Automated Cladding

LLC "Intellectual Robotic Systems" implements projects and solutions for surfacing materials using various methods, from manual to automated, including the use of industrial robots.
Robotic and automated surfacing is being increasingly used in industry every year. At present, there are technologies that make it possible to perform surfacing along complex spatial trajectories on multiple planes, meaning that an entire part can be processed in a single setup in an automatic cycle. By using robots and additional peripheral equipment of the robotic system, as well as by integrating induction heating sources, it becomes possible to implement complex thermal processing cycles (hardening, tempering, aging, preheating).

The main technological feature of surfacing is the application of a layer with properties that differ radically from those of the base metal.
Diagram of automatic surfacing in a carbon dioxide atmosphere: 1 — nozzle; 2 — carbon dioxide supply tube; 3 — gas nozzle; 4 — contact tip; 5 — electrode wire

This method can be used both to create layers with increased wear resistance and to form transition layers.

The use of automated (robotic) surfacing makes it possible to manufacture products with the required physical properties while saving expensive materials. The use of robots for surfacing also significantly reduces production defects, and in some cases completely eliminates them. A robotic system allows the use of advanced welding equipment, the technology of which enables surfacing with minimal mixing of the surface layer with the base metal.

Surfacing can be performed on any geometric surfaces, from flat to complex-profiled ones. In industry, special attention is paid to restoring diameters — both bearing seats and diameters along the entire length of the product.

LLC "Intellectual Robotic Systems" developed and supplied automated pipe surfacing equipment for PJSC "ZIO-Podolsk".
The installation provides welding and metal surfacing of pipe blanks made of carbon and low-alloy steels, high-alloy and austenitic steels, aluminum alloys, and high-nickel alloys such as NIBAS 625, INCONEL 625, Hastelloy G35.

Overall installation dimensions, mm: 13500 (Length) x 5500 (Width) x 2900 (Height)

View of the installation according to the design, including:

• Main equipment group of the IRS 046 installation;
• Pumping station, 1 set
• Cooling liquid tank, 1 set
• Industrial chiller, 1 set
• Filtration and ventilation unit, 1 set
• Powered surfacing carriage, 2 sets
• Remote welding power source control panel
• Fronius MIG/MAG CMT welding torch (internal)
• Fronius wire feeding mechanism
• Marathon-type welding wire drum
• Fronius TPS 5000 CMT welding power source, 2 sets
• Welding machine
• Autonomous cooling system for welding equipment
• Installation control cabinet, 1 set
• Single-axis front rotary headstock with hollow shaft, 1 set
• Laser safety barrier stands, 2 sets
• Laser safety barrier, 1 set
• Mobile installation control panel, 1 set
• Movable support, 10 sets

SHORT TECHNICAL DATA OF THE INSTALLATION

• Maximum length of pipe to be surfaced, mm: 12000
• Pipe diameter range, mm: 38...300
• Pipe wall thickness range, mm: 3.0...25.0
• Maximum pipe weight, kg: 2500
• Rotary chuck bore diameter, mm: 310
• Number of welding carriages, pcs: 2
• Welding carriage travel length, mm: 13200
• Welding carriage travel speed, m/min: up to 8
• Welding carriage positioning accuracy, mm: ±0.1
• Number of movable supports, pcs: 10
• Movable support travel range along installation, mm: ±500 from base
• Number of welding torches, pcs: 2
• Maximum welding current at 40% duty cycle, A: 500
• Maximum welding current at 60% duty cycle, A: 430
• Maximum welding current at 100% duty cycle, A: 360
• Main wire feed speed range, m/min: 1...25
• Welding wire diameter, mm:
  • steel: 1.2; 1.6
  • high-alloy materials: 0.8; 1.0; 1.2; 1.6
  • aluminum: 1.2; 1.6
  • flux-cored wire: 1.2; 1.6
• Welding aerosol filtration and ventilation system included
• Liquid cooling system for the surfaced pipe included
• Power consumption, kVA: not more than 61
• Overall dimensions (L x W x H), mm: 13500×5500×2900
• Weight, kg: 7200