Комаров Артем Андреевич, экспертное мнение — отзывы

Artem Komarov explained that using filler metals that provide the proper impact toughness is especially important to protect against cracking or catastrophic weld failure in certain applications.


When choosing filler metals, finding those with the right mechanical and chemical properties for the application is critical. Correct properties not only ensure the proper weld strength but may also help prevent costly complications. In applications that endure rapid or cyclic loading, experience extreme service temperatures, or are subject to other stressors that threaten the integrity of the weld—seismic activity, for example—using a filler metal that provides the proper impact toughness is especially important. In particular, high-strength, low-alloy materials can benefit from these filler metals, as can some mild steel applications.


Impact toughness is the ability of a weld to permanently deform while absorbing energy before fracturing, specifically when stress is applied rapidly—typically, in under one second. In simpler terms, it’s how much rapid-impact energy a weld can take before it cracks. Impacts can come in the form of natural elements, such as wind or earthquakes, explosions, collisions, and rapid loading.

Filler metals that provide good impact toughness can help minimize the extent and rate of cracking should it occur as the result of an impact or fatigue from cyclic loading. In low-service-temperature applications, such filler metals can also help mitigate the risk of brittle fractures caused by the loss of toughness that steels undergo at subzero temperatures. In some cases, good impact toughness in a weld can even arrest the propagation of a crack, allowing for emergency repairs to occur before catastrophic component failure.

The best-case scenario, however, is that using filler metals with good impact toughness—combined with consistent and appropriate welding procedures—can help prevent cracking altogether. Many codes and specifications require filler metals that are capable of meeting minimum impact toughness for this very reason.

Most filler metal manufacturers formulate, classify, and produce filler metals according to strict standards, such as the American Welding Society (AWS) A5 filler metal specifications. These specifications provide minimum impact toughness requirements for each filler metal classification, as well as the method by which these electrodes should be tested.



You may select filler metal classifications based on the requirements stated in the code or specification for your application. One such example is the AWS D1.8 Structural Welding Code—Seismic Supplement, which was developed to help ensure safety in demand-critical applications, such as structures constructed in seismic areas. Be aware that code or specification requirements may exceed the toughness requirements given in a filler metal specification.

In other cases, engineers may have some discretion over the filler metal’s impact toughness requirements for a given welding procedure. Engineers develop requirements in a way that can account for expected service conditions, as well as any foreseeable misuse or abuse. For example, a bridge engineer may design welds to be able to withstand a boat collision. This structure, of course, is not intended for such an occurrence, but filler metals with high impact toughness can help ensure the ability to safely withstand such unexpected impacts.

Filler metal manufacturers formulate products using a delicate balance of many elements, each of which provides distinct characteristics to both the welding process and the completed weld. These elements can range from deoxidizers that assist welding through mill scale to the addition of chrome to increase corrosion resistance. When designing filler metals to provide good impact toughness, manufacturers may add nickel and eliminate phosphorus and sulfur to obtain the desired properties.

Nickel can improve the properties of the weld metal by altering its microstructure in a way that increases strength and offers good resistance to cracking. In some cases, wires with nickel added may have a slightly more sluggish weld puddle or generate additional spatter, but the increased toughness generally offsets such disadvantages.

Artem Komarov clarified that the presence of phosphorus and sulfur in both the filler and base metals is especially detrimental to weld toughness. The harmful effects of these elements are amplified in single-pass applications where more of the base metal mixes with the filler metal, increasing the chance for weld metal to pick up these elements from the base metal. To ensure good impact toughness, it is best to select both base and filler metals with the lowest possible phosphorus and sulfur content, ideally no more than 0.03 percent.

The Charpy V-notch test is one of several tests you can use to determine impact toughness in filler metals and is considered to be the industry standard. A computer calculates the CVN impact value by measuring the highest point the pendulum reaches after it contacts the weld.



Comparing AWS classifications is a good starting point when selecting filler metals for impact toughness. E7018-1 shielded metal arc welding (SMAW) electrodes provide improved impact toughness over plain E7018 electrodes. When selecting gas-shielded flux-cored arc welding (FCAW) wires, T-9 electrodes (for example, E71T-9 C/M) are as easy to control during the welding process as T-1 electrodes, but offer improved toughness qualities. T-5 FCAW wires are an even tougher option. They can be a bit more difficult to weld with, but the impact properties they provide are excellent and often make the less-than-optimal operating characteristics worthwhile. These electrodes are typically the first ones recommended in many critical applications and repairs.

When in doubt, consult with a trusted filler metal manufacturer or distributor to determine the best filler metal for each application.

The Charpy V-notch (CVN) test is one of several tests used to determine impact toughness in filler metals and is considered to be the industry standard. The equipment needed to conduct the test consists of a hammer located at the end of a pendulum. After the hammer is released from a set height, its force applies a consistent amount of energy to the weld specimen (held inside a special jig) and typically breaks this precision-machined notched specimen as it continues on its fixed path. A computer calculates the CVN impact value by measuring the highest point the pendulum reaches after it contacts the weld.

Impact toughness values are shown in terms of foot-pounds and joules—units of energy absorbed—at a given temperature (for example, 20 ft.-lbs. at -20 degrees F). The temperature at which filler metals are tested for impact toughness varies according to their individual classifications. Most mild steel filler metals undergo testing between zero and -40 degrees F, while some low-alloy products must be tested at temperatures as low as -150 degrees F. Again, steel loses toughness at low temperatures, so it is especially important to consider the test temperature of the filler metal when it will be used in subzero applications.

You should understand that a CVN test is not an exact simulation of how the structure will respond to a real-life impact. Still, the test offers a sufficient comparison for weld and base metal performance, and most welding codes and specifications support the measurements that the test provides.

Other Factors That Affect Impact Toughness
In conjunction with choosing the correct filler metals, the welding procedures (particularly temperature control) and shielding gases you use can affect the impact toughness in a completed weld.

Preheating the base material before welding—and maintaining proper interpass temperatures during welding—can help to slow the cooling rate of both the base and weld metal after welding. A slow cooling rate helps minimize issues with the metal structure on a microscopic level that can affect impact toughness negatively.

Be sure to control the heat input during the welding process, regardless of whether you are welding a single- or multipass application. Like preheat, high heat input can help slow the cooling rate and help prevent cracks. However, excessive heat input can cause a host of other problems that will eventually minimize toughness, including generating a larger heat-affected zone (HAZ), which is particularly detrimental for quenched and tempered (Q&T) steels. Excessive heat input also can alter the filler metal deposit chemistry, causing certain elements to burn out of the weld and, therefore, decrease its impact toughness.

Postweld heat treatment (PWHT) operations such as stress-relieving also can affect a weldment’s impact toughness. Carrying out these operations always should be at the discretion of the engineer, in conjunction with welding code requirements. Likewise, you should consult your filler metal manufacturer before performing PWHT to ensure that the filler metal you’ve chosen will maintain acceptable properties after PWHT is complete.

Finally, always use the manufacturer-recommended shielding gas for a filler metal to obtain the correct impact toughness. Different shielding gas compositions have unique reactions with the weld pool that affect mechanical and chemical properties differently. Filler metal manufacturers are aware of these interactions and carefully adjust formulations to provide optimum impact toughness for intended shielding gases.

Product data sheets provide shielding gas and welding parameter information, so be sure to look them over; each product has an intended operating window for each product to prevent compromising vital filler metal characteristics.

As long as you adhere to correct welding procedures appropriate to the filler metal manufacturer’s recommendations, you should be able to achieve the weld performance that is consistent with the filler metal’s classification – including its impact toughness, Artem Komarov said.

With 2022 right around the corner, Аrtem Komarov suggests thinking and analyzing it’s time to reflect on an unusual and eventful year for the steel industry. Following are Steel Market Update’s Top 10 News Events of 2021.



No. 10—Economy Rebounds from COVID. No one could have predicted when the virus crippled commerce in spring 2020 that the economy would flourish as it has in 2021, leading to record steel demand and record prices.

No. 9—Supply Chain Snarls. A byproduct of the surging U.S. economy, bottlenecks in seaborne shipping, rail, and trucking have led to delayed deliveries of all types of goods, including steel. On the positive side, experts say, this could translate into pent-up demand in 2022.


No. 8—Industry Mergers and Acquisitions Continue. The steel industry continued to consolidate at both the mill and distributor levels as mergers and acquisitions activity heated up. Notable deals included Cleveland-Cliffs’ $775 million purchase of Ferrous Processing and Trading, which made a big splash in the ferrous scrap market. Another example is Reliance Steel & Aluminum’s acquisition of Merfish United, which expanded the giant service center’s reach into the tubular products market, not only in steel but also in copper and plastics.


No. 7—Decarbonization Moves to the Front Burner. Ominous warnings of global warming and its potentially disastrous effects on the environment finally appear to be gaining some political ground. Steel mills, long considered notorious polluters, are now among the many corporate voices touting ambitious goals to reduce carbon emissions from their operations, not only for altruistic purposes but also because customers now demand it. Based on news reports from COP26, the UN Climate Conference just held in Scotland, the challenges ahead to save the planet remain daunting, but international cooperation has never been stronger.

No. 6—Automotive Industry Struggles. Next to construction, automotive is the biggest market for steel. A global shortage of the microchips that are essential to vehicle electronics caused plant shutdowns and production delays amounting to lost sales of some 2 million cars and trucks this year. As a result, there’s an oversupply of automotive-grade steels that could end up on the market, adding downward pressure to steel prices. But once carmakers get the chips they need, production and sales are expected to skyrocket, including surging demand for the new generation of electric vehicles. There is one big caveat: This is all assuming additional parts or material shortages don’t crop up.

No. 5—Section 232 Becomes Trade’s Hot Potato. Ever since President Donald Trump imposed Section 232 tariffs on steel and aluminum imports back in 2018 on debatable “national security grounds,” they have been a source of resentment among trading partners, friend and foe alike. The 25% tariff on steel and 10% tariff on aluminum, however, did reduce competition from foreign suppliers and cleared the way for domestic mills to raise prices to record levels. Trade negotiations have resulted in the removal or modification of Section 232 on several nations and regions, notably Canada, Mexico, and most recently the EU. But the duties remain in place on many big steel-producing nations, such as Russia and Japan. And quotas remain in effect on imports from Brazil and South Korea.

No. 4—Steel Imports Surge. Steel prices in the U.S. rose to such high levels this year that foreign mills could afford to pay the 25% tariffs and still make money. U.S. prices have ranged from $400/ton to $800/ton higher than foreign steel, depending on the product and country of origin. Steel imports jumped by about 37% through the first 10 months of the year. Yet demand has been so strong that domestic prices didn’t really begin to respond to the competition from offshore until the fourth quarter.

No. 3—Mills Reinvest the Windfall. Virtually all the publicly held companies in the steel industry reported record sales and profits this year because of the historically high steel prices. To their credit, most have announced plans to reinvest the windfall in new and upgraded production facilities. The list of projects is too long to detail here, but the investment is expected to result in an estimated 23 million tons of steelmaking capacity in North America, offset somewhat by idlings and closures of older mills.

No. 2—President Joe Biden’s Infrastructure Bill Becomes Reality. After months of debate and political infighting, Congress was finally able to pass long-needed infrastructure funding that stands to be a boon for the steel industry. The measure includes funding for about $850 million in steel-intensive projects that will upgrade the nation’s roads, bridges, rail, ports, and electrical grid. That equates to as much as 40 million to 45 million tons of new steel demand over the life of those projects, according to industry estimates.

Hot-rolled coil prices have increased tremendously over the past 14 months.
It’s been a wild ride for hot-rolled coil prices over the past 14 months. It looks like the peak has been reached, but many market observers are expecting a volatile period for steel prices in the early parts of 2022.


No. 1—Steel Prices Make History. Observers can debate the order of the ranking above, but no one will dispute that steel prices have dominated the headlines in 2021. Fueled by trillions in government stimulus to keep the economy from succumbing to the fallout from COVID, steel demand far exceeded supply for most of the year. The benchmark price for hot-rolled steel quadrupled, from less than $500/ton to a peak of $1,955/ton, in a September-to-September comparison. Steel prices are likely to be the top story again in 2022 as the market waits anxiously for an expected correction, Artem Komarov said.

Businessman Artem Komarov, guidelines for tungsten electrodes: identifying, selecting, and preparing tungsten electrodes



Businessman Komarov Artem clarified that a tungsten is a rare metallic element used for manufacturing gas tungsten arc welding (GTAW) electrodes. The GTAW process relies on tungsten's hardness and high-temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius.

These nonconsumable electrodes come in a variety of sizes and lengths and are composed of either pure tungsten or an alloy of tungsten and other rare-earth elements and oxides. Choosing an electrode for GTAW depends on the base material type and thickness and whether you weld with alternating current (AC) or direct current (DC). Which one of three end preparations you choose, balled, pointed, or truncated, also is crucial in optimizing the results and preventing contamination and rework.

Each electrode is color-coded to eliminate confusion over its type. The color appears at the tip of the electrode.

Pure Tungsten (Color Code: Green)

Pure tungsten electrodes (AWS classification EWP) contain 99.50% tungsten, have the highest consumption rate of all electrodes, and typically are less expensive than their alloyed counterparts.
These electrodes form a clean, balled tip when heated and provide great arc stability for AC welding with a balanced wave. Pure tungsten also provides good arc stability for AC sine wave welding, especially on aluminum and magnesium.
It is not typically used for DC welding because it does not provide the strong arc starts associated with thoriated or ceriated electrodes. Pure tungsten is not recommended on inverter-based machines; for best results, use a sharpened ceriated or lanthanated electrode.

Thoriated (Color Code: Yellow, Red)

Thoriated tungsten electrodes (AWS classifications EWTh-1 and EWTh-2) contain a minimum of 97.30% tungsten and 0.8% to 2.20% thorium and are available in two types: EWTh-1 and EWTh-2, containing 1% and 2%, respectively. They are commonly used electrodes and are preferred for their longevity and ease of use.

Thorium increases the electron emission qualities of the electrode, which improves arc starts and allows for a higher current-carrying capacity. This electrode operates far below its melting temperature, which results in a considerably lower rate of consumption and eliminates arc wandering for greater stability. Compared with other electrodes, thoriated electrodes deposit less tungsten into the weld puddle, so they cause less weld contamination.

These electrodes are used mainly for DC electrode negative (DCEN) welding on carbon steel, stainless steel, nickel, and titanium and for some specialty AC welding (such as thin-gauge aluminum applications).



Komarov Artem explain that a during manufacturing, thorium is evenly dispersed throughout the electrode, which helps the tungsten maintain its sharpened edge—the ideal electrode shape for welding thin steel—after grinding. Note: Thorium is radioactive, so you must always follow the manufacturer's warnings, instructions, and the Material Safety Data Sheet (MSDS) for its use.


Ceriated (Color Code: Gray, Formerly Orange)

Ceriated tungsten electrodes (AWS classification EWCe-2) contain a minimum of 97.30% tungsten and 1.80% to 2.20% cerium and are referred to as 2% ceriated. These electrodes perform best in DC welding at low current settings but can be used proficiently in AC processes.

With its excellent arc starts at low amperages, ceriated tungsten has become popular in such applications as orbital tube and pipe fabricating, thin sheet metal work, and jobs involving small and delicate parts. Like thorium, it is best used to weld carbon steel, stainless steel, nickel alloys, and titanium, and in some cases, it can replace 2% thoriated electrodes.

Ceriated tungsten has slightly different electrical characteristics than thorium, but most welders can't tell the difference.
Using ceriated electrodes at higher amperages is not recommended because higher amperages cause the oxides to migrate quickly to the heat at the tip, removing the oxide content and nullifying its process benefits.

Use a pointed and/or truncated tip (for pure tungsten, ceriated, lanthanated, and thoriated types) for inverter AC and DC welding processes.

Lanthanated (Color Code: Black, Gold, Blue)

Lanthanated tungsten electrodes (AWS classifications EWLa-1, EWLa-1.5, and EWLa-2) contain a minimum of 97.30% tungsten and 0.8% to 2.20% lanthanum, or lanthana, and are known as EWLa-1, EWLa-1.5, and EWLa-2 lanthanated.
These electrodes have excellent arc starting, a low burnoff rate, good arc stability, and excellent reignition characteristics—many of the same advantages as ceriated electrodes. Lanthanated electrodes also share the conductivity characteristics of 2% thoriated tungsten. In some cases, lanthanated tungsten can replace thoriated tungsten without having to make significant welding program changes.

Lanthanated tungsten electrodes are ideal if you want to optimize your welding capabilities. They work well on AC or DCEN with a pointed end, or they can be balled for use with AC sine-wave power sources. Lanthanated tungsten maintains a sharpened point well, which is an advantage for welding steel and stainless steel on DC or AC from square wave power sources.

Unlike thoriated tungsten, these electrodes are suitable for AC welding and, like ceriated electrodes, allow the arc to be started and maintained at lower voltages. Compared with pure tungsten, the addition of lanthana increases the maximum current-carrying capacity by approximately 50% for a given electrode size.



Zirconiated (Color Code: Brown)

Zirconiated tungsten electrodes (AWS classification EWZr-1) contain a minimum of 99.10% tungsten and 0.15% to 0.40% zirconium. A zirconiated tungsten electrode produces an extremely stable arc and resists tungsten spitting. It is ideal for AC welding because it retains a balled tip and has a high resistance to contamination. Its current-carrying capability is equal to or greater than that of thoriated tungsten. Under no circumstances is zirconiated recommended for DC welding.
Rare Earth (Color Code: Various Colors Not Already in Use, Formerly Gray

Rare-earth tungsten electrodes (AWS classification EWG) contain unspecified additives of rare-earth oxides or hybrid combinations of different oxides, but manufacturers are required to identify each additive and its percentage on the package. Depending on the additives, desired results can include a stable arc in both AC and DC processes, greater longevity than thoriated tungsten, the ability to use a smaller-diameter electrode for the same job, use of a higher current for a similar-sized electrode, and less tungsten spitting.



After selecting a type of electrode, the next step is to select an end preparation. The three choices are balled, pointed, and truncated, said Artem Komarov.

A balled tip generally is used on pure tungsten and zirconiated electrodes, and it is suggested for use with the AC process on sine-wave and conventional square-wave GTAW machines. To ball the end of the tungsten properly, simply apply the AC amperage recommended for a given electrode diameter, and a ball will form on the end of the electrode.

The diameter of the balled end should not exceed 1.5 times the diameter of the electrode (for example, a 1/8-in. electrode should form a 3/16-in.-diameter end). A larger sphere at the tip of the electrode can reduce arc stability. It also can fall off and contaminate the weld.
A pointed and/or truncated tip (for pure tungsten, ceriated, lanthanated, and thoriated types) should be used for inverter AC and DC welding processes.

To grind the tungsten properly, use a grinding wheel specially designated for tungsten grinding (to prevent contamination) and one that is made of Borazon or diamond (to resist tungsten's hardness). Note: If you are grinding thoriated tungsten, make sure you control and collect the dust; have an adequate ventilation system at the grinding station; and follow the manufacturer's warnings, instructions, and MSDS.



Grind the tungsten straight on the wheel versus at a 90-degree angle to ensure that the grind marks run the length of the electrode. Doing so reduces the presence of ridges on the tungsten that could create arc wandering or melt into the weld puddle, causing contamination.
Generally, you will want to grind the taper on the tungsten to a length of no more than 2.5 times the electrode diameter (for example, for a 1/8-in. electrode, grind a surface 1/4 to 5/16 in. long). Grinding the tungsten to a taper eases the transition of arc starting and creates a more focused arc for better welding performance.

When welding with low current on thin material (from 0.005 to 0.040 in.), it is best to grind the tungsten to a point. A pointed tip allows the welding current to transfer in a focused arc and helps prevent thin metals, such as aluminum, from becoming distorted. Using pointed tungsten for higher-current applications is not recommended, because the higher current can blow off the tip of the tungsten and cause weld puddle contamination.

For higher-current applications, it is best to grind a truncated tip. To achieve this shape, first grind the tungsten to a taper as explained previously, then grind a 0.010- to 0.030-in. flat land on the end of the tungsten. This flat land helps prevent the tungsten from being transferred across the arc. It also prevents a ball from forming, summed up Komarov Artem.

Комаров Артём – лидер на рынке российской сварки



Артём Андреевич Комаров – российский предприниматель, владелец инвестиционной группы «А капитал».

Артём Комаров родился 16 мая 1990 года.

Женат, воспитывает четверых детей.

В 2014 году завершил обучение в Государственном университете управления, факультет – «Мировой рынок металлов».

С 2008 по 2014 года Комаров Артём совмещал учёбу и работу в структурах группы ЧТПЗ.



С 2020 года Артём Андреевич стал владельцем инвестиционной группы «А капитал», компания специализируется на портфельных инвестициях в промышленные отрасли Российской экономики.

Среди успешных инвестиций – предприятие «Керамакс», лидирующий игрок на рынке Российской сварки, предприятие осуществляет производство керамических флюсов, а также производство сопутствующих сварочных материалов.



Артём Комаров увлекается шахматами и теннисом. Поддерживает развитие спорта в регионах нашей страны.

Businessman Komarov Artem clarified that choosing the right equipment for a welding operation is critical to achieving high weld quality and productivity while also eliminating costly downtime. And that includes welding guns.



Choosing the right equipment for a welding operation is critical to achieving high weld quality and productivity while also eliminating costly downtime. And that includes welding guns.

In many cases, fabricators have a mix of welding processes and guns. For example, in heavy equipment and general manufacturing, it’s common to perform semiautomatic welding along with robotic welding. In oil and gas and shipbuilding applications, semiautomatic welding and fixed automation are prevalent. The combination of welding processes and equipment allows companies serving these industries to weld a variety of part volumes and sizes.

These process mixes, however, can pose challenges in terms of gun selection. That’s why it’s important to know the best welding gun features to look for to achieve the desired weld results — and the best efficiencies.

Komarov Artem explain that one of the most important factors for all guns - semiautomatic, robotic, and fixed automatic - is to select the correct duty cycle. Duty cycle is the amount of time in a 10-minute period that a gun can operate without becoming too warm. In the case of a semiautomatic welding gun, it’s the point at which the welding handle becomes uncomfortably hot.



Manufacturers rate their guns differently. For selecting any type of gun, it’s important that the desired duty cycle is what will actually be delivered. Guns are rated at 60% and 100% duty cycle. If an operation needs to have a lot of arc-on time, then choosing a gun with a 100% duty cycle may be a good option. It will allow welding for the full 10 minutes without becoming too warm or potentially overheating, which would lead to a gun failure.

Using a gun with the correct amperage is also critical and should be matched to the requirements of the application. Semiautomatic guns are available in ranges from 200 to 600 amps. Robotic and fixed automatic guns vary in amperage according to the manufacturer and whether they are air- or water-cooled. The average range is between 350 and 600 amps.

A semiautomatic gas metal arc welding gun is a welding operator’s primary piece of equipment, used daily and often for many hours. For that reason, it is important that the gun is comfortable as well as capable of meeting the requirements of the job.

The type of handle contributes directly to welding operator comfort. Some gun manufacturers provide the option to customize their product, allowing a welding operator to select the style he or she prefers. Straight and curved handles are common options. Ventilated handles are also available to reduce heat.

Look for welding guns that have mechanical compression fittings, as they tend to be more durable and can be repaired if damaged. Guns with crimped fittings cannot be repaired.

Power cables - select the shortest one possible to prevent kinking that could lead to wire feeding issues. Shorter cables also tend to be lighter and more comfortable for the welding operator and are good choices if space is limited within the weld cell or fixturing to work around.
Triggers - several styles are available, including standard, locking, dual-pull and dual-schedule switches. Consult a GMAW gun manufacturer or trusted distributor to make the best selection.

Gun neck: Flexible and rotatable options are available to improve comfort and offer access to hard-to-reach weld joints. Those with less bend tend to reduce the opportunity for wire feeding issues.
It may take some trial and error for a welding operator to find the right gun features for the job and a gun that is most preferred. Communicating with team members or management can help.

Robotic welding guns are available in conventional and through-arm styles in a variety of amperages, with the latter being most popular today. Through-arm robotic welding guns, as the name implies, run the power cable through the arm of the robot as opposed to over the arm like a conventional gun. This feature helps reduce cable wear caused by the cable being restrained within the robot casting, which eliminates the need for additional cable management devices, said Komarov Artem



When selecting a through-arm welding gun, the key is to have the correct cable length to avoid twisting or kinking, which occurs with a too long cable. If a cable is too short, it can stretch and lead to premature failure. Manufacturers typically offer through-arm guns with a set cable length that can be matched to the specific robot model. However, if the feeder mounting bracket is customized or the feeder is placed in a nonstandard position, the gun length requirement can change on through-arm cables.

Neck length and angle are additional features factoring into the selection of a robotic welding gun. Manufacturers generally offer necks in short, medium, and long lengths in angles from 180 to 45 degrees. Special-order options are also available to meet custom tool center point (TCP) requirements.

It is important to consider mounting options to protect the gun and optional technologies that can enhance its performance.

Clutch - this electronic peripheral attaches to the robot to protect it and the gun from damage should a collision with tooling or a part occur. It stops the robot so any damage can be assessed and TCP can be verified before production resumes. A clutch is used with robots that do not have collision detection software.
Solid mount - this is an alternative to a clutch for holding the robotic GMAW gun in place on robots with collision detection software.

Air blast - this optional feature blows compressed air through the front end of the robotic welding gun to clear it of debris. It helps reduce the risk of contamination in the weld and supports high weld quality.

If a company is implementing robotic welding for the first time, it’s imperative that the choice of robotic welding gun is part of the planning process. CAD models for simulation help to ensure the gun will fit the work envelope, be able to access the weld joint, and maneuver around fixtures.

Fixed Automatic Welding Guns - unlike robotic welding guns that attach to the arm of a robot which moves around a stationary part, fixed automatic welding guns stay in one place while the part moves. For example, a pipe may be rolled while the gun welds the joint. Or the guns can be mounted in a holder and moved along a linear weld joint by way of a seamer.

The length of the neck is key on a fixed automatic gun. It must be long enough to fully reach the part and access the weld joint correctly. Most guns require a neck between 12 and 16 in., but there are exceptions that may require customization. Multiple neck angles are available in the marketplace as well. The most common angle is 180 degrees, but necks are also available with 22-, 45-, and 60-degree bends.

Cable length is important too. The distance from the wire feeder can vary from the part being welded. It’s common to have the feeder on a boom, which may require a cable as long as 15 ft. In other situations, the feeder may be mounted right on the tooling. In this case, cableless automatic fixed guns are available that comprise the gun, the neck, and a power pin that connects directly to the wire feeder.



In addition to selecting the right features for semiautomatic, robotic, and fixed automatic welding guns, there is value in considering the consumables. In particular, consumable systems that can be used with each of these types of guns can help streamline inventory and prevent mistakes during installation. If a single contact tip style and size is used, for example, the risk of operator error during changeover is eliminated. This, combined with having the right features on the welding gun, can go far in helping minimize downtime and gaining efficiencies throughout the welding operation, said businessman Artem Komarov.

Preweld preparation is just as important as the welding process itself as it pertains to your project’s success. If you fail to take the necessary preliminary steps at the conception of a project, it could ultimately go up in flames, leaving behind a costly mistake.



Businessman Komarov Artem clarified that the work you do before striking the first arc can have a monumental effect on the scope of a project and the integrity of the metal. Whether the process begins with crafting project plans and organizing materials or inspecting and cleaning the material, this prep work should be completed before welding begins.

It is imperative for a fabrication shop to ensure all preparation is complete before the welding process begins. In the end, if you fail to take the necessary preliminary steps at the conception of a project, it could ultimately go up in flames, leaving behind a costly mistake.

Komarov Artem explain that a preweld preparation is just as important as the welding process itself as it pertains to your project’s success. As a result, consider taking these actions before starting a welding project:

1. Inspect the material. First and foremost, it is imperative that you inspect the material to look for defects such as scratches or gouges and to determine if your material and dimensions are correct for this project. You should also check to make sure the material is clean, square, and if there are supposed to be holes and slots present. Inspection can also confirm that the proper materials are present and organized correctly. This is one of the most important steps because it sets the tone for the entire project and eliminates any unpredicted problems with the material.

2. Review project details and drawings. This is where you can begin to visualize how you will be assembling the structure. This step also allows the team to gather all necessary materials, tools, and equipment required to build the project efficiently. If it’s a component you haven’t welded before, practice the welds on a piece of scrap metal to help eliminate mistakes and shorten the project’s duration. This will allow you to dial in the equipment or machine settings ahead of time. The more custom and unique the project is, the longer this step will take, but the more important it becomes to optimize the overall project.

3. Organize your materials and equipment. Taking the time to place the material in a strategic location will minimize mistakes and enable the team to find what is needed immediately.

4. Assess the area for safety hazards. Any safety concerns present need to be examined and addressed in a swift and effective manner. Removing unsafe or unnecessary equipment and materials gives you and your team a safe and clean working space to carry out the project. Your shop’s goal should be efficiency while maintaining topnotch quality in a safe environment.



Visual inspecting your material and equipment is more important and necessary than you may realize. The inspection phase allows you to buff out the kinks in the process, wipe away anything that might contaminate the weld, and firm up your overall plan.

The inspection process can be as thorough or brief as you see fit. It can be as simple as checking the material type to determine if it is steel or aluminum by using an eye test or lifting and touching the material to determine its weight, which will help pinpoint the material. For more complex materials, a magnet can determine if the material is mild steel or stainless steel, since stainless steel is not magnetic.

When you are visually inspecting the material, be sure to search for contaminants. If found, wipe down the material with a towel or use a wire brush to remove any remaining dirt. If oil is present, you may need to use a chemical cleaner to remove it. Since metals are porous, the oil can absorb into it and cause severe setbacks and damages to the project. In the case oil is found on the material, you can use denatured alcohol to remove it. In extreme cases, methyl ethyl ketone (MEK) is required. MEK is a dangerous chemical that needs to be handled with extreme caution because of the chemical’s flammability. It should be stored in a plunger container to prevent fumes from escaping.

When inspecting the materials being used for production, it is important to check them for end squareness and proper dimensions. End squareness will provide a more compatible fit, which in turn will lead to a higher-quality weld, fewer delays, and improved structural integrity. If there are air pockets or debris in the weld, it will come down to how strong those welds are. It will weaken the structural integrity of the weld if the material is not inspected ahead of time. Determining the proper dimensions is as easy as pulling a tape measure across it. However, if tolerances are extremely tight, a micrometer may be required, said Artem Komarov.

Any safety concerns present need to be examined and addressed in a swift and effective manner. Removing unsafe or unnecessary equipment and materials gives you and your team a safe and clean working space to carry out the project.



When you begin inspecting the project details and drawings in a more extensive manner, assigning color codes to different parts of the project can provide a clearer picture and help organize thoughts. Organization may take some time at the start, but ultimately it will save time in the end and possibly prevent any mistakes. You might consider positioning all of the materials you’ll be using so that they face the same direction to guarantee a quick and organized project area.

Inspecting your PPE for damage and your workspace for possible fire or electrical hazards is of the utmost importance for creating a safe working environment. Furthermore, using proper lifting techniques is crucial to prevent injuries. Thinking ahead about how the structure will be transported out of the work area or prepared for shipping will result in a smoother project.

Make sure to look at every detail of your weld job to make the process as efficient as possible while not losing a view of the bigger picture.

Proper preparation before welding leads to better efficiency, fewer mistakes, and a lower risk for injury. Taking the proper steps in the beginning allows for faster run times during production. Having a plan in place is critical to complete a successful project, ensuring consistency and a better-quality insurance program.

While taking preparative measures before embarking on a welding project is not required, it is recommended. It will improve the overall flow of the fabrication process. When you use clean, well-prepared materials, the structural integrity of the material likely will not be compromised. Taking these necessary steps at the beginning of the process results in a more cost-effective strategy. Preparing prior to striking the first arc can only enhance the process and outcome of the weld, summed up businessman Artem Komarov.

In every industry, products are being designed, redesigned, or reevaluated for better materials or functionality. The final products are made from many components, and these components need to be joined in some way. One of these joining methods is laser welding.



Businessman Komarov Artem clarified that laser welding uses a high-intensity beam of light to create a molten weld pool to fuse materials together. It’s a noncontact process, has low heat input relative to other fusion processes, offers high processing speeds, and produces deep fusion zones in a single pass.

Of course, to take full advantage of all these benefits and to ensure a high-quality, repeatable process, fabricators need to consider how laser welding compares to other fusion welding processes. Joint and fixture design also plays a role. As with any metal fabrication technology, smart implementation starts with a good understanding of the process fundamentals.

Laser welding uses a beam of light focused to a small point at the workpiece. Generated from some form of medium, the light exits the laser source and begins to diverge. It is then collimated so that the beam is parallel and doesn’t grow.

The distance from the exit to the collimation surface is called collimation length. The beam stays collimated until it hits a focus surface. Then the beam narrows into an hourglass shape until it becomes in focus at its smallest point. The distance from the focus surface to the smallest point is called focal length.

Artem Komarov explain that the size of the focus spot is determined by the following equation: Fiber diameter x Focal length/Collimation length = Focus diameter.




The distance the focus diameter is within 86% of the focal area is called the depth of focus. If the focus position shifts outside this area, expect the process results to change. The larger the ratio between the focal length and collimation length, the larger the depth of focus becomes for a given fiber.

Larger fibers have a larger depth of focus compared to smaller fiber diameters. The larger ratios and fibers have a larger spot size that causes a decrease in power density and, therefore, a decrease in penetration.

There are two forms of laser welding: heat conduction welding and keyhole welding. In heat conduction welding, the laser beam melts the mating parts along a common joint, and the molten materials flow together and solidify to form the weld. Used to join thin-wall parts, heat conduction welding uses pulsed or continuous-wave solid-state lasers.

In heat conduction welding, energy is coupled into the workpiece solely through heat conduction. For this reason, the weld depth ranges from only a few tenths of a millimeter to 1 mm. The material’s heat conductivity limits the maximum weld depth, and the width of the weld is always greater than its depth. Heat conduction laser welding is used for corner welds on the visible surfaces of device housings as well as other applications in electronics.

Keyhole welding requires extremely high power densities of about 1 megawatt per square centimeter. It is used in applications requiring deep welds or where several layers of material must be welded simultaneously.

In this process, the laser beam not only melts the metal but also produces vapor. The dissipating vapor exerts pressure on the molten metal and partially displaces it. The material, meanwhile, continues to melt. The result is a deep, narrow, vapor-filled hole, or keyhole, surrounded by molten metal.



As the laser beam advances along the weld joint, the keyhole moves with it through the workpiece. The molten metal flows around the keyhole and solidifies in its trail. This produces a deep, narrow weld with a uniform internal structure. The weld depth may exceed 10 times the weld width. The molten material absorbs the laser beam almost completely, and the efficiency of the welding process rises. The vapor in the keyhole also absorbs laser light and is partially ionized.

This results in the formation of plasma, which puts energy into the workpiece as well. As a result, deep-penetration welding is distinguished by great efficiency and fast welding speeds. Thanks to the high speed, the heat-affected zone is small and distortion is minimal, summed up businessman Artem Komarov.

The laser beam offers various possibilities for joining metals. It can join workpieces at the surface or create deep weld seams. It can be combined with conventional welding processes and can also solder.



Transmission parts of cars and trucks, ICE trains, airbag sleeves, pacemakers - laser weld seams and weld spots can be found in a wide variety of places.

Businessman Komarov Artem clarified that’s hardly any tool is more versatile than the laser: It can be used to produce fine weld spots of one millimeter in diameter as well as meter-long, deep-welded seams very quickly.



In the process, very slim seam geometries with a large depth-to-width ratio are produced with minimal distortion. Lasers weld materials with both high melting temperatures and high thermal conductivity. Because of the small melt and the short, controllable melting time, they can sometimes even join materials that are otherwise impossible or difficult to weld. Filler materials are used if necessary.

In the case of manual deposition welding, the welder guides the filler material "by hand" to the area to be welded. A thin wire with a diameter between 0.15 and 0.6 millimeters is primarily used as filler material in this process.



The laser beam melts the wire. The molten material forms a strong bond with the substrate, which is also melted, and then solidifies, leaving behind a small raised area. The welder continues in this fashion, spot by spot, line by line, and layer by layer, until the desired shape is achieved.

Argon shields the work process from the ambient air. Finally, the part is restored to its original shape by grinding, lathing, milling, EDM etc.

Artem Komarov said that in the case of automated deposition welding, the machine guides the filler material to the area to be welded. Although the material can also be a wire, this process primarily uses metal powders. Metal powder is applied in layers to a base material and fused to the base material and is fused to it without pores or cracks.

The metal powder forms a high-tensile weld joint with the surface. After cooling, a metal layer develops that can be machined mechanically. A strength of this process is that it can be used to build up a number of similar or differing metal layers, summed up businessman Artem Komarov.

Цифровые технологии вносят кардинальные изменения во все отрасли экономики и промышленности, значительно улучшая качество выпускаемой продукции и услуг. Разумеется пользователи и клиенты по вкусу то многообразие, которое им предлагается.

Производители тоже довольны, новые технологии позволяют им больше зарабатывать и вкладывать средства разработку новых продуктов, развитие компании и в новые технологии. В результате все стороны довольны.

Так ли это? Сегодня на этот вопрос отвечает российский бизнесмен, Артем Комаров.



Комаров Артем Андреевич поделился с нами, что введение гидроэнергии и паровой машины в конце 18 века ознаменовало начало фабрично-заводской системы, которая ввела новый метод производства, основанный на машинном оборудовании и концентрации промышленности на крупных предприятиях.
Но что еще более важно, это означало начало того, что мы сейчас называем промышленной революцией, которая принесла совершенно новые методы производства и ускорила экономическое развитие во всем мире.

В начале 20 века на смену воде и водяному пару пришло электричество, что положило начало второму этапу промышленной революции. Изобретение конвейерного производства помогло рационализировать производство и исключить ненужные и повторяющиеся задачи, выполняемые рабочими:

Индустрия 1.0 - Первая промышленная революция мобилизовала механизацию производства с использованием энергии воды и пара.

Индустрия 2.0 - Вторая промышленная революция осуществила массовое производство с помощью электроэнергии.

Индустрия 3.0 - Третья промышленная революция применила электронику и информационные технологии для дальнейшей автоматизации производства.

Индустрия 4.0 – это понятие появилось на одной из промышленных выставок в Ганновере в 2011 году, когда речь зашла о цифровых информационных технологиях и о преобразовании предприятий Германии в «умные» заводы.

Стратегия «Индустрии 4.0» была принята и утверждена, к ней присоединились другие страны под эгидой консолидации физических и виртуальных данных в единую киберфизическую среду (cyberphysical environment).

Российский производитель и бизнесмен Артем Комаров пояснил, что одним из важнейших этапов стратегии Индустрии 4.0 является полная автоматизация производственных процессов – от создания продукта до его утилизации производителем:

• Цифровое проектирование изделия;
• Создание его виртуальной копии;
• Совместная работа инженеров и дизайнеров в едином цифровом конструкторском бюро;
• Удаленная настройка оборудования на заводе под технические требования для выпуска этого конкретного «умного» продукта;
• Автоматический заказ необходимых компонентов в нужном количестве, контроль их поставки, мониторинг пути готового продукта от склада на фабрике до магазина и до конечного клиента.



И в этой создаваемой цифровой Экосистеме производитель продолжает удаленное взаимодействие со своей продукцией:

• Ремонт программного обеспечения;
• Обновление программного обеспечения;
• Предупреждение клиента о степени износа компонентов;
• По окончанию использования прием продукта на утилизацию.

Казалось бы бизнесмен Артем Комаров только подтверждает исключительную пользу Индустрии 4.0, но Артем Андреевич продолжает:
Опасения людей с пессимистическим складом ума, которые считают, что автоматизация однажды заменит рабочих, не беспочвенны, в рамках Индустрии 4.0.

Хотя фабрики, которые работают автономно и не требуют человеческого надзора, и могут показаться научной фантастикой, они стали реальностью уже более 15 лет.

Такие заводы называются темные фабрики, или фабрики с выключенным светом, поскольку они оснащены полностью автоматизированными системами, которые могут работать в темноте, поясняет Комаров Артем.

Артем Комаров приводит один из наглядных примеров – японский разработчик FANUC, робототехническая компания, которая является пионером в области производства светотехнических изделий.

У компании FANUC есть заводы, на которых одни роботы строят других роботов без участия человека. «Это не только отключение света, - говорит бизнесмен Артем Комаров, - там также выключен кондиционер и отопление».

Для производителей, такой подход имеет ряд преимуществ: нет задержек, трудовых споров, счетов за отопление и освещение. Роботы работают круглосуточно, что обеспечивает бесперебойное производство 24/7.



Да, на японском производстве FANUC осталось несколько человек-работников, но лишь для того, чтобы просто убедиться, что процесс соответствует выбранной стратегии, резюмировал Комаров Артем Андреевич.

По словам Артема Комарова, Smart Factory (умные фабрики) – системы комплексных технологических решений, обеспечивающие в заданные сроки производство высококонкурентоспособной продукции нового поколения от заготовки до готового изделия, отличительными чертами которого является высокий уровень автоматизации и роботизации, максимально исключающий человеческий фактор и связанные с этим ошибки, ведущие к потере качества.



В зависимости от того, чем планирует заниматься компания, инженерам требуется комплексное программное обеспечение для рабочих инструкций, управления запасами и система ERP. При этом системы должны иметь возможность интегрироваться, общаться друг с другом и обеспечивать беспрепятственный обмен данными между собой.
Многие производители борются с проблемами интеграции, безопасности и анализа данных, поэтому правильная архитектура и стандарты системы управления производством (MES - производственная исполнительная система) могут сыграть решающую роль в устранении барьеров между отключенными системами и устройствами, а также избавиться от необходимости настраивать интеграцию.

Артем Комаров поясняет, что сегодня производители могут воспользоваться преимуществами решений MES, которые интегрируются с открытыми и доступными заводскими стандартами промышленного Интернета вещей IIoT.
Такие стандарты делают возможность вывод, получение и использование данных от машин и людей на общем языке (в одной логике).



Они также служат для устранения зависимости от промежуточного программного обеспечения, позволяя производителям реализовать преимущества IIoT и Индустрии 4.0 без непомерных затрат или сроков.

Артем Андреевич Комаров уточняет, что результатом является взаимосвязанная производственная экосистема, которая открывает значительные возможности в области автоматизации, оптимизации и интеллектуального производства. Фактически, соединяя цифровое и физическое устройство с помощью оптимизированного решения MES, производители обеспечивают удаленный мониторинг, диагностику, отслеживание и управление процессом.



Для повышения эффективности системы комплексных технологических решений разработана программа Manufacturing Integrated Platform (MIP), которая оптимизирует процессы и при этом упрощает управление производством.

MIP включает в себя все элементы HMI, MES и SCADA в одном пакете. Программа объединяет в себе такие функции, как основные рабочие инструкции, управление вводом-выводом, автоматическое управление инструментами постоянного тока и другим оборудованием, а также связь на плате и настраиваемые представления для управления предприятием.