Consulting services are provided to the customer either via phone, e-mail, fax, or an on-site visit. Typical assignments as a welding consultant include assistance on one of the following issues:
Product evaluation includes assessment of functional and visual requirements of the weld. Weld analysis is most efficiently done in the design stage where the part design and process have not been finalized. The first step is to establish weld performance requirements such as strength, fatigue life, corrosion resistance, and electrical resistance. In some applications, such as for medical devices and appliances, visual appearance of the weld may also be important. Quite often, the weld is exposed to high temperatures after the welds are made. The high temperature exposure may come during a follow-on operation, such as in an injection molding machine, or when the part is used near a high temperature source such an automotive engine.
Part Design, Material Selection, and Process Selection
Once product evaluation is complete, the next step of part design, material selection, and process selection can commence. These three factors are intertwined and decisions have to be made simultaneously. For example, part design and materials depend on the welding process that will be used for assembly. In some cases, selection of materials (requirement based on part functionality) may decide the type of welding process that can be used. In yet another route, selection of process and materials (again based on functional requirements) will limit the options available for part design.
Weld Process Development
Once part design, material selection, and process selection have been finalized, weld process development can proceed. The first step in process development includes design of fixtures, selection of welding equipment, selection of filler metals (for soldering and brazing), and selection of shielding gases. Selection of these factors often depends on production rate (parts per hour). Once all the factors have been finalized, weld process development can be initiated with available parts. Process development can be conducted at the clients site or at WJM Technologies and its partners facilities. A detailed report discussing all steps of the process development is submitted to the client.
Weld Process Optimization
Often a client is already in the production mode for a welding process but is not getting satisfactory results; either poor yield or inconsistent results. WJM Technologies assists the clients by conducting a thorough on-site review of the welding process. The review usually leads to short-term and long-term recommendations. In the short-term, every attempt is made to bring the process in control either with minor modifications of the weld schedule or suitable changes to electrode materials, electrode design, or shielding gas. In the long-term, recommendations are submitted in a written report for suitable changes to part design, materials, equipment, or process.
WJM Technologies acts as welding consultant for a variety of manufacturing industries including medical, aerospace, automotive, and industrial. As a welding consultant, we work with our clients and assist them with the welding process from start to finish. We are often involved with projects where our welding consultant expertise is used for weld failures and process inconsistencies.