Study of welding deposition performance in changing parameters (welding speed and direction) in hard coating application in sugarcane mills using the FCAW process with a focus on sustainable manufacturing

Abstract

Being one of the main sources of waste generation from welding processes, filler metal splashes are a source of waste generation that promotes environmental impacts due to their chemical compositions. Actions that converge towards reducing waste, in addition to mitigating environmental impacts, also represent a significant contribution to reducing costs inherent to welding processes. Actions aimed at reducing waste and costs contribute significantly to sustainable production. In this context, a study is proposed that analyzes welding spatter as a contaminating residue and loss of financial resources. Therefore, the objective of this study is to analyze the application of hard coating using the FCAW (Flux-Cored Are Welding) process on shafts in sugar and alcohol plants. The objective is to study the influence of the coating application speed parameter associated with the direction of rotation (welding direction) on the Deposition Yield. As proposed in this study, using welding speeds of 6, 10 and 13.6 m/min with alternating rotation directions (clockwise and counterclockwise), the Deposition Yield was calculated for the 6 situations. The results showed an improvement in performance when 6 m/min and clockwise were combined. This improvement results in savings of approximately R$6.7 million per year and would avoid the generation of 385 tons of hazardous materials in Brazil. These results contribute to more sustainable production.