The Xiris Blog

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, Tube and Pipe welding, ROI, return on investment, productivity tools

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, Tube and Pipe welding, ROI, return on investment, productivity tools

Monitoring Welding Processes in Color

Posted by Justin Grahn on Tuesday, September 13, 2016 @ 12:52 PM

In most situations, a high dynamic range (HDR) image that provides a clear view of the weld arc and immediate work environment is enough to provide operators everything they need to control or adjust their welding process.  Typically, such images are provided in monochrome because, in certain circumstances, it provides better image saturation and fidelity. Monochrome images can accentuate the light and shadows of a welding scene, making the texture of the welding surfaces, torch tip, wire and melt pool easier to see.  Images with a wide range of tonal values, such as what might exist in a high dynamic range image of a welding scene, tend to work well in monochrome.  This is especially the case when the tones in the image range all the way from the blackest blacks of the background to the whitest whites of the welding arc, with lots of varying grey tones in between.

However, for some welding situations, color imaging that delivers high dynamic range imaging has particular value.  The presence of color allows the boundary of aspects of the weld process to be easily detected by the operator.  Bright hues that highlight an element, such as the melt pool, shielding gas or torch tip can improve the visibility of that object to the operator.

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Color Image of a Manual TIG Process

Of all the types of welding, perhaps the most suitable for color imaging is GTAW (TIG).  Some of the features that are better seen with color in a TIG process include:

  • Melt Pool: Better edge definition and detection of flow of molten material.
  • Shielding Gas: Operators are able to see if there is any shielding gas present.  Also, each shielding gas mixture typically has its own signature certain color.  If the gas chemistry in the welding environment changes, then so does its color. 
  • Oxidation: Very easy to detect the presence of flames resulting from the burn-off of any oils or impurities.
  • Heat Affected Zone (HAZ): The leading edge of the heat affected zone can be detected in the parent material as it typically colorizes at elevated temperatures.  This can indicate the amount of heat penetration and energy transfer.
  • Temperature Indicator: Operators can clearly see discoloration of metal due to excess heat in the welding process.
  • Torch Tip: Easier to see the definition of the torch tip and cup relative to the weld arc.  Allows the operator to monitor the impurity build up on the torch tip and spatter presence on the cup.

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Narrow Gap TIG Welding – Color Exposes Different Details

Conclusion

Ultimately, the choice of whether to use color or black and white camera technology depends on what feels right for the operator.  Nevertheless, for certain welding operations such as TIG, the use of color imaging can significantly enhance the clarity and detail of the image, thereby improving the operator’s ability to detect even small changes in the weld scene.

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

Sign up to receive our Weld Video of the Month

Topics: quality control, Xiris, welding, High Dynamic Range, TIG, productivity tools, color imaging

Free ROI Calculator for Tube Weld Inspection Systems

Posted by Karen Serles on Tuesday, August 30, 2016 @ 02:30 AM

Two of the most important competitive advantages in tube production are the quality of the weld and the quality of the formed profile of the tube.  How can you improve your quality while also driving down costs and delivery times?

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The Xiris WI2000 Weld Inspection System helps Tube fabricators improve quality and save costs by reducing:

  • Mill Set Up Time
  • Lab Time
  • Mill Downtime
  • Scrap
  • Customer Returns

 

Now, there's a powerful way to justify your productivity investment.  Use your own cold, hard figures to calculate Return on Investment (ROI). 

 

 Download your FREE ROI Calculator Now!

Make an informed decision about a XIRIS WI2000 Weld Inspection System purchase and see how you can achieve consistently higher quality while reducing costs and increasing customer satisfaction.

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

Sign up to receive our Weld Video of the Month

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

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