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Innovative welding methods:
- Tubular construction using innovative methods of tube welding
- High strength welding of heat-treatable materials such as aluminum alloys
- Resistance welding of medium carbon and other hardenable steels with good toughness
- The use of diffusion barriers in dissimilar material welding of combinations such as steel-titanium, nickel based super alloy-titanium, etc. with appropriate diffusion barriers between metals welded
- Redesigning a component/structure to reduce weight, tool investment and overall cost through the use of innovative weld methods for the new structure
IWSL offers a range of services for a variety of industries.
Click on the services below to know more.
Resistance Welding
- Process optimization in a large volume factory
- Cosmetic low-indentation welding of thick-thin and multi-sheet combinations
- Projection welding of hardenable and coated steels
- Upset welding for good durability
- Welder training
- Preventive and predictive maintenance
- Factory floor visual aids and boundary samples
- Tube joints of large diameters
Arc Welding, MIG and TIG Welding (GMAW & GTAW)
- Process optimization in a large volume factory
- Reduction of spatter
- Coated steels
- Techniques for improving the durability of welded part
- Welder training including hourly, shift, daily and weekly maintenance
- Procedure and performance qualifications to ASME Codes and AWS Standards
- Productivity improvements
- Techniques for good arc starts and stops
- Pipe welding techniques and welder training
- Other arc weld methods such as SAW, SMAW, etc.
Brazing and Soldering
- Furnace, induction, resistance and flame brazing
- Joint design for good fill at brazing temperature and optimization of joint strength
- Cleaning procedures and fluxes for a variety of materials
- Experience with brazing of carbide tips, bicycle parts, brake hoses, etc.
- Brazed part quality evaluation and metallurgy
- Operator training
- Productivity improvements
Laser Welding
- Selection of appropriate laser for application to maximize productivity
- Variety of materials
- Optimization of tooling and process for consistent joint penetration and quality
- Metallurgical evaluation of joints
- Operator training and maintenance procedures
Codes and Standards
- Procedure and performance qualifications to ASME Section IX
- AWS structural welding code requirements
- ASME Code case approvals for specific new applications
Consulting
- Assistance with very difficult welding quality issues with a variety of processes and materials
- Resistance Spot, Projection and Seam Welding, Gas Metal and Gas Tungsten Arc Welding with single and multiple torches, Submerged Arc Welding, other arc welding processes, Friction, MIAB welding processes, Laser and electron beam welding processes
- Steels (bare, coated, high strength, dual-phase), stainless steels, aluminum alloys, titanium alloys, nickel base super alloys and a variety of other materials
- Large volume factory welding optimization
- Equipment specs, purchase, run-off and validation, stabilization of large-volume processes from disturbing variables, operator and engineer training, maintenance methods, shop-floor visual aids and problem solving
- New joining techniques and innovation to reduce costs and structure weight
- Dissimilar material welding in the solid-state, innovative tubular construction using commonly used welding processes, multi-layered materials, combining welding heat treatment of hardenable materials for tough microstructures
- Vendor quality enhancements
Training
- Basic Resistance Welding including weld schedule development and validation and documentation
- Maintenance of resistance welders: electrical, mechanical and plumbing
- Basic gas metal arc welding including techniques of starting and ending an arc well
- Arc welder maintenance every hour, shift, day, fortnight and month
- Welding for the product design engineer
- Weld equipment specifications including commonly made errors
- Metallurgy of welding stainless steels, including austenitic, ferritic, martensitic and duplex stainless steels
- Welding of hardenable steels
- Welding of aluminum alloys
- Resistance weld monitoring
- Arc weld monitoring
Shop-floor Aids
- Visual aids for correct set up
- Arc welders
- Resistance welders
- Boundary samples of acceptable, marginal and unacceptable welds
- One page maintenance record for each weld machine
- Elementary problem solving trees
- Weld test method instructions and details
Expert Witnesses
- Extensive experience with failure analysis of a component/structure and documentation
- In-depth knowledge of the metallurgy and welding of a variety of materials
- Familiarity with advanced destructive and non-destructive test/evaluation methods including electron microscopy
- Excellent communication skills
- Ability to arrive at the root cause of a failure
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