who participated! Seeing the cameras in action all around the show encouraged attendees to visit our team experts and ask their burning questions. If your company will be exhibiting at Fabtech 2019 or any other welding automation or fabrication show, and you feel you could benefit from displaying or operating a Xiris camera, please contact our sales team.

Xiris Team at Fabtech 2018

Final Thoughts

In conclusion, it has been a very successful trade show season for Xiris Automation. It was a pleasure meeting everyone who had the chance to stop by one of our booths and we are looking forward to connecting with you further. If you did not have the opportunity to visit us, or if you have any further questions about our equipment, please feel free to check out our website or contact us. A lot of work goes into one of these shows, so we would like to send out a big thank you to everyone who made them possible, it is so satisfying to see all that hard work pay off. The preparation for these shows begins many months, sometimes even years, in advance, so it is time to sign off and start planning for the future. Until next time!

 

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Sources:

[i] https://www.euroblech.com/2018/english/event/exhibition-profile/

[ii] https://www.euroblech.com/2018/english/event/about-euroblech/

[iii] https://www.fabtechexpo.com/about

Topics: XVC Weld Camera, Trade Show, weld camera

Rugged, Robust, and Ready to Use - The XVC-S Sub Arc Weld Camera

Posted by Cornelius Sawatzky on Thursday, November 01, 2018 @ 09:00 AM

Submerged Arc Welding (SAW) is a common welding process used in a variety of applications pipe and pipeline fabrication.  In many applications, pipe is tack welded together to hold the pipe in shape, then submerged arc welded from the outside using a continuous process such as on a spiral welded pipe mill, or in butt joining pipe segments using an orbital welding process.  Many of these applications have a very confined or awkward working environment that makes it difficult, if not impossible, for a human to observe the weld process in a production environment.

XVC S Column and BoomAn XVC-S Mounted to a Column and Boom Robot Performing Welding and
Cladding on Large Pipes

In any such welding work environment, whether it be the confined space of a pipe welding application or a high-height welding application such as in large pressure vessel construction, operator safety is always a priority. In the welding industry, workforce demands, government regulations, changing business practices, and increasing environmental awareness are driving the manufacturing environment to be safer, healthier, and friendlier for workers. As a result, the use of camera technology is becoming more prevalent in order to alleviate some of the dangers and liabilities.

While the welding environment is particularly harsh on electronics, the Xiris XVC-S cameras for Sub-Arc welding applications have proven to be very durable and reliable in some of the toughest environments. The XVC-S cameras have been used in hot, confined spaces to provide a clear view of the submerged arc weld torch and its alignment to the weld seam, or in a post-weld application to inspect the weld as the slag comes off the weld bead. The cameras allow the operator to remotely view and manage the welding process by providing the ability to adjust the weld process real-time, ultimately reducing potential subsequent rework.  For the fabricator, this means saving time and money with less machine stops and more on-arc time.

XVC-S ViewThe View of the Sub Arc Welding Process Using an XVC-S Camera

But the benefits of the XVC-S are not just financial: since the XVC-S submerged arc weld camera allows the welding processes to be viewed remotely, operators can monitor the welding process from the comfort of a process control cabinet as the cameras are placed at the weld head.  As a result, welders are no longer required to work in cramped, uncomfortable places or dangerous heights, reducing fatigue and safety issues.

With clearly demonstrated financial benefits from cost savings and improved health and safety considerations, the business case for implementing an XVC-S camera is straightforward.  Don’t you think it’s worth looking into a camera for your sub arc business? Learn more about the XVC-S camera and download the FREE Datasheet for more details. If you have any questions, please do not hesitate to contact us.

Topics: submerged arc welding, Sub Arc welding, XVC Weld Camera, pipe, Xiris, Robotic Welding, welding automation, weld inspection

Xiris in Shanghai, Tube China 2018

Posted by Dean Zhao on Thursday, October 18, 2018 @ 10:30 AM

 

Just a couple of weeks ago, Xiris had the opportunity to showcase our Weld Inspection Systems at Tube China in Shanghai. This was a four-day trade show which ran from September 26th to the 29th. Tube China has grown into Asia’s most influential tube and pipe industry event and attracts tens of thousands of visitors to thousands of leading brands. As the show has grown over the years, it has been fascinating to see the visitor interest grow as well. Participants were significantly more informed about the various technologies and were asking insightful questions as a result.

Xiris-Belwin Booth Weld-Inspection-System

The live demonstration of our laser-based 3D inspection system, the WI2000, resonated with many visitors as they could see it detect various quality issues on smaller diameter tubes. In collaboration with our Chinese distributor, Belwin Intelligent Technology Co, we are able to better accommodate our customers overseas.

If you have any questions about Xiris’ Weld Inspection Systems, or are trying to choose the right system for your process, please visit our website or contact us directly.

Topics: Trade Show, Tube China 2018, weld inspection

Detecting Bead Ripple During Tube Manufacturing

Posted by Cameron Serles on Friday, October 05, 2018 @ 11:45 AM

Lighter wall mild steel pipe production requires bead height monitoring for bead ripple. Bead ripple is a condition sometimes associated with a weld process that is too hot and may result in longitudinal weld cracks.  Bead ripples appear along the length of the weld bead as undulations with measurable differences in height by as much as 1/8” (3 mm).  Often the height of the bead ripple on a welded pipe is a function of the heat that has gone into the weld process:  the higher the heat, the greater the height of the bead ripple. In most applications, a weld bead should have a smooth, consistent height as an indicator of a stable weld process.

Bead Ripple1An image of a weld bead with bead ripple

In some applications, a weld bead ripple can be desired, such as in certain coated steel products. This ensures that all contaminants from the area of the weld have been squeezed out, preventing potential inclusions from occurring in the weld bead, which would result in compromised weld quality.

By measuring the bead height on a weld bead over a period of time using a laser based triangulation system , an indication of the smoothness of the weld bead can be made.  By calculating ongoing historical statistics of the head height (e.g. min/max, average, standard deviation), an indication of smoothness of the weld bead or bead ripple can be made.  Tolerances of the amount of smoothness or ripple can be set to match the process and when exceeded, an alarm can be set.

Bead Ripple Detection1 Measuring the weld bead height over successive images can detect bead ripple over time

Topics: tube mill, tubedefects, productivity tools, tube, bead height, Tube and Pipe welding, quality control

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