Are you looking for solutions to welding problems, Annual Consultancy Contract Services

Design, Fabrication, Supply and Commissioning of Special Purpose Welding systems and other custom-built equipments.

Technology Development

• Joining methods for similar & dissimilar material combination
• Introduction and adaptation of new processes
• Mechanisation & Automation for welding
• Selection of processes, consumables and techniques to reduce defects
• Solving problems related to joining of reactive and exotic materials
• Overlaying, Cladding and Hardfacing
• Microjoining and Brazing

Power Source Testing & Evaluation

WRI can offer services to evaluate static & dynamic characteristics of Arc welding power sources using Analysator Hannover. The transient arc voltage and current signals will be statistically evaluated using special software integrated to the Analysator and statistical parameters like standard deviation, variation co-efficient etc. can be evaluated in real time.

Welding Consumable Testing

WRI has been acknowledged by Bureau of Indian Standards (BIS) for qualifying welding consumable. For initial and periodic surveillance qualification of welding consumables manufactured, WRI can offer its services to qualify as per applicable codes and standards such as AWS & BIS.

Management Support Services

For customers desiring to set up new installation and /or modernizing the welding & fabrication facilities, following management support services are offered:

Weld & Quality audit covering Welding Procedure Specification, Procedure Qualification Record, industrial practices, power sources, welding equipments, online monitors, welding consumable, welding personnel, storage & handling, safety, quality control procedures, etc.

Plant layout covering preparation of blue prints of the location of plant & machinery, selection of welding systems, infra-structural facilities, material handling, power requirements, vendor listing & registration, system manuals, etc.

Modernisation to improve productivity and retrofitting of existing welding systems with semi-automatic and automatic equipments.

Repair & Reclamation

Assistance can be provided in rectification and repair of worn-out or cracked components, assessment of the extent of damage & feasibility of repair and recommendation of appropriate weld repair & reclamation procedure. Services for surveillance during repair at site and if necessary, the repair can also be carried out.

Welding Procedure Specification (WPS)

All critical pressure vessel and structural fabrications call for usage of WPS as per applicable codes such as ASME, AWS, API etc. In this connection WRI can assist in the development and qualification of WPS.

Residual Life Assessment (RLA) of Power Plants and Process Industry Components

In view of the prohibitively high cost of setting up new installations, Residual Life Assessment for extending the operating period of aged Power & Process plants has now become a mandatory requirement. WRI has all the expertise to carry out Non Destructive and In-situ metallographic examination and assess the extent of damage. After detailed analysis, recommendations will be furnished to the customer for further follow up actions like extended usage, replacement, repair, etc

Engineering Services

• Stress measurement and analysis of engineering components under external and internal service loading conditions

• Theoretical stress analysis using Finite Element Method (FEM) by special software like ANSYS

• Design validation using hydro-test

• Prediction and control of distortion through weld sequencing & other methods involving jigs & fixtures for large scale structures with number of sub-assemblies

• Residual stress measurement & analysis to arrive at the need for stress relieving heat treatment

• Structural Integrity Analysis to assess the reliability & safety of welded structures subjected to static and dynamic loading

• Weld design analysis & recommendation as per various international codes like ASME, AWS and other piping codes.

• Interpretation and recommendation of applicable welding Codes & Standards.

Production Assistance to Industries

Establishment of welding fabrication methods and jobbing services on a case to case basis are offered.

Metallurgical Investigations

Testing & Inspection Services

WRI has full fledged mechanical, metallurgical, NDT and electronics laboratories to carryout various types of tests conforming to national and international standards.

Mechanical Testing, Chemical Testing and NDT

WRI laboratory is well equipped to carryout the following tests as per applicable sections of various codes like ASTM, EN, IBR, BIS, ISO, AWS, API etc.

• Tensile Test of Steel, Aluminum, Copper and Titanium alloys
• Hardness Test by Vickers, Brinnel & Rockwell
• Charpy Impact Test
• Bend Test
• Fatigue Test
• Low Cycle Fatigue Test
• Fracture Toughness Test
• Macro – Etch Test
• Micro-examination
• Diffusible Hydrogen measurement by Mercury method
• Diffusible Hydrogen measurement by Gas Chromatography
• Delta Ferrite measurement
• Residual Stress Analysis by Blind Hole Drilling method
• Magnetic Particle Testing (Surface & Sub-Surface defects)
• Liquid Penetrant Examination
• Radiographic Testing with X-Rays
• Ultrasonic Testing
• Ultrasonic thickness measurement
• Chemical analysis of Carbon, Low alloy and Stainless Steels
• Chemical analysis of Ferro alloys

Weldability Evaluation of New Materials

The Institute houses a wide range of equipments to assess the fabrication and material weldability aspects to enable defect free welding. Determination of materials resistance to Hydrogen Induced Cracking, Liquation & Hot cracking, Lamellar Tearing etc. and optimization of welding parameters can be done. Facilities like indigenously developed Implant Test Equipment, Elastic Restraint Rig, Lamellar Test Rig, Thermal Cycle Simulator are available for ascertaining the susceptibility of the material to cracking.

Weldability evaluation of Ferritic Stainless Steel (FSS) type 409 M grade (8mm and 3.15mm) was carried out for coal bunker application. Base material tests like chemical analysis, tensile, bend and hardness were conducted. Weld cracking sensitivity and weld joint tests were also carried out. The plates were found to be of weldable quality and the mechanical test results of butt joints were found satisfactory.

Consultancy Enquiry Form

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Major Customers Served

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