Shipbuilding

Familiarc

Our Welding business has been developing with shipbuilding in Japan.We keep on proposing welding solutions to shipyards all over the world.

* Familiarc stands for FAMILIARC™, Trustarc stands for TRUSTARC™, and Premiarc stands for PREMIARC™.

KOBELCO Welding Solutions for Automation with Higher Quality & Efficiency

Our Line-ups for Welding Automation Technology by Stage

Integrated technolgy of welding consumables, welding system and welding process enables welding automation at every stage.

Our Line-ups for Welding Automation Technology by Stage

Large Assembly Welding System

  • Automatic vertical upward and horizontal fillet welding within the confined space of ship hull block made possible by a miniature ARCMAN™ robot mounted on a robot carry.
  • By integrating the data from 3D models with our automatic programming soft "SMART TEACHNG™", manual programming is not required. SMART TEACHING™ can establish program at around 3minitues for about 400 welding joints of the ship hull block
  • 30% improvement in welding speed in vertical upward welding over connventional all-positional welding wire whilist keeping the weldability of horizontal fillet welding using FAMILIARC™ DW-100R special FCAW.

System Configuration

System Configuration

Welding parts where Large Assembli Welding System is applied

Applied Welding Parts

Introduction Movie

FAMILIARC™ DW-100R ‐ Specially designed for Large Assembly Welding Robot System

DW-100R

Achieves both efficient vertical upward welding and beautiful bead appearance in horizontal fillet welding

DW-100R

Welding Process to improve productivity

SEGARC™ - for vertical upward welding

  • SEGARC™ - extremely efficient welding process in vertical upward
  • High deposition rate, 180cm/min at 380A
  • Applicable to inclined upward welding
  • Optimum oscillation of welding torch enables one pass welding up to 65 mm plate thickness

SEGARC

Mechanisim

SEGARC

Welding parameter

Current
(A)		 Voltage
(V)		 Travel speed
(cm/min)		 Heat input current
(KJ/cm)
400 43 2.6 397

SEGARC

SEGARC 2Z CE

Automated Horizontal Butt Welding Ishimatsu × FAMILIARC™ MX-100ER

Features

  • Optimized welding parameter is preset on compact & portable welding robot ISHIMATSU and excellent bead appearance can be obtained.
  • Small amount spatter generation with FAMILIARC™ MX-100ER reduces nozzle replace and cleaning time and the risk of insufficient shielding gas flow.
  • Slag removals is not necessary for 2 to 3 pass due to little slag generations.

Shipping Approvals

NK ABS BV DNV-GL LR
KSW53Y40G(C)H5 3Y400SAH5 SA3Y40MH5 ⅢY40MS (H5) 3Y40H5

Low Spatter Generation

Low Spatter Generation
Low Spatter Generation

High Efficient Horizontal Welding with Ishimatsu

Macrostructure

Macrostructure

FAMILIARC™ MX-100ER

Horizontal Welding (2G)
Plate thickness: 32 mm
Wire diameter: 1.2 mm
Welding Sequence: 9 layers 34 pass
Heat input: 0.8 kJ/mm

TRIFARC™ (high speed triple tandem one pool method) for Horizontal Fillet Welding

TRIFARC (High Speed Triple tandem One Pool Method)

Higher Productivity

Torch arrangement

Leading & trailing wire: FAMILIARC™ MX-200HS Filler wire: FAMILIARC™ MG-1HS

TRIFARC™ Torch Arrangement

Bead appearance and shape

Bead Appearance and Shape

Welding parameter

L: 560A-38V
T: 440A-36V
Filler wire: 80A (DC-EN)
Travel speed: 2.0m/min

HT-MAG™ Process: An effective porosity-reduction method for welding primer-coated steel plates

Configuration of HT-MAG™

Configuration of HT-MAG
Configuration of HT-MAG

Penetration of leading electrode

Penetration of leading electrode

Observation by X-ray transmission type high speed camera

Features of HT-MAG™

  • Deep penetration obtained with buried arc of leading electrode can reduce porosity in welding primer coated steel plate.
  • Low Spatter generation even in CO2 tandem welding
Features of HT-MAG

Test plate: 9mm thickness, Inorganic Zinc Primer coated

Shipping Approvals

NK

ABS

DNV-GL

LR

BV

KAW53Y40MG(C)

3Y400A

ⅢYM

3YM

A3Y40M

Click the link below for the details of HT-MAG™ at KOBELCO Global Website

FCB™ process and equipment for butt joint of large plates

FCB process and equipment
FCB™ process and equipment

Familiarc PF-I55E, PF-H55EM / Familiarc US-36 / Familiarc PF-I50R


Plate thickness: 25mm
Process: 4 electrodes FCB™ one-side SAW
Travel speed: 800mm/min.

Features

  • Consistent reverse bead at high welding current
  • Applicable for 10 to 40mm plate thickness. (3 electrodes: up to 35 mm, 4 electrodes: up to 40 mm)

RF™ process and equipment

RF
RF™ process and equipment

FAMILIARC™ PF-I55E / FAMILIARC™ US-36 / FAMILIARC™ RF-1

Features

  • Easy to make good plate-to-backing contact, particularly in joints with misalignment and tapered transition, and in thin plate

RF

Welding parameter

Plate thickness: 20mm × 50mm
Taper: 1-to-3 taper
L: 1400A-26V
T1: 1000A-40V
T2: 1100A-46V
Travel speed: 80cm/min

FAMILIARC™ DW-100V - Improved vertical-up performance

Features

  • FAMILIARC™ DW-100V enables an high current vertical-up welding at 250 to 300A.
  • Stringer run at vertical up welding
  • Superior resistance to root gap

Relationship between leg length and travel speed

溶接速度と脚長の関係

Macro structure (Example)

Macro

Leg length＝6.8/5.8 (mm)
Welding parameter: 230A-360mm/min

Macro

Leg length＝7.8/6.3 (mm)
Welding parameter: 250A-320mm/min

Macro

Leg length＝9.5/9.3 (mm)
Welding parameter: 280A-200mm/min

Relationship between root gap and welding current

Relationship

Specification

Specification Shipping approvals
JIS AWS NK, ABS, LR, DNV, BV, GL, CCS
Z3313 T 49J 0 T1-1 C A-U A5.20 E71T-1C

Our proposal and progress on horizontal fillet welding

Welding wire for single pass

Product Porosity Resistance
(Applicable travel speed)		 Sputter generation Bead shape / appearance HF
Range of leg length
FamiliarcMX-200 ≦600mm/min Good Good 4 to 8mm
≦600mm/min Better Better 5 to 9mm
≦700mm/min Good Good to Better 5 to 9mm
FamiliarcDW-200 ≦500mm/min Good Better 6 to 10mm

FAMILIARC™ MX-200F - Large leg length with smooth bead appearance

  • Applicable for 5 to 9mm weld leg length
  • Smooth bead shape with large leg length
  • Less undercut at upper leg length ensure required paint film thickness by PSPC

Small under cut / large frank angle bead appearance

Welding parameter: 320 to 340A-34V-300mm/min. Wire dia.: 1.4mmΦ

FAMILIARC™ MX-50H - Large leg length with high travel speed

  • 5 to 9mm weld leg length available
  • Smooth bead shape with large leg length
  • Excellent slag removal and shinny bead appearance
  • Excellent porosity resistance

Large leg length with high travel speed

Welding parameter: 300A-33V-250mm/min. Wire dia.: 1.2mmΦ

Large leg length with high travel speed

Welding parameter: 300A-33V-250mm/min. Wire dia.: 1.2mmΦ
Plate 20mm×50mm 12mmt. inorganic zinc primer, thickness: 30μm

Welding in Sub-Assembly to Assembly Stage

  No. Member and Joint Welding Position Welding Process Typical Welding Consumables Remarks
We   Built-up Longitudinal HF GMAW (MAG) Familiarc MX-(Z)200 Welding carridge
Familiarc MX-200H (X2) twin-tandem one pool method
Familiarc MX-200HS (x2) /
Familiarc MG-1HS
  No. Member and Joint Welding Position Welding Process Typical welding consumables Remarks
We ① Butt joint (Flat Panel) Flat SAW (Double-side) Familiarc US-36 /
Familiarc PF-H55E,
Familiarc US-36,
Familiarc PF-H52
  
② Stiffner HF GMAW (MAG) Familiarc MX-(Z)200,
Familiarc MX-50H,
Familiarc DW-200		 Welding carridge
Gravity welding (SMAW) Familiarc Z-27,
Familiarc LT-B50,
Familiarc LT-B52A		 Gravity welding
We ③ HF GMAW (MAG) Familiarc DW-(Z)100, Robot applied
We ④ Flat

Familiarc US-36 /
Familiarc PF-I55E,
Familiarc PF-H55EM

 Wire & Surface Flux
Familiarc PF-I50R Backing Flux
Familiarc US-36 /
Familiarc PF-I55E		 Wire & Surface Flux
Familiarc RF-1 /
Familiarc No.1296

Backing Flux /
Underlay Flux
⑤ HF GMAW (MAG) Familiarc MX-(Z)200 Welding carridge
Familiarc MX-200H (x2) twin-tandem one pool method
Familiarc MX-200HS (x2) /
Familiarc MG-1HS
We ⑥ HF, V GMAW (MAG) Familiarc DW-(Z)100 Robot applied
Familiarc DW-(Z)100, Semi-auto
We ⑦ Inner Double-hull/Fillet HF, V GMAW (MAG) Familiarc DW-(Z)100 Semi-auto
We ⑧ Bilge/Butt Flat FAB (One side SAW) Familiarc US-36 /
Familiarc PF-I52E /
Familiarc FA-B1 /
Familiarc RR-2		 FAB method
GMAW (One side) Familiarc DW-(Z)100 /
Familiarc FB-B3T		 Semi-auto
GMAW (One side) Familiarc MG-50D /
Familiarc FB-B3A		 Automatic
⑨ Horizontal HF GMAW (MAG) Familiarc MX-(Z)200 Welding carridge

Welding in Erection Stage

Welding Hatch combing rail (Stainless) / Fillet Tank top / fillet Top side tank / butt Side shell / butt Builge hopper / butt Tank top / fillet Upper deck / butt Tank Top (Seam, Longitudnal) Tank Top (butt, trans) Bottom shell / Butt

No. Member and Joint Welding Position Welding Process Typical welding consumables Remarks
⑩		 Bottom shell / Butt Flat GMAW (One side) Familiarc DW-(Z)100 / Familiarc FB-B3T Semi-auto
⑪		 Tank Top (Seam, Longitudnal) Flat FAB (One side SAW) Familiarc US-36 /
Familiarc PF-I52E /
Familiarc FA-B1 /
Familiarc RR-2		 FAB method
GMAW (One side) Familiarc DW-(Z)100 /
Familiarc FB-B3T		 Semi-auto
GMAW (One side) Familiarc MG-50D /
Familiarc FB-B3A 		Automatic
⑫		 Tank Top (butt, trans) Flat GMAW (One side)
+SAW		 Familiarc DW-(Z)100 /
Familiarc FB-B3T + Familiarc US-36 /
Familiarc PF-H55E		 Semi-auto
+ Auto
GMAW (One side) Familiarc DW-(Z)100 /
Familiarc FB-B3T		 Semi-auto
⑬		 Side shell / butt Vertical EGW Familiarc DW-S43G /
Familiarc KL-4
GMAW (One side) Familiarc DW-(Z)100 /
Familiarc FB-B3T		 Semi-auto
⑭		 Top side tank / butt Flat GMAW (One side) Familiarc DW-(Z)100 /
Familiarc FB-B3T		 Semi-auto
⑮		 Builge hopper / butt Vertical GMAW (One side) Familiarc DW-(Z)100 /
Familiarc FB-B3T		 Semi-auto
⑯		 Hatch combing rail (Stainless) / Fillet HF GMAW (MAG) PREMIARC™ DW-309,
PREMIARC™ DW-309LP		 Semi-auto
GMAW (MAG) PREMIARC™ DW-309,
PREMIARC™ DW-309LP		 Welding carridge
⑰		 Upper deck / butt Flat GMAW (One side)
+ SAW (Double-side)		 Familiarc DW-(Z)100 /
Familiarc FB-B3T
+ Familiarc US-36 /
Familiarc PF-H55E		 Semi-auto
+ Auto
⑱		 Tank top / fillet HF GMAW (MAG) Familiarc DW-(Z)100 Semi-auto
Familiarc MX-Z200 Welding carridge
⑲		 Long / butt Flat, V GMAW (One side) Familiarc DW-(Z)100 /
Familiarc FB-B3T		 Semi-auto

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