African Fusion March 2016

Contents

March 2016

FEATURES 4 SAIW KZN branch an immediate success

Published four times a year and mailed out together with Mechanical Technology by: Crown Publications cc Crown House Cnr Theunis and Sovereign Streets Bedford Gardens 2007 PO Box 140

African Fusion visits the Westville premises of SAIW’s new KZN branch and talks to training administrator, Elizabeth Shole and branchmanager GeorgeWalker. 6 South African company chooses quality cornerstone This month’s SAIWmember profile features Efficient Engineering. African Fusion visits the company’s Phase IV facilities in Tunney, Germiston and talks to qualitymanager Louis Smuts, alongwith engineering andmarketingmanager Gerhard van Zyl and the new MD of Efficient Trotech, Mike van der Walt. 14 An investigation of residual stresses and distortions produced in tubular K-joints This paper investigates the effects of welding on tubular weld joints during themanufacture of lattice boom cranes frommodern high-strength materials. 20 Investigating the electrodes under the welding process of similar and dissimilar materials in resistance spot welding This paper presents an experimental investigation into copper-chromium electrode caps in the resistance spot welding process. 24 Quality benchmarking for ongoing improvement African Fusion visits DCDHeavy Engineering and talks to Rakesh Mohan the company’s quality assurance manager, about how the systems the company has put in place are securing global competiveness and quality standards under tough economic conditions. 26 Spray coating and PTA cladding for harsh environments Shaik Hoosain explains the use of thermal spray and plasma cladding processes in the power industry before going onto talk about the use of coatings to overcome erosion damage. 28 Seamless flux-cored wires for large offshore wind project Seamless flux-cored wire from voestalpine Böhler Welding has been used in the construction of one of themost impressive offshorewind farms in the Baltic Sea. 29 ESAB restructures SA route to market through Howden Donkin African Fusion talks to KimBrightwell of ESABMiddle East and Africa. 31 Gasless Innershield welding benefits Renttech’s Johan Bester talks about gasless flux- cored welding and the advantages of using the company’s UniArcMag200MCmulti-process inverter. REGULARS 3 Sean’s comment 8 SAIW bulletin board 12 Front cover story: A new dimension in strip cladding 32 Welding and cutting forum 36 Today’s technology: ITER chooses narrow gap welding

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Editor: Peter Middleton E-mail: mechanical@crown.co.za Advertising: Norman Welthagen E-mail: normanw@crown.co.za Publisher: Karen Grant Director: Jenny Warwick Cover design: Lincoln Electric Production & layout: Darryl James Circulation: Karen Pearson Subscriptions: Wendy Charles Printed by: Tandym Print

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Lincoln Electric company, through its global multi-arc welding systems specialist, Uhrhan & Schwill Schweis- stechnik, has developed a new hybrid electro-slag strip cladding process (H-ESC) for significantly better deposition rates and lower dilution levels on nickel-based and stainless steel cladding applications.

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March 2016

AFRICAN FUSION