The Ochtrup-based company Fortuna Fahrzeugbau has two production sites where impulse welding with REHM equipment is now a matter of course. This is because the management is absolutely convinced of the advantages of these devices and their technology. Plant II, the contract welding shop, works with the MEGA.PULS® FOCUS, while the employees in Plant I rely on the step-switched SYNERGIC.PRO² from REHM.

Plant II of the Ochtrup contract welding shop is primarily used for manual welding, whereby the range of parts is extremely extensive. It ranges from parts required for the production of tippers to beams several metres long and welded with a welding tractor. Simple struts or anchors are processed in the factory just as much as larger welded constructions. Sandblasting all parts before further processing ensures perfect conditions. As the components are then painted, Fortuna Fahrzeugbau attaches great importance to the cleanliness of the components and weld seams as well as the seam quality. For the vehicle construction division, the contract welding shop in Plant II welds S235 to S355 steels with SG3 1.2 mm welding wire by pulsing.

Although the old welding machine met the quality criteria, the management of the contract welding shop was very dissatisfied with various points. Above all, the health of the employees was of great concern to those responsible. The air quality in the hall was poor. ‘It used to be a real fog in the hall and was no longer tolerable for health reasons,’ says Christian Schwarteck, Managing Director of Plant II, the subcontract welding shop.

The solution came with detailed advice from Dieter Enge from ENGA Schweißtechnik, who referred to the FOCUS.PULS process developed by REHM and the fact that it produces up to 70 per cent less welding fume emissions during pulse welding than a conventional arc. In addition, the use of this innovative technology reduces the need for intensive post-processing, which currently takes two hours per day and workstation, placing an enormous burden on costs and unnecessarily jeopardising competitiveness in the medium to long term.

After extensive analyses, ENGA provided a MEGA.PULS® FOCUS 400 on loan and welder Guido Bitting, who works at Plant II, put the welding machine and its functions through their paces. Conventional welding was carried out with the MEGA.PULS® FOCUS 400 as well as pulse welding or double pulsing.

After just a short changeover phase, the new welding machine was fully accepted and continues to impress today with the following results:

• Significantly reduced rework.
• Welding fume exposure at the workplace is noticeably reduced.
• Impressive arc due to high precision and visibility of the welding process.
• Significantly increased deposition rate.

The advantages of REHM's innovative welding technology quickly convinced employees and management alike.

At the same time as testing the MEGA.PULS® FOCUS 400, the company tested a competitor's product. The result was a clear decision in favour of the innovative REHM welding machine. In addition to the advantages already mentioned, the MEGA.PULS® FOCUS from REHM is significantly more user-friendly than the competitor's product. Another strength of the MEGA.PULS® FOCUS is the complete programme of welding processes and characteristic curves available. With the second product tested, this has to be purchased separately.

Fortuna decided in favour of six MEGA.PULS® FOCUS due to the positive experiences in general, the high level of efficiency and the extremely low emissions in the form of welding fumes.

At present, ten machines with the innovative technology for REHM-optimised pulse welding are in use in the contract welding shop. In line with the motto ‘Pulse your way to success’, each of the new stations is showing its best side. The conclusion of the Fortuna management is a convincing statement in favour of the MEGA.PULS® FOCUS.

The top priority in the context of the use of new welding equipment for pulse welding was a significantly improved air situation in the hall of Plant II. This success is clearly noticeable and the employees appreciate the clean air.

The second priority cited by the Fortuna management was the high costs incurred by reworking. These are also a thing of the past. ‘Running a glove over it once is all we have to do,’ explains Managing Director Christian Schwartbeck. And the list of savings goes on. In addition to improving the quality of the weld seams, the current welding speed with the new devices is at least 25 per cent higher than the old speed.