Abstract: Process and apparatus for welding workpiece have heat sensitive material are proposed. The heat sensitive material includes austenitic manganese steel, also referred to as Hadfield manganese steel. The process reciprocates filler metal in and out of weld pool. The motion of the filler metal may be synchronized with waveform of power source. Welding parameters are adjusted such that weld may be performed on the workpiece without cracking the heat sensitive material. The process allows Hadfield manganese steel to be welded to generator components in power generation applications. The process provides reliable and repeatable welding quality.

Abstract: A process and a system for welding rotor coils are presented. A plurality of rotor coils are arranged on a table of a machine. A welding tool welds the rotor coils on one end using a Friction Stir Welding process. Transition pieces are each arranged between the rotor coils to create a continuous welding path. A run-off tab is placed at an end of the welding path. The welding tool is changed to a milling tool after completion of the welding. The milling tool traces back along the welding path to separate the rotor coils. The milling tool may be changed to the welding tool to repeat the process for another end of the rotor coils. The process is completely automatic and controlled by a control unit.

Abstract: A process and a system for welding rotor coils are presented. A plurality of rotor coils are arranged on a table of a machine. A welding tool welds the rotor coils on one end using a Friction Stir Welding process. Transition pieces are each arranged between the rotor coils to create a continuous welding path. A run-off tab is placed at an end of the welding path. The welding tool is changed to a milling tool after completion of the welding. The milling tool traces back along the welding path to separate the rotor coils. The milling tool may be changed to the welding tool to repeat the process for another end of the rotor coils. The process is completely automatic and controlled by a control unit.

Abstract: Process and apparatus for welding workpiece have heat sensitive material are proposed. The heat sensitive material includes austenitic manganese steel, also referred to as Hadfield manganese steel. The process reciprocates filler metal in and out of weld pool. The motion of the filler metal may be synchronized with waveform of power source. Welding parameters are adjusted such that weld may be performed on the workpiece without cracking the heat sensitive material. The process allows Hadfield manganese steel to be welded to generator components in power generation applications. The process provides reliable and repeatable welding quality.