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ESAB welding sets improve quality & reduce finishing time

ESAB Group : 21 July, 2004  (New Product)
Crossland Tankers purchased Massey Tankers of Burnley in early 2003, forming Crossland Tankers (Burnley) Ltd. However, it was soon realised that the efficiency of the welding at the Burnley factory was not as high as that achieved at Crossland's Swatragh plant in Northern Ireland.
Because ESAB equipment had been used for many years by Crossland with excellent results, and with technical backup to match, the decision was taken to re-equip the Burnley factory with up-to-date welding sets from ESAB. Initially six AristoMig 400 welding sets were purchased and these were soon followed by another five.

These welding sets are used to fabricate chassis and tanks for road tankers used to transport milk, water, liquid waste and dangerous goods (ADR tanks). Much of the welding is on stainless steel, requiring high-integrity welds with a good visual appearance. ESAB assisted Crossland Tankers to select the AristoMig 400 units, which were supplied as compete packages with integral water cooling pumps, MA6 control panels, AristoFeed wire feeders and water-cooled torches capable of maintaining a consistent weld quality for weld runs up to 6m long.

At a 35% duty cycle the AristoMig 400 delivers 400 A at 34 V. These machines benefit from an Alutech extruded aluminium chassis that helps to save weight, and the sophisticated but proven IGBT inverter technology ensures that performance and reliability are excellent. A further contributory factor behind the high reliability is the use of a CAN-bus communications and control system that reduces cabling.

One of the main advantages of the MA6 control panel is that it is pre-programmed with synergic lines, plus it can store up to 10 sets of weld parameters. This is ideal for Crossland Tankers, as it helps to ensure consistently high quality welds from all welding operatives, including those with less experience. For welding the stainless steel tanks, Crossland Tankers uses ESAB OK Autrod 16.32 for its good corrosion resistance, particularly in acid and chlorinated environments. This consumable was selected by Crossland Tankers in line with advice received from ESAB.

To ensure that Crossland Tankers gained maximum benefit from the new welding equipment, ESAB provided two days of on-site training for the welders when the first machines were delivered.

Brian Steer, Crossland Tankers' Technical Estimator, comments: 'Following the introduction of the ESAB equipment and welding wire we have seen a dramatic improvement in quality. Consequently the amount of rework and fettling has been reduced, so most welds just need brushing rather than dressing. This saves us time and gives a more attractive finish on exposed welds. In fact we are so impressed with the eleven welding sets that we already have decided that we are likely to purchase another two in the very near future.'
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