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Our corporate missions and vision
Welding Alloys Japan Ltd., founded on October 18, 1999, is a young company with a history of less than 17 years. We established corporate missions at the time of our foundation and have been committed to conducting our business activities based on the missions.
Our corporate missions are as follows:
- To gain customer satisfaction through trying to share information inside and outside of the company.
- To capture the essence of things by viewing things from multiple and long term perspectives.
- To foster employees who are cheerful, positive and capable of executing promptly.
We aim to be a development-type core company specializing in wear-resistant welding and corrosion-resistant cladding. Our vision is to grow into a company as below.
- A core company with unique technologies in wear-resistant welding and corrosion- resistant cladding
- A core company that is capable of providing customers with the latest information relating to wear-resistant welding and corrosion- resistant cladding
- A company that is recognized by both ourselves and others as a leading company in the field of wear-resistant welding and corrosion- resistant cladding
Our business activities, manufacturing policy, and toward the future
Cladding is a type of welding like joint welding. Cladding is to weld the proper welding material selected to the surface of the parent material or the damaged surface of the parent material for surface reformation, according to the requirements for use of the component and wear- resistant /corrosion-resistant characteristics required.
Welding Alloys Japan Ltd. has developed business specializing in surface reforming for about 17 years since our foundation. Our business activities experienced since our foundation are explained below. We would like to expand our surface reforming technologies into wider range of industries.
Our business is related to industries, including electric power (for business and self-generation), cement, steel making, and construction machinery, as of now. In any industry, important components receive periodic maintenance every year for reduction of wear and corrosion.
It is said by some that the approximate maintenance cost for these fields is required for about 7 % of the original cost of the component when purchased new.
Table 1 shows some typical components to be periodically rebuilt with cladding work in these industries.
The table also includes components where cladding is not adopted as of now, but is likely to be adopted in the future.
Some examples of the maintenance methods listed in the table are shown in Picture 1-5.
|Picture 1. The status of work of the boiler panel in workshop|
|Picture 2. Cladding of the boiler panel around the soot blower|
|Picture 3. Cladding of the discharge screw with TRI-S method (triple satisfaction-automatic welding, use of the best suited material, site welding)|
|Picture 4. Rebuilding 2 pieces of rollers in the narrow mill|
|Picture 5. The status of rebuilding the large gyratory crusher with two welding machines|
Policy of manufacturing
We are striving for manufacturing based on the policies below.
- In addition to our current automatic cladding welding technology, we are aiming for fully automated operation of rebuilding components by automating the related constituent technologies (inspection, measurement, grinding, etc.). (It is called Smart Welding®) Also, in order to suggest some WPS (Welding Procedure Specification) and determine the welding method best suited for the component from the PQR (Procedure Qualification Record), it is important to always work on acquisition of new constituent technologies and development of technologies.
In connection with WPS and PQR, the cladding department needs to have a strong policy on quality assurance as a manufacturer's liability.
The policy represents a philosophy of manufacturing, leading to pursuit of customer satisfaction.
*Smart Welding® acquired trademark registration in January, 2010.
- To explain to users that the suggested method has advantages in cost effectiveness, disclosure of technical information is necessary, and also it is extremely important to accumulate and release the database, including the consumption rate and service life obtained through operation of the machine.
Through inspections during the period of common use, we grasp the characteristics of clad metal executed by us while gaining customer understanding, and accumulate a huge amount of data.
- Observation of the surface condition enables us to learn to find the true cause of the damage.
Especially in the maintenance suddenly required in the installation site, logical judgment based on the damage condition is required. Therefore, the daily endeavor to improve the skills of the welding technicians is essential. As acquisition of "Standard for certification of welding coordination personnel "JISZ3410（ISO14731)/WES8103 is encouraging for them, all of our technicians are required to be WES certified.
- Development of an enterprise and industry cannot be expected without acquisition of human resources. To be a first-rate "manufacturing country", our country needs to create attractive images of the industry, including creation of a better work environment and development of human resources, in cooperation among industries, government and academia.
Toward the future
Welding technologies are essential constituent technologies for manufacturing industries dealing with metals. Cladding is also an important constituent technology of surface reforming.
However, in Japan, under the influence of the concept of "Scrap and build" in the high economic growth period in Japan, cladding seems to have been accepted as a repair technology for long years.
While in Europe, cladding is placed as a maintenance technology in the same position as joint welding.
Based on such background and the policy of manufacturing described above, we will work on business toward the future with recognition below.
- Development based on the needs is also essential in the future. Without development, there is no growth of enterprises and cladding industry. Development supports nearly perfect manufacturing.
- Cladding is performed in the workshop or on the installation site. Especially, welding work on the installation site is accompanied with a short lead time and danger. More efforts need to be made for constituent technologies, including automation technology, inspection/measurement technology, and monitoring technology, as well as operation before and after welding.
- Efforts to recruit talented young people into this industry needs to be made among industry, government and academia, without depending only on the educational world industry. Also, regardless of the enterprise's size, an in-house system of developing employees is more demanding than ever. Human resources development is also included in the development.
- When performing maintenance, history of operation/welding works and technical information, etc. are required to be released.
- Cladding technology should be developed into new product development technology as well as repair welding technology. Accordingly, it is important to improve individual's technology development skills by setting a higher goal and training employees. Under this goal, daily technical tasks are solved. By making it a practice thoroughly, higher qualification (e.g. consultant engineer) can be observed. This will be an encouragement for employees after acquisition of "Standard for certification of welding coordination personnel".
WA group business activities
Welding Alloys Ltd., founded in 1966 in UK, has thrown into its energy into development /production of flux cored wires and development of their application technologies, in order to be a leader of wear-resistant /corrosion- resistant welding material industry for about 50 years.
Now, Welding Alloys Group (Group company with over 30 subsidiaries, each of which independently develops business worldwide. It covers 150 or more countries and territories.) has about 1200 employees working as specialists across the world, who tackle welding tasks and gain customer satisfaction.
As described above, the Welding Alloys Group manufactures flux cored wires with materials, such as carbon steel, low steel alloy - high steel alloy (including stainless steel), nickel-based alloy and cobalt-based alloy, in diameters ranging from 0.9mm to 5mm.
Additionally, we manufacture custom-designed welding equipment, including semi-automatic wire feeders, fully-automated welding systems with robotic controls, and portable systems for works at site.
We rebuild worn components by providing welding service using our welding wires and fully-automated welding system. Welding Alloys Group calls this welding service Integra Service, and is promoting business development of Integra Service globally.
WAJapan Integra Service
WAJapan Integra Service, defined as our dominant service, selects welding materials excellent in wear resistance and corrosion resistance and provides cladding service.
Our welding services can be selected from two types, "site welding" and "shop welding". "Site welding" provides flexible service to the customer when the component maintenance plan/period below are restricted. "Shop welding" performs rebuilding in our new workshop designed specifically for cladding.
Our welding technician brings the automatic welding system and a set of auxiliary equipment for cladding to the customer's site after inspection of the component at the customer's workshop, and performs cladding for rebuilding after taking safety training.
During execution of welding work, we always communicate with the customer, work on the progress report of work, safety measures as well as quality assurance based on ISO9001, making engineers aware of them in the training every day.
After completion of the welding service, we perform a simple report. About a week after the welding service, we submit a welding completion report including suggestion.
Also, according to the customer's maintenance plan/period, a 24 hour welding service is available. Site welding is recommended for the customer who puts the highest priority on the shortening of the component maintenance plan/period. [Moving video example of Site welding]
In May, 2012, we constructed a workshop designed specifically for rebuilding of worn components to provide cladding work, which is in operation. Using our experience of ISO9001 accreditation in our previous workshop (in Iwatsuki Industrial Park), we make improvements every day to offer safer and more efficient operation.
In the workshop, a variety of equipment, including the rotating equipment exclusive to crushing equipment, the equipment for rebuilding of boiler panels, and the equipment for rebuilding of screw conveyors, is installed to enable us to provide cladding service using multiple equipment simultaneously. The room specifically designed for gouging that emits no welding fume is kept to improve dustproofing and soundproofing.
Shop welding is recommended for the customer who has sufficient time, or for well-planned rebuilding. A private show can be arranged at customers' request.
We have a following application examples in each industries.[Application examples]
・Application examples in steel-making industry
・Application examples in cement industry
・Application examples in electric power industry and waste power generation industry
・Application examples in sugar production industry and food industry
・Application examples in earth moving, mining and quarry industries
・Application examples in oil and petrochemical industry
Technical documents, reference documents and Contributed essay
These documents are written in Japanese for our customers. Please understand. You can download from the following pages. [Japanese Documents]
Technical documents and reference documents
- Cladding of the boiler water-cooled wall panel (WAJ5G852)
The boiler water-cooled wall panel corrodes or wears out due to its operating conditions including the used fuel, and reduces wall thickness. Cladding technology is introduced as a surface reforming technology leading to long term stable boiler operation, and as a countermeasure against wall thickness reduction using corrosion- resistant(corrosion caused by cadmium or sodium) technology and wear -resistant technology. (290KB/pdf)
- Completion ceremony of Welding Alloy's new workshop (WAJ5G851)
On Wednesday May 11, 2012, the completion ceremony of our new workshop was held in Kuki-Shobu Industrial Park, in Kuki city, Saitama prefecture. (307KB/pdf)
- Welding Alloys was certified as "Sainokuni management innovation model enterprise" in Saitama prefecture and received a commendation (Report) (WAJ5G850)
On January 25, 2012, we were certified as "Sainokuni management innovation model enterprise" and received a commendation in Saitama Super Arena.
- 12 th anniversary commemorative trip (WAJ5G847)
Commemorating the 12 th anniversaries, the whole employees went on a company trip in December, 2011. Our company trip is held once a year to remember when the company was founded and to increase communication opportunities among the employees. (349KB/pdf)
- Cladding for rebuilding the body liner (WAJ5G845)
The body liner controlling the flow of crushed rocks wears out by hot air and crushed rocks. As wear proceeds, local penetration and loss occur, causing damage to the inner wall of the mill. Accordingly, the body liner needs to be replaced. Our efforts related to wear resistance are introduced in this document. (193KB/pdf)
- We exhibited at the 54th annual meeting of Japan Technical Association of the Pulp and Paper Industry in 2011. (WAJ5G846)
In October, 2011, the 54th annual meeting of Japan Technical Association of the Pulp and Paper Industry in 2011 was held at Tokushima Industry and Tourism Exchange Center (Asty Tokushima). 68 groups were participated in this meeting and it drew 1000 or more people. (189KB/pdf)
- Welding Alloys exhibited at Japan International Welding Show 2010 in Tokyo (WAJ5G840R)
Known as one of the world's three largest welding shows, International Welding Show took place in Tokyo Big Site, Japan from April 21 to 24, 2010. It was our third exhibition, and we exhibited with a theme as "Innovation from SMART WELDING ". (443KB/pdf)
- Site welding of the ultra-large raw material mill (MPS4500) (WAJ5G838)
We introduce a part of the welding status of "cladding for rebuilding of the ultra-large raw material mill "executed for the first time in Japan. In this welding process, for the maintenance of the roller bearings, cladding of the roller is performed in the state of being removed from the mill. (407KB/pdf)
- Jacket shut report (WAJ5G834R)
The jacket inner wall is exposed to high temperatures due to the exhaust gas emitted from the revolving furnace. It needs to be replaced when it wears out and oxidizes within a short time. Then, the operating rate may be reduced. This document suggests and recommends wear-resistant cladding as the solution. (296KB/pdf)
- Wear-resistant screw conveyor (WAJ5G823R1)
Screw conveyor is one of the transportation means. Some transportation goods cause the screw to wear out. We provide wear- resistant welding to the whole surface of assorted screws (wing and rod) with our exclusive automatic cladding equipment. We call this method TRI-S method (Triple Satisfaction, Satisfaction by automatic welding, Satisfaction by use of the best suited materials, Satisfaction by site welding). An example of the welding work is shown below. (304KB/pdf)
- Automation of grinding process after hard facing by welding for giant equipment
This essay received the "Award from the chairman of the executive committee" in the 21st QEA Annual Conference (held on June 20-21, 2013). Presentation of essay 34 pp134 (664KB/pdf)
- Close up - Current and future tasks of cladding
Monthly magazine "Welding technology" September 2012 issue Close Up (pp. 86-90)
Welding Alloys has developed business specializing in cladding for 13 years since its foundation. The magazine introduces mainly what we have experienced with the title of "Current and future tasks of cladding". (2,606KB/pdf)
- Case introduction - Construction of a welding personnel development system in enterprises
Monthly magazine "Welding technology" April 2011.
Cover story - Desired way of handing down the skills to the next generation (pp. 64-68) (1,768KB/pdf)
- Analysis and the wear phenomenon of the carbohydrate dispersion state of various weld metals
The Surface Finishing Society of Japan Proceedings of 119th Annual Meeting 2009 pp. 2-3 (2,092KB/pdf)
- Influence of the hygroscopic powder on the evaluation of wear resistance by the rubber wheel test
The Surface Finishing Society of Japan Proceedings of 117th Annual Meeting 2008 p. 38 (1,008KB/pdf)
- The evaluation of wear resistance of high chromium cast iron-based cladding metal by the rubber wheel test No.2
The Surface Finishing Society of Japan Proceedings of 116th Annual Meeting August 2007 pp. 140-141 (684KB/pdf)
- The evaluation of wear resistance of high chromium cast iron-based cladding metal by the rubber wheel test
The Surface Finishing Society of Japan Proceedings of 115th Annual Meeting March 2007 p.212 (278KB/pdf)
- Welding Alloy's wear-resistant welding and corrosion-resistant cladding technologies (WAJ7G023)
"Welding technology" September 2008 Cover story Latest information about cladding (1,883KB/pdf)
- Rebuilding technology using cladding observed in the vertical mill (WAJP200404)
"Welding technology" April 2004 (288KB/pdf)
- Wear-resistant cladding of continuous casting rolls using an open arc welding method (WAJP200208)
"Welding technology" April 2002 (263KB/pdf)
The Bank of Tokyo-Mitsubishi UFJ, Ltd.
Sumitomo Mitsui Banking Corporation