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Afrox's extended 360° job site solution
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Afrox's MUPP solution was originally designed for GTAW and has proven to be suitable for any gas shielded welding process, including GTAW, GMAW, FCAW and MCAW. In addition to solving the problem of cylinder clutter in power boilers, the system also provides a safer solution for cylinder handling in other industries. In these industries, welding is usually performed on suspended platforms with restricted access and narrow workstations.
Johann Pieterse, Afrox's manufacturing industry business manager, said that it is now part of the GasReach™ series, and the Afrox solution works perfectly with Miller's ArcReach™ technology. ArcReach™ does not require a control cable between the power supply and auxiliary equipment, and the digital communication takes place via welding cables: pure and simple.
"This means that we can increase the distance between the welding machine and the power supply to 100 meters, further reducing clutter, and only need to bring smaller auxiliary equipment to hard-to-reach places," Pieterse said. ArcReach™ completely eliminates the high level of maintenance required to maintain control cables and torch extensions on site by qualified personnel.
ArcReach™ technology can be used in a variety of arc welding processes. Welders can use GTAW to weld the open root, and then directly change to SMAW for filling and capping, just unplug the GTAW welding gun from the Miller ArcReach™ Stick/TIG remote control and insert the SMAW electrode holder. The system automatically senses process changes and switches from GTAW mode to SMAW mode. The polarity reversal technology will automatically change from DCEN to DCEP, and the current (amperage) control is done directly on the remote control.
Similarly, if the welder needs to switch to GMAW or FCAW, the welding cable can be connected to the ArcReach™ suitcase feeder while the multi-process power supply is kept away from the workstation. The ArcReach™ luggage feeder is also available in a smaller 8-inch version, which is ideal for use in work spaces with small entrances.
When the Miller ArcReach™ SmartFeeder is connected to the Miller XMT FieldPro power supply, the greatest benefits and cost savings will ultimately be realized because the same equipment, the same welding wire and the same shielding gas can be used. This advanced technology allows welders to use RMD (a pulse modified short-circuit mode) to deposit perfect single-pass roots at a faster rate than using the traditional GTAW process. In addition, RMD eliminates the need for hot beads, so the GTAW process in traditional large-diameter pipe welding is replaced with a process that is usually five times faster than depositing traditional GTAW roots and hot beads.
Once the root is welded, the welder can immediately switch the wire feeder to GMAW-P mode and start filling the weld quickly. The capping is done using the same pattern.
This process is suitable for the welding of solid or metal flux-cored welding wires to eliminate slag and slag inclusions. The use of metal core wire can further increase productivity and save costs, so it is recommended to use metal core wire when suitable consumables are available. Compared with traditional welding, RMD and GMAW-P technology are at least three times faster than traditional GTAW and SMAW, and the resulting cost savings per kilogram of deposited weld metal usually exceed 80%.
"Don't walk, weld" is the key Miller stage used to describe the advantages of ArcReach™. This shows that there is no need for welders to commute to and from the power source and its welding station on a regular basis, thereby saving time and safety advantages.
The combination of Miller ArcReach™ and Afrox GasReach™ now offers new and unique opportunities to improve welding profitability and safety in a wide range of industries, and elevate modern welding technology to levels and positions previously unimaginable.
Many programs of this extended Afrox 360° solution have now been successfully certified. These include carbon steel, stainless steel, and low alloy creep resistant steel applications. These procedures have been successfully applied to large-diameter boiler pipe repairs, car room assembly and cladding, as well as on-site repair welding and replacement welds in power boilers and petrochemical gasification plants.
Pieterse guarantees that, in addition to the advantages of on-site safety, handling and time saving, these Afrox 360° solutions provide considerable direct welding cost savings compared to traditional GTAW and SMAW procedures.
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