CALLIDUS WELDING SOLUTIONS

K-TIG 1000 WELDING SYSTEM

CASE STUDY

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CALLIDUS WELDING SOLUTIONS

Callidus Welding Solutions is a specialist service provider dedicated to the supply

of welding solutions to users of high end corrosion resistant metals (CRM’s). Over

the past 12 years Callidus has emerged as a leading maintenance fabricator

specialising in the repair and replacement of Titanium components. Clients range

from the Laterite Nickel (HPAL), Oil and Gas, Pressure Oxidisation (POx) of Gold

and Chemical processing industries in the ASEAN region.

Callidus undertake specialist fabrication for a wide range of clients, including

Conoco Phillips, Woodside Petroleum, Goro Nickel, Minara Resources, Lihir Gold,

Coral Bay Nickel Corporation and First Quantum Minerals.

THE CHALLENGE

Post GFC Australia has seen major changes to many sectors. The major effect on

Callidus has been the cost of labour based on an increase in the AUD$ from

USD$0.85c to USD$1.04. This effect coupled with a worldwide shortage of skilled

tradesmen in the welding sector has sent Callidus looking for ways to improve

productivity based on innovation and technology.

THE SOLUTION – K-TIG

Callidus was fortunate to have had access to a pre-production version of the K-

TIG system, and has been quietly utilising the Keyhole TIG process to achieve

blazingly fast, full penetration welding in Titanium for its clients in the ranges of 6

thru 12mm. Recently Callidus has upgraded to the new K-TIG 1000 system and

coupled this with a VR 32A Panasonic robotic arm. The fully integrated control

unit on the K-TIG 1000 controls all of the welding parameters meaning the

welding is now left in the hands of semi-skilled robotic operators.

K-TIG Case Study

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RESULTS

Production of all items requiring seam welding of longitudinal butt welds has

nearly doubled in the first 2 months of use. This has resulted in shorter lead

times giving Callidus an advantage over competitors with 3 key international

clients. For many of our fabrications, short (800mm to 1100mm) sections of pipe

are required. These are between 150mm and 450mm diameter and have a wall

thickness of between 6mm and 15mm. Manufacture of the cylindrical hollow

section uses stock plate which is cut, rolled, seamed , X-rayed and machined.

An analysis of the impact of K-TIG on the welding of Titanium nozzles showed:

Welding time Reduced by 94%

Filler Wire usage Reduced by 98%

Edge preparation time Reduced by 60%

Gas Usage Reduced by 12,000 litres per item

Man hours Per Item Reduced from 22hrs to 6.5hrs

Total Man Hours Reduced by 62 hrs

Material Input Cost No Change

Forming Time and Cost No Change

Fit & Tack No Change

Total Cost Reduced by $9814

Job Gross Margin Increased by 22%

Analysis of K-TIG welding on Titanium Nozzles

K-TIG Case Study