Welding consulting, materials expertise and process optimisation
For manufacturers, fabricators and maintenance providers in mechanical and plant engineering:
welding consulting, materials consulting, welding qualification and systematic process analysis – as the interface to the notified body and the basis for stable, code-compliant production.
CHALLENGE
In mechanical and plant engineering, joining technology and material selection determine quality, costs and code compliance.
- Excessive scrap rates in welding – cause unclear, whether material, process, parameters or operator.
- A welding procedure test or brazer qualification is due – preparation and interface to the notified body are missing.
- A new component requires a material or joining process decision – without in-house expertise for special cases.
- Corrosion or wear on components shortens service life and increases maintenance costs unexpectedly.
Welding qualification, high scrap rate or upcoming acceptance by a notified body?
SERVICES
Our services for mechanical and plant engineering
Welding consulting & welding qualification
Consulting on the selection and qualification of welding procedures – from procedure testing to DIN EN ISO 15614 through to welder qualification to DIN EN ISO 9606. We prepare, accompany and take over the interface to the notified body.
- Welding procedure test (WPS / WPQR) to DIN EN ISO 15614
- Welder qualification and certification to DIN EN ISO 9606
- Support for approval procedures (TÜV, DEKRA, Lloyd’s)
- Peer Review of welding plans and WPS documents
- Consulting on filler metals, preheating, post-weld heat treatment
Brazing consulting & brazing procedure testing
Consulting on brazing-soldering processes, filler materials and fluxes for demanding joining tasks. Execution and support of brazing-soldering procedure tests to DIN EN 13134 – with complete documentation for approval procedures.
- Brazing-soldering procedure test to DIN EN 13134
- Consulting on filler and flux selection
- Assessment of brazed-soldered joints to DIN EN ISO 18279
- Optimisation of brazing-soldering processes in case of quality problems
Materials consulting
Consulting on material selection for components, structures and joints – taking into account operating conditions, code requirements and manufacturing constraints. Risks from material mix-ups or unsuitable materials are ruled out at an early stage.
Process analysis & optimisation
Systematic analysis of manufacturing processes by technical experts – to identify causes of scrap, process instabilities and optimisation potential. Introduction and monitoring of process improvements with measurable results.
Corrosion consulting & surface technology
Consulting on corrosion protection and surface technology for components and structures – to reduce wear, corrosion and fatigue. Coating consulting, diffusion processes and functional surfaces for longer service life.
STANDARDS EXPERTISE
Our basis
WELDING QUALIFICATION – WHAT REALLY LIES BEHIND IT
A welding procedure test is more than a test certificate – it is the basis for your production release.
We draw up or review welding procedure specifications (WPS) to DIN EN ISO 15609 – with all relevant parameters for reproducible, code-compliant production.
We plan, accompany and document the welding procedure test (WPQR) to DIN EN ISO 15614 – including test scope, weld assessment and acceptance by the notified body.
We take over the technical communication with the notified body – from test plan preparation to acceptance documentation. No unnecessary follow-up requests, no schedule delays.
Cracks, lack of fusion, porosity or undercut have specific causes. We analyse weld seam defects metallographically and derive concrete measures for defect elimination.
Special materials require specific know-how in preheating, post-weld heat treatment and filler metal. We also provide consulting and support for demanding material combinations.
Introduction and ongoing monitoring of welding processes in series production – to ensure process stability and reduce scrap rates.
PROCESS OPTIMISATION
How we solve manufacturing problems systematically
Current-state analysis
Recording of the current process, defect patterns, scrap statistics and operating parameters.
Root cause analysis
Systematic root cause analysis – material-related, process-related and operational.
Measures
Concrete corrective measures prioritised by effectiveness and implementation effort.
Implementation & verification
Support of implementation, success monitoring and documentation of the process improvement.
PROJECT REFERENCES (ANONYMISED)
Examples from practice – what we have achieved for manufacturers and fabricators
Systematic analysis of an 18% scrap rate in welded joints. Cause: insufficient preheating at fluctuating ambient temperatures. Process adjustment and SPC introduction.
→ Scrap rate reduced to under 2%
Development of WPS and WPQR for three welding procedures, support of the procedure test and complete documentation for TÜV acceptance to AD 2000.
→ Initial acceptance without follow-up requests, schedule kept
Consulting on coating selection for steel components in a maritime environment. Assessment of existing systems, development of a new protection concept with a service life target of 25 years.
→ Maintenance intervals doubled, coating costs reduced by 30%
WHY TECHNICAL CENTER
What manufacturers and fabricators value about our work
TYPICAL OCCASIONS
When manufacturers and fabricators contact us
-
A welding procedure test or brazing procedure test is due – preparation and TÜV interface sought
-
Excessive scrap rates in welding or brazing – cause unclear, internal effort too high
-
A new component or a new material combination requires a reliable welding recommendation
-
Peer Review of welding plans, WPS documents or design drawings by an external expert
-
Corrosion or wear on components – protection concept and coating consulting sought
-
Introduction of a new manufacturing or joining process – support through the qualification process sought
FREQUENTLY ASKED QUESTIONS
