The Xiris Blog

Checking Tube Welds Before and After Scarfing

Posted by Cameron Serles on Wednesday, December 07, 2016 @ 10:01 AM

The process of tube welding requires several variables to be in check for efficient and stable production and to meet the quality demands of the industry.  Mill dynamics, from setup to production, have an impact on the stability of these variables.  Measuring and monitoring these variables is the first step in controlling them and improving weld quality for tube fabricators.

In response, tube fabricators employ laser based weld inspection systems to monitor a variety of geometrical features around the weld area of the tube and to provide early warning of quality issues related to the welding and forming process.  Traditionally placed right after the weld box on a tube mill, where the majority of tube forming and weld bead measurements can be made, such systems provide the operator with an early warning of weld related process variations that could lead to quality defects.  

While most tube mill customers use the system right after the weld box where the most as-weld related information is available, some fabricators use it after scarfing to check for quality issues related to the scarfing process: does the scarfing tool cut too deeply, or not enough?  Is the tool damaged?  Is the scarf cut a consistent amount?  All these questions can be addressed by installing a weld system after scarfing.

Now, Xiris has developed a double head laser based weld inspection system that allows for one head to be placed immediately after the weld box and one head immediately after scarfing.  In this way, tube fabricators can monitor their tube production before scarfing for weld related defects; and after scarfing for potential scarf related issues.

 

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WI2000 Double Head Configuration: One Head Post Weld, One Head Post Scarf

 With a double head configuration, tube fabricators can better control their process and improve quality by monitoring the tube profile, weld bead geometry and final scarf cut, all controlled from a single system. 

 

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com or sign up to receive the Weld Video of the Month 

Topics: quality control, weld camera, weld inspection, Xiris, welding, scarfing, weld seam

Reducing Tube Mill Downtime with Weld Inspection

Posted by Cameron Serles on Wednesday, November 23, 2016 @ 03:00 AM

Tube mills require a large capital investment that often gets amortized over several years.  Even assuming that a mill is written down over an extended period, such as 10 years, the total cost of running a mill can be substantial when including the hourly amortized cost of the mill, the operating costs and related personnel costs.  Not surprisingly, minimizing mill downtime is always a priority for tube producers.  When a tube mill stops for planned events (such as product change overs, mill qualification, planned maintenance), or unplanned events (such as equipment failures, material input problems, shortage of operators, unscheduled maintenance), production stops.  For most tube fabricators, downtime is the single largest source of lost production time.  While there could be many reasons for a mill’s downtime, focusing attention on the constraints of the mill to ensure optimal use of resources is the most direct route to improved productivity.  When manufacturing processes get out of control on a tube mill, common trial and error solutions typically prolong the time needed to correct the process.  The result is high wastage and repair costs. 

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(photo courtesy of www.prweb.com)

In contrast, by implementing automated tools such as an automatic weld inspection system, mill downtime can be reduced by improving the use of resources needed to keep the process in control.  With this equipment, tube fabricators can get a better and more advanced warning of process issues that are moving out of tolerance so that the mill does not have to be shut down to fix major tooling or welding issues.

Want to reduce downtime in your mill?  Justify an automatic weld inspection system using a ROI worksheet where you can enter your own mill data. 

 

    Download your FREE ROI Calculator Now!

 

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com or sign up to receive the Weld Video of the Month 

Topics: quality control, Xiris, welding, ROI, return on investment, productivity tools

Xiris Helps Tube Producer Eliminate Weld Problems

Posted by Cornelius Sawatzky on Wednesday, November 16, 2016 @ 10:08 AM

Xiris’ WI2000 Weld Inspection System measures weld bead and formed tube geometry for tube and pipe producers.  Recently, the WI2000 was featured in an article in the Tube and Pipe Journal, where it was identifed as a major reason why Middletown Tube of Ohio, USA was able to improve its tube quality and reduce its scrap rate.

Providing more benefits than was expected, the WI2000 has helped the tube producer find defects with their mill equipment and setup; catching potential defects before they become failures and cause scrap.  As a result, tube mill setups have become a science rather than an art for Middletown.

Read the full article here.

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For more information on how Xiris Weld Inspection Systems can improve the quality and productivity of your tube and pipe production, visit Xiris.com 

You may also be interested in our Weld Video of the Month 

Topics: quality control, weld inspection, Xiris, welding, Tube and Pipe welding, productivity tools, Middletown Tube

How to Reduce Quality Lab Time Associated with a Tube Mill

Posted by Cameron Serles on Wednesday, October 26, 2016 @ 10:04 AM

Lab time is a precious commodity.  As part of the changeover process on a tube mill, the tube to be produced must first be qualified to a desired level of quality in the lab. This line qualification process often includes cutting as many as three separate cross sections of a tube and sending them to the lab for processing where they get polished and photographed as micrographs. Once created, the micrographs can be measured or analyzed to verify that the weld structure of the tube meets the specifications required by the customer.  By using a weld inspection system that can accurately measure weld bead geometry and tube profiles, it may be possible to reduce the number of micrographs taken for each line qualification from a sample made for 100% of every change over to a lower, statistically relevant percentage.  The net result is that fewer line qualifications are required, leading to fewer tests (e.g., micrograph samples) performed in the lab, saving both lab time and lab personnel costs.

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Image of a Sample Micrograph

courtesy www.twi-global.com

 

Want to reduce your lab times?  Investigate how to justify an automatic weld inspection system using a ROI worksheet where you can enter your own mill data. 

 

   Download your FREE ROI Calculator Now!

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com or sign up to receive the Weld Video of the Month 

Topics: quality control, Xiris, welding, ROI, return on investment, productivity tools

Xiris Attends CanWeld 2016

Posted by Catherine Cline on Wednesday, October 12, 2016 @ 09:14 AM

Xiris had the pleasure of co-exhibiting with Maverick Testing and TIP TIG USA at the CanWeld Tradeshow and Conference, held at the Expo Centre in Edmonton Alberta, Oct. 5-6, 2016.   The conference was well attended and drew from a wide range of industry, including mining, oil and gas, pipelines, power generation, petrochemical, fabrication and construction, manufacturing, steel and shipbuilding and pulp and paper.  Educators were also out in full force including attendees from Red Deer College, Thompson River University, Southern Alberta Institute of Technology (SAIT) and Northern Alberta Institute of Technology (NAIT).   All were very enthusiastic about the Xiris weld videos on display at the booth citing the unbelievable image clarity Xiris is able to achieve with its high dynamic range weld cameras.Blog_Oct_12_Image_1.jpg

The Maverick and TipTig Booths at CanWeld with “TEX” Front and Centre.

Maverick Testing, with locations in La Porte, Texas and Corpus Christi, Texas, is a full spectrum, state-of-the-art testing laboratory providing a comprehensive range of metallurgical and mechanical testing services as well as Welding Procedure Specification development.  Maverick was exhibiting its welder test coupons which are used in house for its Welding Process Qualifications but are also available to be purchased and shipped to other facilities or jobsites.  Visit coupons@mavtechinc.com

TIP TIG offers a very unique hotwire GTAW welding process that uses patented wire feed technology to provide the highest quality, highest deposition rates with the lowest possible heat input values, while consistently delivering the greatest metallurgical results on all alloys.  The process has also been proven to provide the lowest possible hexavalent chrome weld fume emissions which have been measured as “undetectable”.  The TIP TIG technology can be used successfully on a number of alloys including; Carbon, Duplex and Super Duplex Stainless Steels, Inconel, Stellite, Titanium, Aluminum, Hastelloy and many others.  Visit www.tiptigusa.com for more information.

Xiris was also fortunate to be able to integrate our cameras into the orbital welding system at the Lincoln Electric booth.   The welders were extremely impressed by the camera system and found it far easier to weld looking at a clear picture on the computer screen versus the view through a weld helmet!

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The Xiris XVC-1000 integrated into the Lincoln Orbital Welder.

 

Next, Xiris looks forward to Fabtech 2016 in Las Vegas, November 16-18 where both Lincoln and TIP TIG (as well as many others) will be welding with Xiris Cameras.  Check future blogs for details.  We look forward to seeing you there!

 

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For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com 

Topics: weld camera, Xiris, welding, High Dynamic Range, fabtech, Maverick Testing, CanWeld 2016, Tip Tig, Lincoln Electric

How to Reduce Set-Up Time on a Tube Mill

Posted by Cameron Serles on Tuesday, September 27, 2016 @ 02:30 AM

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Every time a tube mill is changed over to run a new product, a set-up process must be performed to adjust the mill accordingly.  This process can be quite time consuming as a number of variables, input materials and equipment need to be adjusted to allow the mill to run the best quality product possible.  Reducing  the set-up process time and complexity is welcome news to all mill operators.  One approach is to add an automatic weld inspection system right after the weld box on the tube mill.  By adding such a system, immediate feedback of the weld geometry of the tube being produced can be provided to the mill operators as set-up adjustments are being made.  The result is a faster set-up process, less mill downtime and a more efficient tube mill.

 

Now, there's a powerful way to justify your productivity investment.  Use your own mill parameters to make an informed decision about buying a post weld inspection system.

 

  Download your FREE ROI Calculator Now!

 

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com 

Topics: quality control, Xiris, welding, ROI, return on investment, productivity tools