As reported by MarketsandMarkets, the Welding Materials Market will grow from USD$13.6 billion in 2020 to USD$17.3 billion by 2025, at a CAGR of 4.8 percent during the forecast period.
The increased spending on the building & construction market, development of manufacturing sectors, and growing repair & maintenance activities are likely to drive the welding materials market.
APAC is the fastest-growing market for welding materials due to growing demand in Japan, China, and India. Increasing residential building constructions, as well as remodelling/reconstruction of existing infrastructures, are also expected to drive the market in the region.
APAC has also experienced significant growth in the last decade and accounted for approximately 34% of the global GDP in 2019. According to the Population Reference Bureau, China, India, and other emerging APAC countries had a combined population exceeding 4 billion in 2019. This is projected to become an increasingly important driver for global consumption over the next two decades.
The major advantage of arc welding is the concentration of heat applied to a large surface that enables better welding by providing a depth of penetration, which ultimately saves time. Arc welding is the most preferred technology due to its low cost and can be applied to a wide range of metal surfaces, making it highly sought after.
Key players operating in the welding materials market are Colfax Corporation (US), Air Liquide S.A. (France), Air Products & Chemicals (US), Illinois Tool Works (US), Linde PLC (UK), Lincoln Electric Holdings (US), Tianjin Bridge Welding Materials Group (China), and Kobe Steel (Japan).
These are the players that have adopted various growth strategies to expand their global presence and increase their market share.
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Frost & Sullivan’s recent analysis, Newer Welding Techniques to Enable Growth in the Digital Age, reports that increasing competition in the global welding equipment and consumables market has led manufacturers to focus on energy efficiency, operational excellence and reducing maintenance costs. Amid the uncertain economic conditions caused by COVID-19, the industry is forecast to reach $21.74 billion by 2024, growing at a CAGR of 1.3 percent. Growth is driven by opportunities from developing regions where infrastructure building, the introduction of new welding technologies, and automation are top priorities.
“Several new developments in welding technologies and materials are emerging due to an increased focus on energy efficiency from vendors and end-users. Advancements such as the ability to monitor and regulate the weld temperature while in the process are generating highly efficient outputs and better quality. These innovations will reduce operational tasks, improve energy management and extend electrode life,” said Krishnan Ramanathan, Industry Manager, Industrial Technologies Practice, Frost & Sullivan.
Digital transformation is gaining traction in Australia and Singapore as their communications infrastructure is upgraded. This digitalisation is expected to propel the welding market as other countries modernise. China, India, and Brazil are also vital for welding equipment and consumables suppliers as they have high energy and infrastructure requirements. However, the development rate is likely to be gradual as economies recover from the impact of COVID-19.
“IIoT is a major trend affecting equipment manufacturers as end-users continue to emphasise on improving their plant maintenance and curb operational expenditure (OPEX),” Ramanathan said. “With the global economy currently experiencing a dynamic environment, manufacturers are striving to improve operational efficiency in their existing plants and are keen to cut down the maintenance and operational costs due to unexpected failure and asset downtime. Realising that the future of manufacturing is likely to be driven by IIoT, companies today are turning their focus toward data ownership, security, and integration with existing infrastructure, with an intent to achieve returns on their investment in these solutions.”
Welding equipment manufacturers should explore these strategic recommendations to increase growth opportunities:
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Nasmyth Group has appointed Tony Sexton as the Group Sales Director. In his new position, Tony will develop a new integrated, global sales and marketing focus for the Nasmyth Group’s UK engineering businesses and those in the USA, India and the Philippines. The Group has exciting opportunities for new and more established business across a range of customers and programmes in sectors including Aerospace, Space, Defence, Energy etc.
Tony will lead Nasmyth’s sales, business development and strategic teams to ensure the Group successfully interfaces with global customers and partners and secures this business as we return to a sustained growth phase. Tony will also lead the development of the Group’s digital sales and marketing tools as the world rebuilds from COVID-19.
“We would like to take this opportunity to acknowledge Tony’s strong contribution to the growth of Nasmyth and especially the Systems and Defence Division and we wish him every success in his new role in which he contributes to the integration, continued success and growth of the Nasmyth Group,” commented Peter Smith, Chairman and CEO of Nasmyth Group.
Tony will start his new position in February 2021. Commenting on his new role, Tony said: “Having worked as a member of the Nasmyth Group Senior Management team for over fourteen years, I believe I have the experience and knowledge to develop further the global growth strategy for the future as we begin to emerge from the pandemic.”
Tony joined the company in 2007 as Managing Director of IEC and has more recently held the position of Director of Systems and Defence for both the Nasmyth IEC and Nasmyth CE businesses.
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AMADA WELD TECH, INC. has released the CD-A1000A, a 1000 watt-second advanced capacitive discharge welder, ideal for battery tab welding, honeycomb tacking, and welding of conductive terminals. This next generation CD welder is the latest in a long line of CD welders manufactured by AMADA WELD TECH.
The unit is automation-ready and features dual pulse output with control and monitoring of both pulses. The dual pulse function helps overcome surface inconsistencies –such as dirt and oil contamination – during the first pulse and makes consistent welds with the second. A built-in process monitor measures peak current for both pulses; this value is displayed after each weld. Upper and lower limits can be set for both pulses to ensure weld consistency. An option to inhibit Pulse 2 if Pulse 1 is out of limits prevents weld blow out. The process monitor helps operators assess performance with a color coded bar graph that gives operators an instant weld history of in limit/out of limit percentages.
CD-A1000A offers up to four selectable pulse widths, increasing the range of welding applications and improving process optimization. Extremely efficient power electronics provide high repetition rates. 63 schedules can be stored locally when a variety of welding processes are planned at the same station.
“The CD-A1000A is the latest generation of advanced CD welders at AMADA WELD TECH.” says Mark Boyle, Product Manager. “Our previous generation units have been workhorses in the battery and aerospace industries. We are excited about this new product that will carry on that tradition and transition those products into modern manufacturing.”
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Branson R&D Center receives designation for exceptional work delivering high-performance plastic and metal assembly technology to China and the world.
The Shanghai municipal government recognised Emerson’s Branson Research and Development Center for its contributions to technical innovation in ultrasonic, laser, vibration, infrared and thermal plastic welding, as well as ultrasonic metal welding and precision cleaning.
In a Nov. 19 ceremony, Gong Zheng, mayor of Shanghai Municipal People’s Government, presented the designation “Shanghai Multinational Company R&D Center” to Emerson’s David Shen, general manager for Emerson’s Branson welding and assembly products. The Center, which employs a staff of more than 30 R&D personnel, was one of nine organisations recognised that day for meeting specific investment, employment, facility, and technology transfer and adoption benchmarks set by the government.
“China’s industrial supply chain is undergoing a rapid economic recovery, a factor that has injected confidence into the global fight against COVID-19,” said Shen. “We will continue to adhere to the localised development strategy of ‘in China, for China,’ using innovative technologies and industry expertise, proactively focusing on new product development, and contributing to the transformation and upgrading of industry.”
As a large-scale, comprehensive ultrasonic equipment production and technology development enterprise, Emerson is committed to technological innovation in the fields of plastic welding, ultrasonic metal welding and precision cleaning.
Shen added that as a trusted welding expert for leading companies in various industries in China, Emerson will continue to advance welding technology, provide customers with professional and reliable customised welding application solutions, and help customers to succeed in light of new market trends. “The strength of our research and development expertise contributes to this effort,” he noted.
The plastic and metal welding experts at the multinational center in Shanghai have played a primary role in developing and introducing key Emerson technologies to China and to the world. These include the Branson GLX-Micro ultrasonic plastic welder, the Branson GL-300 laser welder, the Branson GMX-20 ultrasonic metal spot welding platform, and the Branson GCX ultrasonic generator for precision ultrasonic cleaning systems.
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Coils with multiple termination points can be welded at one automation station. Article by James Tod, Amada Miyachi UK.
Pulse micro arc welding is a good choice for coil termination applications, especially as coils are getting smaller and smaller. Other processes do not lend themselves as well for these applications. For example, it can be difficult for lasers to target the pins, while resistance welding is not practical due to electrode size, and soldering involves potentially hazardous fluxes. Multiple output pulsed arc welders are available that offer great automation layout flexibility and increase production line throughput.
Pulse micro arc welding is a zero-contact process in which an electrical arc is struck between an electrode and target component. The arc generates very high and concentrated energy density, which results in high local temperatures that can be used for welding. Sophisticated closed loop power supplies are used to establish and maintain the arc under precisely controlled electrical conditions.
The micro arc coil termination process requires wire to be wound onto the pin in a uniform fashion and density. The welding process is accomplished by heating the pin and encapsulating the wire in the molten pin material. The wound pin is positioned close to a welding electrode and an arc struck between the pin and the electrode.
Operators profile the energy and current within the arc in terms of rate of rise, period of peak, and downward cooling to control the rate at which the pin begins to melt back. The process of melting the pin back creates a molten ball that causes the wire and its insulation to melt simultaneously, thus welding the wire to the pin.
With micro arc welding, the materials must flow together based on the heat generated by the welding arc and the surface tension of the materials. Any contamination can cause the materials to fail to fuse with one another.
Wire insulation is critical because it must be broken down by the heat in the weld before the materials can fuse with one another. In the process, the pin is heated directly and the wire indirectly; if the wire insulation remains intact during the weld, the pin will be melted but the wire will not. Pulsed micro arc termination welding works best with wire insulation rated for temperatures of 180 deg C or lower.
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AMADA WELD TECH has launched its Jupiter series of modular systems for precision joining, available for laser welding, laser marking, resistance welding, micro arc welding, and hot bar bonding applications. Jupiter modular systems can be equipped with all joining process modules available from AMADA WELD TECH to provide solutions to customers.
With the Jupiter series, customers purchase an automation platform from a global joining equipment leader and receive intensive process development support in AMADA WELD TECH application development centers. Joint early stage process development in AMADA WELD TECH labs ensures that customers receive the ideal system solution for years of high-quality production. Any welding, soldering, bonding, brazing, laser micromachining, and laser marking application can be handled by equipment in the Jupiter series.
The Jupiter modular system platform is a flexible system that comes in four sizes, so it is adaptable to specific production requirements. The stable platform enables connections of very high quality and accuracy. The modular design is configurable to fit all process components and modules. The Jupiter models feature an ergonomic system design with high quality components, designed for 24/7 continuous production. All models are equipped with a human-machine interface (HMI) with touchscreen for easy programming and standard safety features.
Control systems, based upon a programmable logic controller (PLC) or industrial PC, collect all available process parameters and process data into one control system. The data can be stored in local and remote storage areas, all engineered to seamlessly integrate with an Industry 4.0 factory concept.
Optional features for the Jupiter systems include a combustion suppression unit (CSU) for battery pack welding; a transport system with two individual belts that can be configured for a wide range of product carriers, including transfer systems; an automatic cleaning station for electrodes and thermodes; a “Not OK” bin to separate products outside the control limits from those within control limits; and a range of water cooling options. Also available are upgraded data collection and traceability functionalities, including a barcode reader or a label printer; and interfaces for a variety of robotic systems.
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