ZUGIL S.A.
implements the project co-financed from the European Funds:
“Development of an innovative technology for the production of large-size elements and structures, including cranes, which reduces deformation of welded structures, including pilot process line in the ZUGIL S.A. company.”
– Value of the project: 11,845,229.68 PLN
– Contribution from the European Funds: 6,251,096.69 PLN
Project Description:
The subject of the project is implementation of R&D activities related to the development of a pilot technological line based on an innovative technology for the production of welded structures and large-size structures, including cranes, that limits deformation of welded structures by replacing fillet welds with butt and butt-fillet welds. The R&D work will concern welding processes for easily, moderately and hard-welded steels including fine-grained and HARDOX type.
Development and demonstration of the technology will provide a systematic solution to the technological problem in the steel structures industry related to the quality and strength of the manufactured welded structures by improving it due to the minimization of the welding thermal effect.
The objectives of the project will be achieved by carrying out industrial research and development work which will result in:
1. Reduction of final deformation of welded structures.
2. Increasing the strength of joints in welded structures.
3. Reduction of the material consumption.
4. Reduction of the operating times of welded structure manufacturing technology
Scope of works:
At the stage of industrial research, the optimal welding parameters and geometry of hybrid joints will be determined to obtain high-strength structures and minimize welding deformations and consumption of additional materials. A project of pilot line for implementing the innovative technology will be developed. Additionally, informationregarding the impact of the surface cleaning (shot blasting), thermal cutting (plasma and laser) and their parameters on the surface quality and the cut gap, the magnitude and distribution of deformations resulting from cutting the sheets of a different thickness and material groups, and regarding the effects of the vibratory pressing process on the surface layer parameters will be obtained.
Main technological issue is to develop a method of reducing the level of tensile stresses in sheets after their thermal cutting, especially on the edges, and its impact on reducing deformation of the prefabricated elements.
At the stage of experimental development works, welding joints with optimal strength and geometric properties will be obtained. Additionally, a full systematization/ ranking of joints with various parameters and individual strength and operational characteristics will be made. A line to prepare parts for welding and to carry out the cutting, welding and other processes will be configured, so that products with a minimum deformation, high quality and high level of static and dynamic strength can be obtained.
