Is welding experiencing a green revolution?

The reality is that while welding does produce heat, noise fumes and dirt, the industry as a whole is not Dickensian. “If you look at it from a very literal perspective, and characterize welding as taking place in dirty environments and that the process itself is dirty, that is a bit of a misnomer.

There are many welding environments that are kept quite clean and sterile based on the types of welds that are being made,” said Jim Totzke, general manager — industrial fabrication and manufacturing, Miller Electric Co. “Welding processes and filler metals are being advanced every day to minimize fumes and smoke from the welding process, and new personal protective and fume extraction technologies are keeping welders protected and the environment clean.”

The manufacturing process is inherently not green yet welding manufacturers are cooperating in making it less of a detrimental effect on the environment. “When it comes to the manufacturing of product, for instance MIG wire, the process by which you etch the wire, copper plate and the involvement of lubricants, has all been worked on for many  years to the point where the water that we put back in the city’s sewage is almost pristine,” said Bruce Clark, director, marketing and export sales for Lincoln Electric Canada. “We have also made great strides in reducing our overall water consumption during the manufacturing process. We are presently partnered with Ontario Power Authority and Natural Resources of Canada in a pilot project to implement ISO 50001 in Canada. The three areas of concern are water, electricity, and natural gas consumption.”

The onus for changing welding’s image does not lie with the welding manufacturers alone.  “The welding suppliers have to provide an effective and economic way to clean up the welding fumes and it is up to the shop itself to implement it,” said Clark. “We work hand in hand with them to make sure that they buy the right equipment and once the equipment is delivered that it is deployed properly and it works efficiently and effectively. It is a partnership.” The individual shops are more responsible for the actual welding environment of its workers, according to Totzke. “That’s where the personal protective equipment and fume extraction technologies come into play. Individual welding shops have the tools at their disposal to make the work environment as clean and comfortable as possible for their workers. This includes respiratory equipment, heat stress relief equipment, and fume extraction technologies.”

For some shop owners, the idea of becoming a ‘green’ shop sends shivers down their spine. For them the misconception is that reducing environmental impact is a money drain that despite some marketing goodwill will not bring any real financial benefit to the company. “Welding suppliers are building equipment that is as energy efficient as possible while retaining the necessary performance qualities of that piece of equipment,” said Totzke. “This is something that, as an industry, we will continue to innovate and help reduce the industry’s carbon footprint. We really share this responsibility because we can help educate the industry on the financial, productivity and environmental benefits of these machines. Individual welding shops have every incentive to convert to welding equipment that is more energy efficient. It’s often smaller, it requires less energy (which in turn allows shops to add more welding units on the existing power in the shop and increase productivity), and it lowers the utility bill compared to older equipment. The energy savings and increases in productivity often provide relatively fast return on investment.”

Efficient use of electricity has been improving for many years, it started when people went from motor generators to transformer rectifiers, then to inverters. Inverters are inherently more efficient. Recently inverter frequencies have gone as high as 120,000 Hz,” said Clark. “This has resulted in much lower current draw, increased efficiency and improved Power Factor. Another benefit is the reduction in the cost of cable and electrical equipment required to power these machines.”

Having an efficient plant makes economic sense. “Energy efficient technology helps reduce a company’s total carbon footprint, and some utilities throughout North America have offered rebates based on an estimated reduction in power requirements. This is good for both the business and for the environment,” said Totzke. “In terms of how it’s done, it simply comes back to finding new and efficient ways to build a mousetrap. With engine-driven technologies, we’re incorporating elements such as Electronic Fuel Injection (EFI) and Auto-Speed technology that significantly reduce fuel use without sacrificing any power. Inverter-based technology has really changed how our industry looks at equipment for both the shop and field, and has exponentially reduced power consumption compared to older equipment.”

For the past several years automation in welding has been the talk of the town. The advances in this field have been remarkable, as the systems have become more affordable and easier to program and use. “What automation has not done is to eliminate the need for skilled welders on the shop floor. It is always recommended to have a welder operate an automated welding system as they understand the process and can identify or troubleshoot potential problems,” said Totzke. “It is not as easy as throwing someone on an automated weld cell and saying ‘hit the button’. It should be a fabricator who understands welding and fabrication.”

Welding automation will continue its inroads into Canadian manufacturing because of the realities of the world market. Mark Carney, the governor of the Bank of Canada recently told a Canadian Auto Workers meeting that the industry needs to embrace automation if it is to remain viable and profitable.  He said Canadian business has to use more automation to make more products competitively and not hope that a low Canadian dollar will return to boost Canada’s competitiveness.

Another area where technology is advancing in leaps and bounds is in welding waveform control. One area that waveform control is being used is in the welding of aluminum. “The supply of helium is in very short supply,” said Clark. “Helium is used with Argon to increase the ionization point which increases the heat in the arc. When you can’t get the helium anymore you have to find a different solution. We are using waveforms control as one solution to put more heat into the arc to do what helium used to do. Waveform control has become one of the fastest growing technologies out there.

Where on one hand the welders are getting more complex, with more options and settings, on the other hand they are getting smarter. “Welding manufacturers are making welding power sources as intuitive as possible, taking much of the guesswork away from the welder,” said Totzke. “On more advanced power sources this includes built-in programs and the ability to update the unit’s hardware with new processes and programs. We’re building power sources with specialized functions for certain industries and applications. Even on relatively smaller products, designed for smaller shops and the personal user, we’re building in controls that simply require the operator to enter the type and thickness of material they are welding.”