MIG Welding Failure Modes and PFMEA Sample Needed ASAP

K

kbock

#1
I am looking for a sample PFMEA for an aluminum MIG welding process. My company is new to welding as this is going to be our first production cell. I am trying to figure out what information is needed in the FMEA so that when our team meets to create this, I can make sure the correct info is in there. Any help would be EXTREMELY helpful. Thanks.


*After doing more research, I feel that I need to update my inquiry. I think that I am looking more for specific failure modes for aluminum MIG welding. This way, we can get our minds going in the right direction for making our own FMEA.
 
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P

prototyper

#4
Are you performing manual or robotic welding?

Other things to consider are the type of wire (Is it compatable with the grade of aluminium?), the wire thickness, the weld settings (current, voltage, pulsed or non pulsed), the torch position and angle to the weld. Consider the age and cleanliness of the wire and parent material. Also the preparation of the weld joint.

Hope this helps.
 
K

kbock

#5
Thanks. This information will help greatly.:agree: We are doing manual welding. The wire has been chosen for us by the company that we bought the welder through. It is matched to the material as well. The weld settings are going to be determined once we get the welder in house and set up.
 
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SteelMaiden

Super Moderator
Super Moderator
#6
Do you have any welders that have actually done this type of welding? (as in a professional welder vs. someone who has only been exposed to "backyard welding"?) A good welder can can help you put together your PFMEA, and I recommend that you include them in this process of putting together your FMEA. Too many times we rely on what others have done and ignore the resources in our own plants. FMEAs are meant to be a collaborative project including personnel from all depts involved.:2cents:
 
K

kbock

#7
I agree with you that a PFMEA should be a collaborative project but unfortunately we do not have anyone in house that is an experienced welder. We are actually looking to send a few of our operators for training. We are going to get our electrical department, maintenance, set-up, operators and quality in on the writing FMEA, along with myself for engineering. I am hoping that with people from all departments, we will catch the majority of the potential problems. Thanks for your help.
 
Q

Quality-Geek

#10
I agree with you that a PFMEA should be a collaborative project but unfortunately we do not have anyone in house that is an experienced welder. We are actually looking to send a few of our operators for training. We are going to get our electrical department, maintenance, set-up, operators and quality in on the writing FMEA, along with myself for engineering. I am hoping that with people from all departments, we will catch the majority of the potential problems. Thanks for your help.
Have you asked the power source supplier if they can participate in the FMEA or provide any information? They should be "experts," and very aware of not only what can go wrong, but why it happens and common controld to prevent it.
 
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