Correct processing of fine-grain structural steel and aluminum
The main challenge at Bruns is the processing of fine-grain structural steel and aluminum. Fine-grain structural steel is very sensitive in terms of heat input, while the 1.5 mm aluminum sheets are also very time-consuming to process.
The manufacturing of aerial work platforms that can reach up to 60 meters in height gets especially tricky when welding the longitudinal seams of the telescopic booms. The telescopic booms, which later enable the platform to be extended, consist of two composite half-shells with a narrow opening angle. In the conventional manual welding process, there is a risk of welding distortion and spatter, which makes the reworking of the weld seam necessary.
Time and material cost savings with WisePenetration+
Metallbau Bruns welds the telescopic boom for aerial work platforms with their water-cooled X8 MIG Welders. The welding process takes place on both sides, with two welding guns moving in parallel on a trolley along the longitudinal seam. In this semi-automatic application, the X8 MIG Welder performs pulse welding with Ø 0.8mm and Ø 1.0mm filler wire, depending on the material thickness.
Available in Kemppi's welding systems designed for industrial welding, the Wise modified arc processes are software solutions that raise welding performance to a new level by enhancing the conventional MIG/MAG welding process. Bruns relies on WisePenetration+, a welding function for synergic and pulsed MIG/MAG welding. This process makes it possible to weld deep and narrow joints, as required when assembling the two telescopic boom half-shells. As a result, fewer weld passes are needed, which saves the welder a lot of time and filler wire.
WisePenetration+ also guarantees perfect penetration regardless of the distance between the contact tip and the workpiece. As the welding current remains stable in all situations despite the variation in stick-out length, welding quality improves because fewer welding spatters are produced and land on the workpiece. In most cases, reworking on the weld seam is no longer necessary while material cost savings are achieved by having fewer weld passes in the joint structure.