How to qualify a welder who operates a semi-auto welding lathe ? 1

[dho]

we have annual eye examination, etc.. for a welder.
also we will ask the welder to weld two units and cut apart to check the weld penetration. to me, it is a total waste. the (small) welding will finish in 5 seconds. if the machine dials, switches set up right, the shielding gas mix right, the electrode fresh clean, the setup geo position right, etc, etc, the operator can not do a thing. just hit the button and wait the machine stops.
any comment?
thanks.

 

[Sparweb]

Until you come up with the next part, with thicker walls and maybe different base metals. Is your welder qualified to determine what the new machine settings are?

STF

 

[dho]

each new configuration, engineering will determine all the machine/shielding-gas setup parameters and followed with a weld coupon to verify. so the welder is merely to follow the paper to dial all knobs, and spin the part once to see it runs true, and make sure the electrode is fresh/clean.
qualify welder by semi-auto welding machine coupon for weld penetration is a waste. is it?

 

[CoryPad]

We use semi-automated equipment such as you describe and we do not qualify a human welder, only the welding process parameters. Of course the human requires training to operate the equipment.

 

[dho]

thanks to CoryPad.
Hello, anyone there to give me support to kill our (human) welder qualification by coupon's penetration from semi-auto machine !!!
(yes, we gave training and also have vision examination.)

 

[Sparweb]

Okay,
If engineering selects the parameters of the machine, do your engineers have the qualifications needed to do so?
Have coupon tests been done on parts made to the engineers' specifications to demonstrate that the welds they specify are good (and that the machine accomplishes what it's supposed to)?

(I expect the answer is yes in both cases, of course...)


STF

 

[WKTaylor]

Dho...

AWS WHC1.11 Mechanized, Automated, and Robotic Welding discusses this very topic in great detail and places definitions on the levels of man-machine interface. From these levels comes a fairly good understanding of where 'the human' fits in the equation; and the when the human transitions from the 'primary/skilled welder/monitor' to simply becoming an 'equipment operator' [set-up, take-down, etc] without QA or corrective action, or unique set-up capabilities/responsibilities.

Many career fields are struggling with the question: when could automation/robotics/AI take-over their specific 'sacred-cow' career field??? Pilots, truck-drivers, health care workers of all types [including doctors and surgeons], farm workers, etc... to name a few could be replaced by AI driven robotics/automation.

Regards, Wil Taylor

o Trust - But Verify!
o We believe to be true what we prefer to be true.
o For those who believe, no proof is required; for those who cannot believe, no proof is possible.
o Unfortunately, in science what You 'believe' is irrelevant. ["Orion"]
o Learn the rules like a pro, so you can break them like an artist. [Picasso]

 

[Timelord]

You qualify the machine operator (not a welder) to operate the machine and then you qualify the process completely separate with each process variable determined and verified by testing.

Timelord

 

[tbuelna]

The quality of the weldment in production is ensured by using a validated and controlled process. The controlled process defines things like machine settings, joint preparation, consumables, etc. If there is an operator involved, the operator must demonstrate that they are capable of performing the exact procedure defined in the controlled process. And this would include making sure the joints are prepared properly, the machine settings are correct, and the finished weldment is satisfactory.

The requirement to use an operator qualified to perform a specific controlled process is common throughout the aerospace industry. Why would it be a waste to section a pair of sample welds to qualify an operator for performing a controlled process? How else do you propose to verify the qualification weldments produced by the operator are sound? If it only requires 5 seconds to make each weld, then it seems that a large number of parts will be produced by the operator over a single shift. And if the operator does not have the proper training to produce and evaluate that each weldment has sufficient quality, then you could end up with a huge number of defective products.