Solutions

Design and prototyping

We like challenges; we create custom designs and prototypes according to our customers’ needs. If the market is not able to meet the customer’s needs, we build tailor-made machines for them.

Integrated software applications

It is important to choose the right software to support production. It can solve productivity problems, improve cutting efficiency, prevent welding deformations and improve the quality of the final result.

Training courses for standard and special processes

Welding training is based upon theory to be put into practice and validated by experience.

We organize training courses at our facility or at our customer’s location where we try to pass on the passion and experience of those who have been working in this industry for over half a century.

In addition to the classic manual processes (MIG, TIG and electrode), we organize courses devoted to special processes upon customer’s request:

• Course for manual aluminum welders
• Course for pipe welders with STT process
• Course for thermal cutting machine operators (flame and plasma)
• Course for orbital tube-to-tubesheet welders
• Course for submerged arc welders

Organization of schools and welding departments

We are able to design and develop turnkey welding schools where, based on the customer’s needs, we assemble grinding and welding boxes with their generators, support benches, suction systems and all related accessories.

In the 4.0 context, we develop interactive computer systems where the operator has an industrial touch-screen panel inside the box with the ability to track welds by manually inserting data that cannot be automatically recorded by remote welding monitoring systems.

Technological upgrades and System retrofits

An ever-evolving technology requires the constant updating of a machine inventory. However, it is not always necessary to completely replace a system. In many cases, it is enough to keep the parts that are not subject to wear or technological obsolescence and only replace the components that provide a real added value.

For this purpose we offer several packages: from torch and generator replacement to an actual system retrofit.

By system retrofit we mean the replacement of all electronics (motors, electrical panel and control) which drive the dynamics of the machine. In addition to using premium quality components, we have been working with the source and control manufacturer Hypertherm for some time.

Sheet metal cutting machines

We offer solutions for those who integrate cutting into their production cycle and also for those who center their main business around this activity.

For example, starting from a small base model (3 x 1.5 m or 4 x 2 m) with a simple air generator, up to 3.5 x 26 meter systems with high-definition generators. All the proposed solutions can be equipped with a tilting head for beveling and an additional torch station for oxy-fuel cutting or marking.

Systems for cutting and preparing pipes

For the preparation of pipes we offer dedicated machines with 4 or 5 axes controlled by a PLC or a numerical control. The machines can cut sections of straight or shaped pipes, to create holes, slotted holes and coupling points in the desired position, with or without a chamfered weld preparation. There are different ranges available depending on the diameter of the through hole and we are open to developing custom solutions.

Robotic cutting systems

In situations where a portal machine cannot be used, we offer turnkey robotic solutions for cutting and preparing complex geometries (e.g. ends, nozzle). Thanks to our collaboration with Yaskawa, we are able to offer you the latest off-line programming solutions.

Technological upgrades on high productivity lines and automatic systems

Thanks to our established partnership with Lincoln Electric, we offer ad hoc solutions for high productivity processes. The use of the new Power Wave AC/DC 1000 modulable square wave generator is the ideal solution for every submerged arc application.

Some applications:

• Welding of marine panels in a Series Arc configuration
• High deposition welding in Long Stick Out or Tandem configuration
• Integration with CircleWelder equipment for the welding of nozzles on cylindrical bodies

Systems for first pass and filling pipe welding

We offer several automated or semi-automated solutions for pipe welding with the aim of obtaining a certified and verifiable quality (with radiographic or ultrasonic controls) and a productivity increase both in prefabrication and in operation.

Some examples:

• First pass radiographable MAG welding in conjunction with rotary pipe positioner
• Orbital welding of stainless steel pipes with closed or open chamber
• Automatic welding with TIG cold/hot wire with Lorch RoundSeam or SwingArm positioners

High productivity MAG welding systems with spatter reduction

Our customers’ end user needs increasingly detailed and economical structural steelwork.

Current regulations (e.g.: 3834 or 1090) leave no room for compromise or improvisation. This is why we advise our customers to standardize their production processes as much as possible with a quality of welding that does not require expensive reworks.

In this light we offer:

• Automated linear welding trolleys (powered by electricity or battery)
• Quality welding wires suitable to withstand high currents and capable of eliminating or significantly reducing welding spatter in combination with the correct gas mixture
• Elevating positioners for the safe handling of large pieces so that the operator can always work in an easy and convenient position

Automatic plating systems

The plating process (or cladding) is being used more and more frequently for the transfer of noble materials to ferrous steel. In addition to the traditional submerged arc or continuous wire plating, in recent years the use of TIG hot wire processes has increased which, besides ensuring the quality and controllability of the plated product, has allowed interesting levels of deposit rate to be achieved (especially using a bi-cathode version).

The processes can be integrated into different automations depending on the object to be plated. Example:

• Horizontal lathes for TIG Hot Wire application for plating pipes
• Manipulators (standard, with a numerical control or endless heads) for horizontal SAW or GMAW or vertical TIG Hot Wire plating applications
• Robots for GMAW or TIG Hot Wire plating

Integration of robotic systems

Nowadays robotics is an essential and integral part of serial production, and the use of robotic systems is the unavoidable path for the future of welded structures. Thanks to modern offline programming systems and to the reduction in the cost of anthropomorphic robots, today it is possible to consider automating even limited series productions down to a single piece in exceptional situations.

For example:

• Tandem MIG welding robot
• Submerged arc welding robot
• Adaptive welding robots
• TIG Hot Wire robot for Narrow Gap conditions

Preparation of WPS, Welding Book and Welding Map

Within our company we have welding engineers who can act as External Welding Coordinators or simply support your coordinators in preparing a Welding Book to comply with process and product standards (EN 1090, EN 3834, EN 15085 etc.).

Welding monitor systems

We are able to implement systems for the monitoring of welding and cutting parameters to certify production quality. The systems we supply are universal and adaptable to different production situations. Thanks to the recent developments in the Internet of Things, it is also possible to link generators to the corporate network and remotely monitor production by storing data on a corporate PC or via the cloud.

Personalized training

At the end of each installation, we organize training days and production support to help our customers maximize plant productivity. Training is conducted for production and maintenance staff to avoid costly and unmotivated plant stoppages.

Maintenance plans 4.0

We are available to coordinate the maintenance records of welding systems and to carry out planned maintenance and calibration of the electrical parameters measuring instruments in compliance with current regulations. Where possible, we use modern remote diagnostic technology to provide remote assistance.