Economical and Ecological Welding with a Focus on Carbon Footprint

Sustainability and resource efficiency are key topics that companies grapple with daily. Beyond profitability, the carbon footprint of their production processes and the components they manufacture is becoming increasingly important.

For many industries, sustainability is no longer a luxury but a necessity to remain competitive. Manufacturers of welding technology, used across various sectors in the production of consumer and industrial goods, can significantly support producers in addressing this critical issue. In addition to cost pressures and regulatory compliance, demand is growing for environmentally friendly products and greater transparency throughout the entire supply chain.
 

When purchasing welding equipment and designing production lines, consideration should be given to the longevity and repairability of equipment, along with the possibility of maintaining state-of-the-art performance through updates and expansions. For some companies, multi-process welding systems—which can handle multiple welding processes with a single device—may offer significant advantages, helping reduce the carbon footprint associated with component manufacturing.
 

High-quality welding plays a critical role in reducing the carbon footprint of assembled components. It ensures materials are used optimally, preventing scrap and rework from the start. Reliable, high-quality welded joints thus benefit both the environment and profitability. Therefore, a comprehensive analysis of production at the component level (TCOP – total cost of production) can be highly instructive, as basing decisions solely on operational costs (TCO – total cost of ownership) often provides only a partial perspective.
 

A complete life-cycle assessment (LCA) of welding according to ISO 14044 offers an in-depth view of sustainability and resource utilization. This comprehensive 'cradle-to-grave' approach covers everything from raw material procurement and production of welding equipment, through transportation, years of industrial use including shift operations and replacement of wear parts, to eventual disposal at the end of the equipment's lifespan.

All environmental impacts from influencing factors in welding applications—such as materials, energy, gas, and emissions—are thoroughly documented. This holistic assessment precisely identifies key levers to reduce the carbon footprint per weld, providing crucial data for optimizing the overall carbon footprint of components and welding production as a whole.
 

Welding and careful resource management are not mutually exclusive. A crucial lever, for instance, is welding digitalization. Effective management and monitoring of welding data significantly enhance both quality assurance and resource efficiency. Continuous tracking and documentation of welding parameters ensure weld quality and compliance with safety standards, while also delivering valuable insights into process optimization, saving time and reducing energy, gas, and filler wire consumption.

Moreover, digitally controlled welding systems provide companies the flexibility to quickly adapt production to changing conditions and new challenges. New or additional welding processes can easily be integrated via software uploads. Advanced digital gas regulators exemplify this technology, optimally shielding the welding arc with protective gas while minimizing initial gas losses. This approach typically achieves savings around 40%, with even greater potential in many short weld scenarios.
 

The automotive industry provides a clear example, as vehicle manufacturers have already closely examined their major energy-intensive processes and are actively optimizing them. The next step involves performing life-cycle analyses to bring greater transparency to the joining process, offering critical insights for further improvements. Undoubtedly, manufacturing companies and suppliers of welding technology can make significant progress together in achieving resource-efficient production.