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A Louisiana shipyard uses a large gantry and the submerged arc welding (SAW) process to weld deck plate from 3/8-in. thick in a square butt joint configuration. A magnetic hold-down bed secures the plates with a consistent gap, and a copper backing bar enables one-sided welding.
The vice president of operations contacted ESAB’s welding automation sales director because the yard was struggling with the reliability of a competitor’s tandem arc system with a DC 1500A lead and an AC 1200A trail, both with 5/32-in. diameter wires. The call was further prompted because the yard faced several other productivity issues, including distortion that required straightening to correct, rework to repair weld defects, and the need to manually weld the last few feet of the plate because otherwise excess heat input caused weld cracking.
The ESAB automation team solved the customer’s immediate technical issues, getting the competitor’s unsupported system running. As a result of these efforts, the team earned a PO for an ESAB tandem ICE™ (Integrated Cold Electrode) system that enabled the shipyard to completely weld the entire 40-ft. seam. ICE™ Technology reduced distortion and rework by 75% and delivered weld quality that exceeded all expectations.
Read more about this ESAB Case Study by downloading a printable pdf version here.