METALSA

Seeking a solution to eliminate spatter from the welding process in steel assemblies production

Posted by JAVIER from METALSAResponsive · Specific Technical Innovation · Project Size Range : 250,000 - 1,000,000 € · Deadline at 17/10/2019 · Mexico

Desired outcome

We are seeking a solution to eliminate spatter from the welding process. The solution should be able to be incorporated into an actual GMAW process. Welding spatter is usually measured by the quantity of balls or welding beads that are added to the assembly parts (which latter have to be removed) and/or the amount of sparks that jump from the arc weld.

We are seeking innovative new methods that are capable of efficient and complete removal of the spatter effect during the GMAW process.

METALSA

Details of the Technology Call

We produce a variety of steel assemblies using gas metal arc welding (GMAW). During this process, spatter is generated due to the relation between the different welding parameters (wire feeder speed, voltage, current, travel speed) and the peripheral conditions of the system (grounds, wire feeder system). The spatter cause process problems such as:

  • Part variation due to spatter accumulations on fixtures
  • Damage to electrical cables and sensors
  • Problems to assembly nuts if the spatter is inside.
  • Dimensional assembly problems if the spatter is between two flat areas.

We are interested in technologies that can demonstrate the effectiveness of the technology. We expect to see a scalable process from partners capable to prove that they can provide a solid technology, expertise or know-how on this topic.

We will consider for advancement an approach that meets performance criteria with acceptable economics and pathway to commercialization. While commercially available technologies are of primary interest, we will also consider maturing technologies with a reasonably short timeline to commercial viability.

We are planning for the new technology to start its deployment in our facilities in late 2019 or early 2020. Proposals will be evaluated as they come along.

The successful technology will...

• Allow a high-speed GMAW process without a spatter effect (70 inches per minute for carbon steel and 45 inches per minute for galvannealed andgalvanized steels);

• Will be applicable to steel thickness of 2.5 to 4 mm;

• Have no negative impact on steel substrate;

• Be easily implementable into existing assembly lines

• Be robust and repeatable

What the Solution must Include...

Your response should address the following:

- Non-confidentialdescription of the proposed technology and working principle

- Availability of technical data including:

  • Processing rate
  • Number of operators required
  • Safety considerations for operations
  • If applicable, equipment or technology’s maintenance

- The technical maturity of the approach (concept, reduced to practice, prototype, ready to commercialize, ready to implement, commercialized)

- Pathway to commercial scale including timing, estimated budget, and capacity for manufacture

- The estimated unit cost of technology

- Position on intellectual property including patent references

- Desired relationship with us

- Team description and related experience (please update your professional and organization profile on the submission form)

Discarded Solutions

The following approaches are not of interest:

• Technologies that damage the steel assembly;

• Technologies not capable of meeting throughput requirements;

• Technologies that require a change of the welding-wire specification (ER70S-6) or the gas mixture (90-10 Argon-CO2);

• Technologies that only prevent the spatter from attaching to the component instead of preventing the spatter effect.

Related keywords

  • Industrial manufacturing, Material and Transport Technologies
  • Industrial Manufacture
  • Erosion, Removal (spark erosion, flame cutting, laser/plasma cutting, electrochemical erosion, waterjet cutting)
  • Jointing (soldering, welding, sticking)
  • Machine Tools
  • Machining (turning, drilling, moulding, milling, planning, cutting)
  • Process control and logistics
  • Plant Design and Maintenance
  • Iron and Steel, Steelworks
  • Road Vehicles
  • Industrial Technologies
  • Process Plant Engineering
  • Apparatus Engineering
  • Protecting Man and Environment
  • Waste Management
  • Speciality metals (including processes for working with metals)
  • Motor vehicles, transportation equipment and parts
  • welding
  • spatter

About METALSA

Large Enterprise from Mexico

Metalsa is a private company and a subsidiary of Proeza Group.

We manufacture tier 1 and tier 2 structural components for the light and commercial vehicle markets. We are constantly growing and innovating. Having state of the art technology that keeps products at the forefront. Our portfolio includes light duty frames, space frames, suspension modules, body structures, safety systems, transmission modules and fuel tanks for passenger cars and light trucks as well as chassis frames, side rails and cross members of heavy trucks and buses.

For us, our collaborators are the engine of the company and everyone works together to achieve our vision; “Best global option for automotive structures”.

Our culture is a strong asset to foster collaboration and communication in order to support efficient decision-making processes. We continually strive to eliminate barriers of collaboration and seek for human development and the well-being of our communities. We create a multicultural team of more than 13,000 employees around the world giving Metalsa the opportunity to offer solutions to the customer with a strategically global perspective.

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