Weld evaluation after initial weld development will often reveal deficiencies in selection of materials, design, and process. For example, metallurgical cross-sections could reveal cracks in the welds as can happen during welding with electro less nickel plating that introduces a high amount of phosphorous in the plating; changing to electroplated nickel can eliminate the cracks. Rapid cooling rate can also produce cracks in many alloys due to formation of unstable phases or excessive residual stress on cooling; introducing a long cool down at the end of a laser pulse can avoid those issues.
Process development should also involve determination of process throughput (welds per minute) to make sure the process and power supply are fully capable of meeting the production rate. Issues related to production such as part loading/unloading, part alignment, cleanliness, and part cooling should be discussed in detail to make sure the machine builder is aware of all the nuances. Keep in mind that any last-minute change to an automation equipment can mean weeks of delays to the project.
Once the preliminary development is complete, the final optimization will have to be carried out on the real production machine with production fixtures and setups.
- Review of Welding Specifications During the BID Phase.
- Development and Qualification of Welding Procedures.
- Development of Welder Qualification Programs.
- Development of Welding Specifications.
- Review of Procedures and Qualifications of (Sub) Contractors.
- Representing the Client during Kick-Off / Pre-Inspection Meetings.
- Audits at Location during Qualification or Production Phase of the Project.
- Troubleshooting during the Project on Welding and Material Issues.
- Selection of Materials and Welding Consumables
- Selection of the Welding Process
- Welded Joint Design
- Welder Training ; Testing
- Preparation and Approval of WPS ; PQR
- Welding Procedure Qualification Witnessing
- Weld Failure Analysis