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.
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)
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.