Manufacturing Question

I never worked in transformer manufacturing units.But, both GMAW and GTAW are prone to porosity in open air welding irrespective of raw material shape (pipe or plate).

welding is performed in workshop conditions, closed no windy conditions, X ray quality experienced by myself in the past, GMAW.(38 years welding technology).The topic should actually be increased productivity and lower cost of consumables compared to SMAW. I have allready comparision cost with 22% improvement .Do you maybe suggest that i place my thread under electrical engineering, because the fabrication is one part in the supply chain to complete delivery to a power station ?

Consumable selection and process selection is totally based on client quality requirement in some industry. If your client has no specific requirement then you can select any welding process to make more profit for your company.

"Do you maybe suggest that i place my thread under electrical engineering, because the fabrication is one part in the supply chain to complete delivery to a power station ?"

This is not my problem.

I suggest you hire a welding expert who can observe your operation first hand and then make intelligent suggestions about how to improve your quality.

Asking for help improving unknown, undefined welding processes from an anonymous group of strangers will only produce more befuddlement than you already seem to have.

I am a welding expert with 38 years experience in pressure vessels and hi tech steel for the armour manufacturing industry like the abrahams and the challeger tank, where welding failure had never been a option(including a quilified welder, and 15 years quality manager), because welding is tested with landmine testing before the product is qualified. My concern is mainly the transformer when warm is more than the capillary action of liquid penetrant testing and will go anywhere the tiniest pinhole.

I'm not sure what you just said here, but if you really were a "welding expert" you would not be here asking total strangers for help.

I can't help you.

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I do not have to prove to you that i am a welding expert, you are not contributing to my discussion. I have allready prove to our excective comittee members to be promoted to group management position after 4 months.but thanks for your comments.i only registered today,buting so there will be much more positive contributing members than yourself.

AWS Online Forum - American Welding Society

WeldingWeb™ - Welding forum for pros and enthusiasts

Miller Welding Discussion Forums

Weld Talk Message Board and Online Forum - Hobart Welders

MIG Welding Forum

Thanks for these specific links lyn! you are correct, these links will address the correct contacts i need, sorry for the remarks i commented would you please accept my appology!

No apologies needed.

Free, honest speech is always appreciated.

Thanks, but i do have all the links already in comprehensive online library and a corporate member of our welding institute(I.I.W welding technologist), I really like where you want to be, i want to fly now in my aeroplane, not the size and complexity of the stealth bomber on your reference, seems if we were to meet each other,that we both so enthusiastic and have passion for welding and all related issues,but my position requires me than welding now in the field of seals and paint technology and material control, which relates to massive transformer structures. I further have auspices for all welding inspectors, non destructive technicians,and quality control and quality assurance managers. Do you maybe have contacts in the transformer industry in the states ?

You're asking about quality vs price, this should be determined by company policy....Is the mission statement of this company to provide high quality or low priced goods? You as a welding expert should already know what the most robust method would be....The other half of the equation is highly qualified workers and quality materials...Getting the highest quality product at the lowest possible price is a constant battle, and one we cannot help you with, other than moral support...To get any real help you would need to post pictures of your current process with detailed info, testing and results...good luck with your new venture....

You have an action plan to minimize leaks at the fabrication process?

Ok, a bandaid.

To really get over it, you have to start implementing a project plan to address the eliminate thesource of your leaks. In other words, change the process.

This is all in place,project plan,action plan and already have the source of the leaks after only a week after my appointment, with support from business, its like to re route the flow of a river from the past to the future.This is my kpa"s for my appointment. No i am global to ask experts in the field of transformer manufanufactring

Is the parent material defect-free?

Jip, high quality certified material.

And your welding operators?? Properly trained?? A good operator can make the difference to the final joint.

Soap Test-- No No

MIG is best if Parameters are made repeatable

Invest in a small Gamma Ray /Xray Post Weld Inspection - where 1 every 10 are inspected PERFECT

I have experience and qualifications in gamma /x,rays and will not detect minute pinholes. good suggestion, but not practical, better have root liquid penetrant testing and capillary do the work, i.a.w red inside and white outside, my vast experience on pressure vessels, remember this a structure and not a pressure vessel with acceptance criteria to AWS D.1.1 otherwise we will be not competitive, basic diccipline to be excecuted, which i have a action plan for.

Pole-mounted 795 MVA transformer?

Large pole.

Jip haha.

From pole mounted transformers(5 kVA) to massive 795 MVA transformers, i.a.w ,we are able to manufacture the whole spectrum of transformers. The real challenge is transformer oil when warm with a 150 ton complete weight when completed, the compressive force , the capillary action is more than liquid penetrant penetrant(red)!!

You do realise you're probably the only cr4 reader who does this kind of thing, Mildred?