IIW White Paper

5 Needs and challenges in welding and joining technologies

The change from electrodes (MMA) to solid (MIG/MAG) and cored wires (FCAW) is estimated to be as shown in Figure 5.12 . It has been obvious for 30 years to automate the welding operations by introducing robotised stations. The number of stations continues to grow quickly to increase productivity and to improve the working environment and to eliminate monotonous tasks. To design purpose built installations without robots is almost a malpractice due to the price reduction for robots. During the last 15-20 years robot prices have been reduced by 46%.

Worldwide weld metal consumption - by region

6000

5000

N. America

Europe

4000

Asia

Other

3000

2000

Source: ESAB estimates

1000 0 Thousands of metric tonnes

Figure 5.12 Changes in welding consumable types (Reproduced courtesy: ESAB)

1998 2001 2004 2007 f

2010 f

2013 f

Worldwide weld metal consumption - by weld process

6000

5000

4000

Solid wire

Electrodes

3000

Sub Arc wire Flux cored wire

2000

Source: ESAB estimates

1000 0 Thousands of metric tonnes

1998 2001 2004 2007 f

2010 f

2013 f

One should consider the higher capability of the robots today particularly since the prices have dropped by 77% since 1990 ( Figure 5.13 ).

Price index of industrial robots for international comparison (based on 1990 $ conversion rate), with and without quality adjustment

0 10 20 30 40 50 60 70 80 90 100

Robot prices, not quality adjusted

Figure 5.13 Changes in prices of robots ( Reproduced courtesy: B. Pekkari)

Index 1990=100

Robot prices, quality adjusted

In mechanised applications one can further increase the productivity by using large packaging solutions.

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Through Optimum Use and Innovation of Welding and Joining Technologies

Improving Global Quality of Life