Capacitive Discharge Welder

THE CHALLENGE

A specialised welder to facilitate clients patented manufacturing process.

Our client, a long-standing company in the downhole industry, started business in 1968, manufacturing hardfacing materials for the oil and gas drilling industry. As the company grew it continued to develop its hardfacing technology and diversified into the manufacture of downhole tools. 

They developed a proprietary hard facing solution designed to enhance the longevity and performance of downhole equipment subjected to extreme temperatures, pressures, and abrasive conditions. This hard facing process required the development of a specialised welder.

THE SOLUTION

Initial R+D work determined that capacitive discharge welding was the most effective method for our client’s application.

Through initial R+D stages it was found a short, high-energy pulse discharge was found to produce the best weld/bond between insert and tool. 

This weld discharge profile requirement, coupled with the difference in material and thickness between the insert and tool, helped to determine that capacitive discharge welding was the most effective means of welding for our client’s application.

THE IMPLEMENTATION

Drawing upon our expertise in electronics design and engineering, we developed a specialized capacitive discharge welder tailored to meet our clients particular process requirements.

Our solution incorporated the following key features:

• Compatibility with Patented Hard Facing Solution: We worked closely with our client to ensure seamless integration of their patented hard facing solution with our welder. Through extensive testing and collaboration, we optimized the welder’s energy and discharge parameters to achieve optimal bonding and performance with the hard facing material.
• Ruggedized Design: Recognizing the harsh conditions encountered in downhole operations, we engineered the welder with a ruggedized design capable of withstanding extreme temperatures, pressures, and vibrations. High-quality materials and meticulous craftsmanship ensure long-term reliability and performance in challenging environments.
• Precise Energy Control: Our welder features precise control over a high weld energy, with peak discharge currents up to 6000A, with a short discharge time of approximately 2mS. The user can adjust welder discharge voltage (and thus energy) from a range of 5V to 50V (through control of a precision programmable SMPSU). This precise control allows operators to tailor the welding energy specific to the clients hard facing applications. This enables consistent and reliable bonding of the hard facing material, ensuring superior performance and longevity of downhole equipment.
• Real-time Monitoring and Data Visualization: To facilitate quality control and process optimization, we equipped the welder with real-time monitoring capabilities. Operators can connect the welder to a laptop for instant visualization of weld discharge profile, and other performance metrics, enabling quick adjustments and troubleshooting as needed.

THE RESULTS

An advanced capacitive discharge welder optimized for our clients hardfacing process

Our advanced capacitive discharge welder has delivered tangible benefits to our client, and their customers operating in the downhole sector, including:

• Enhanced Performance: The precise control over weld energy, and other parameters, ensures optimal bonding of the patented hard facing solution, enhancing the longevity and performance of downhole equipment in challenging environments.
• Increased Reliability: The ruggedized design and high-quality construction ensure reliable operation in extreme, minimizing downtime and maintenance costs.
• Improved Efficiency: Short weld discharge time (sub 2ms) and real-time monitoring capabilities enable operators to optimize the welding process, maximizing productivity and reducing waste during downhole operations.
• Competitive Advantage: By providing our client with a tailored solution that meets their specific needs, we have helped them maintain a competitive edge in the downhole industry.

In conclusion, our design, development, and manufacturing expertise have enabled us to deliver an advanced capacitive discharge welder optimized for our clients hardfacing process.

 By collaborating closely with our client and leveraging our technical capabilities, we have provided a solution that enhances performance, reliability, and efficiency in the challenging downhole environment. We are proud to have contributed to our client’s success and look forward to continuing our partnership in the future.