Welding Services

Frigate provides exceptional welding solutions tailored for any manufacturing business. With our extensive knowledge and experience, we are equipped to ensure your business thrives through our high-quality welding services. 

Our Clients

Advantages of Welding with Frigate

Thermal Properties Control

Welding allows precise control over heat input, minimizing thermal distortion and preserving the material's mechanical properties during fabrication.

Seamless Integration

Welding enables the creation of seamless structures, eliminating potential weaknesses from fasteners or joints, thus enhancing overall integrity and reliability.

Complex Geometries

Advanced welding techniques can effectively join complex geometries and shapes, allowing for innovative designs and enhanced functionality in engineering applications.

Fatigue Resistance

When executed correctly, welded joints can exhibit superior fatigue resistance, making them ideal for components subjected to cyclic loading in demanding environments.

Tailored Custom Welding Services for Your Needs

Frigate offers specialized custom welding services to meet your project requirements. Our skilled welders use advanced techniques like MIG, TIG, and stick welding, which ensure strong, durable joints across various materials, including aluminum, steel, and stainless steel. We focus on precision and quality, tailoring each weld to your specifications, resulting in seamless integrations and optimal performance. 

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Our Welding Process

HY D R O L Y SIS RESIS T ANCE
Project Assessment

We thoroughly assess the requirements, including material types, joint configurations, and load specifications. This evaluation helps us determine the most suitable welding techniques and methods. 

Material Preparation

Proper material preparation is essential for optimal weld quality. This step includes cleaning surfaces to remove contaminants, aligning components accurately, and, if necessary, preheating materials to improve weldability. 

Welding Technique Selection

Based on the project assessment, we select the appropriate welding technique, such as MIG, TIG, or Stick welding. Each method has advantages depending on the materials and the application. 

Execution of Welding

Our skilled technicians execute the welding process with precision, controlling parameters like heat input, travel speed, and filler material. This ensures strong, consistent welds that meet the desired specifications. 

Quality Control

After welding, we conduct rigorous inspections, including visual checks, non-destructive testing, and dimensional measurements, to verify weld integrity and adherence to industry standards. 

Finishing Touches

Finally, we perform any necessary post-weld treatments, such as grinding, polishing, or painting, to enhance the final product's appearance and protect against corrosion. 

Welding Materials

Welding is a critical joining process that involves fusing materials to create strong, durable connections. Various materials can be effectively welded using specialized techniques tailored to their unique properties. 

Steel

Steel is one of the most widely used materials for welding. It is easily formed, robust, and long-lasting.  

Stainless Steel

This type of steel resists rust and corrosion. It is often used in food, medical, and chemical industries. 

Aluminum

Aluminum is lightweight and resists corrosion well. It is commonly used in automotive, aerospace, and construction applications. 

Cast Iron

Cast iron is tough and durable. It is used in machinery, piping, and heavy equipment but requires special welding techniques. 

Copper

Copper is a good heat and electricity conductor. It is often used in electrical components and plumbing. 

Bronze

Bronze is strong and resistant to corrosion. It is used in marine applications, bearings, and artistic sculptures. 

Nickel Alloys

These alloys are known for their strength and resistance to extreme temperatures. They are often used in aerospace and chemical processing. 

Titanium

Titanium is lightweight and very strong. It finds utility in high-performance applications, medical implants, and aircraft. 

Advanced Welding Services for Various Key Challenges

Our welding services address key manufacturing challenges. We prioritize structural integrity with precise welding techniques that create strong, seamless joints, enhancing durability and reducing failure risks. Our automated processes expedite production, helping you meet tight deadlines without compromising quality. Additionally, we excel in welding various metals, accommodating complex designs, and resolving compatibility issues. By minimizing material waste, we help lower costs while maintaining the highest quality standards, ultimately boosting your bottom line. 

Compliance for Welding Services

Frigate fully complies with industry standards for its Sand Casting services. It follows strict material specifications, process controls, and environmental guidelines. The company prioritizes quality and safety at every step, ensuring that each casting is precise and reliable. Our certifications demonstrate its commitment to customer satisfaction and operational excellence. 

Key Compliance Standards for Welding

AWS D1.1-2020

Structural Welding Code for steel, ensuring welds are robust and capable of withstanding high-stress environments. 

ASME Section IX

Sets requirements for welder qualifications, ensuring competence for specific materials, thicknesses, and welding procedures. 

ISO 3834-2:2005

Defines quality requirements for fusion welding, ensuring consistent process control and reliable welded joints. 

API 1104-2020

Pipeline Welding Code for oil and gas, ensuring high-quality welds that meet safety and structural integrity standards. 

ISO 9001:2015

Establishes quality management systems, ensuring standardized procedures and consistent weld quality in production processes. 

MIL-STD-2219A

Military standard for welding, ensuring compliance with stringent military specifications for weld integrity and performance. 

Tolerance for Welding Services

Penetration Depth
± 0.5 mm

Tolerance for the depth of weld penetration into the base material, ensuring complete fusion. 

Bead Width (Butt Weld)
± 0.75 mm

Tolerance for the width of the weld bead in butt welding to ensure strength and uniformity. 

Heat Input
± 10%

Variation in heat input applied during welding, controlling metallurgical properties and distortion. 

Weld Reinforcement (Fillet)
± 1 mm

Tolerance for the thickness of the reinforcement bead in a fillet weld, ensuring joint strength. 

Interpass Temperature
± 10°C

Tolerance for temperature between welding passes, ensuring optimal material properties. 

Tensile Strength
± 5%

Allowable variation in tensile strength of the weld to meet material specification requirements. 

Hardness Profile
± 5 HV

Control of hardness variation across the weld zone, ensuring no material weakness or brittleness. 

Weld Porosity
Zero tolerance for visible pores

No visible porosity allowed in the weld, ensuring full strength and integrity of the joint. 

Root Gap (Butt Weld)
± 0.2 mm

Deviation allowed in the root gap of butt welds, critical for ensuring full penetration and fusion. 

Toe Angle (Fillet Weld)
± 1°

Tolerance in the angle of the weld toe, critical for load distribution and strength. 

Angular Distortion
± 0.5 mm per meter

Tolerance in angular distortion due to thermal effects, ensuring parts stay within alignment. 

Preheat Temperature
± 15°C

Tolerance for preheating the material to avoid cracking, especially in high-carbon steels. 

Post-Weld Heat Treatment (PWHT)
± 25°C

Control of the temperature range during PWHT to relieve stress and optimize mechanical properties. 

Angular Deviation in Groove Welds
± 0.5 mm

Tolerance in the angle of groove welds, important for maintaining correct joint fit and strength. 

Weld Toe Radius
± 0.3 mm

Control of weld toe radius, crucial to minimize stress concentration and fatigue failures. 

Weld Deflection (Warping)
± 1 mm

Tolerance for overall deflection caused by welding, critical for maintaining the dimensional accuracy of large components. 

Crack Sensitivity Index (CSI)
≤ 1.0

Maximum allowable CSI to ensure that the weld does not exhibit excessive susceptibility to cracking under stress. 

Residual Stress
± 10%

Control of residual stresses in the weld area to ensure dimensional stability and minimize distortion. 

Weld Appearance
≤ 2.5 mm

Control of visible imperfections such as undercuts, overlap, or excessive spatter in welds. 

Quality Testing Standards for Welding Services

Weld Fusion
X-ray / Ultrasonic Testing (RT/UT)

Tests the extent of fusion between the base material and weld, ensuring complete bonding and integrity. 

Weld Metal Cracking Resistance
Charpy Impact Test / CTOD

Evaluates the ability of the weld to resist cracking under stress at different temperatures. 

Residual Stress Distribution
Neutron Diffraction / X-ray Diffraction

Measures the residual stress field in the welded zone to ensure minimal distortion and warping. 

Weld Shrinkage
Dimensional Measurement / Strain Gauges

Measures changes in dimensions due to the contraction of the weld metal during cooling. 

Weld Zone Hardness Profile
Microhardness Testing

Measures variations in hardness within the heat-affected zone (HAZ) to ensure strength and toughness. 

Hydrogen-Induced Cracking (HIC)
Electrochemical Testing / Gas Chromatography

Detects the presence of hydrogen in the weld, which could lead to delayed cracking. 

Porosity Level
Optical Microscopy / X-ray / UT

Assesses the internal porosity of the weld, which can impact structural integrity and fatigue resistance. 

Weld Fusion Line Integrity
Macroetching / Cross-Sectional Examination

Ensures the fusion line between base metal and weld is continuous, without any gaps or weaknesses. 

Heat Affected Zone (HAZ) Size
Microstructural Analysis

Measures the width and properties of the HAZ to ensure it falls within acceptable limits for strength. 

Weld Distortion
Strain Gauges / Digital Imaging

Measures changes in geometry due to thermal expansion and contraction during welding. 

Tensile Strength of Heat Affected Zone
Sub-size Tensile Testing

Determines the tensile strength specifically in the heat-affected zone, ensuring no weakness in the HAZ. 

Weld Defect Depth
Ultrasonic Testing (UT) / Radiography

Measures the depth and size of defects within the weld to assess structural safety. 

Weld Fatigue Resistance
Fatigue Testing / Rotating Bend Test

Assesses the performance of the weld under cyclic loading, ensuring it can withstand long-term fatigue. 

Crack Tip Opening Displacement (CTOD)
CTOD Test

Measures the ability of a welded joint to resist crack propagation, especially at low temperatures. 

Intergranular Corrosion Resistance
Electrochemical Polarization Test / ASTM G48

Tests the susceptibility of the weld area to intergranular corrosion, particularly in stainless steel. 

Transforming Aerospace Manufacturing Through Welding

The aerospace industry faces significant challenges, including strict safety, performance, and weight reduction requirements. Welding addresses these pain points by creating strong, lightweight structures for aircraft efficiency. Advanced techniques ensure precise joint integrity, reducing the risk of structural failures during flight. Combining various metals, like aluminum and titanium, enhances design flexibility for specific aerospace applications. Automated welding processes boost production speed and consistency, helping manufacturers meet tight deadlines without sacrificing quality. Effective welding services empower aerospace manufacturers to achieve superior product performance and reliability. 

Industries We Serve

What You Get

↓ 7-8%

OPS COST

↓ 2-3%

COGM

3X

Aggregation

↑ 25%

Machinery Utilisation

↓ 50%

Expedition

↑ 30%

Frigater Revenue

Achieving Consistent Weld Quality in High-Volume Production

In high-volume production, maintaining consistent weld quality is a significant challenge. Variations in welding techniques, heat input, and filler materials can lead to defects that compromise structural integrity. Advanced monitoring systems are essential for tracking parameters and enabling real-time adjustments to uphold quality standards. Strict inspection protocols, including visual assessments and non-destructive testing, help identify issues early and ensure regulatory compliance. Additionally, automated welding technologies enhance consistency by reducing human error and providing uniform results across components. Focusing on these quality control measures allows manufacturers to achieve reliable welds that meet stringent performance requirements. 

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What Our Customers Say about Frigate

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Having Doubts? Our FAQ

Check all our Frequently Asked Question

What factors influence the heat input during the welding process?

The welding current, voltage, and travel speed influence heat input during welding. Higher current and voltage increase heat, while a slower travel speed allows more heat to penetrate the material. Properly controlling these factors ensures optimal fusion and reduces the risk of defects. 

How does the choice of filler material affect weld performance?

The choice of filler material impacts the mechanical properties of the weld. Different fillers have varying strengths, flexibility, and corrosion resistance. Selecting the right filler ensures compatibility with the base metals and can enhance the overall performance and durability of the welded joint. 

What is the role of preheating in welding dissimilar metals?

Preheating helps minimize thermal shock and reduces the risk of cracking when welding dissimilar metals. By raising the temperature of the base materials, preheating improves fusion and promotes better metallurgical bonding, leading to a stronger and more reliable weld. 

How do automated welding systems improve weld quality?

Automated welding systems enhance weld quality by providing consistent heat input, travel speed, and precise control over parameters. This reduces human error and variability, resulting in uniform welds that meet strict quality standards. Automation also increases production efficiency and allows for more complex joint configurations. 

What non-destructive testing methods are used to evaluate weld integrity?

Common non-destructive testing methods include ultrasonic, radiographic, and magnetic particle testing. These techniques assess weld integrity without damaging the material. Each method offers unique advantages, such as detecting internal flaws, surface defects, or material inconsistencies, ensuring the welded joints meet safety and performance requirements. 

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur,  Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ã…¤

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