The welding industry has been suffering from a shortage of skilled labour for some years, as some estimates project a shortage of 327,000 skilled welders by 2026 in the United States alone.
This explains why many companies have looked to automated welding as a solution, using robots and tools like artificial intelligence (A.I.) to make up for the shortfall.
While a shortage of skilled welders has been a cause of concern in recent years, automation is nothing new for the industry.
Automation has been shaping the welding industry for decades, with both semi and automatic welding working alongside or in place of manual welders.
Manual welding is where a human welder controls the entire welding process by hand, but there are two types of automated welding; semi-automatic and fully-automatic.
In semi-automatic welding, robots work alongside humans. A human is needed to place parts into the welding system before the robotic system makes the weld and the parts are then removed, again by a human.
With fully-automatic welding, a series of custom-designed machines complete the entire process, from loading to the actual welding.
Welding robots have a number of advantages, with industrial robots offering greater levels of repeatability than human welders. Plus, robots don’t tire or need to sleep or take breaks and can even be cheaper than skilled human welders once the initial costs of the systems themselves have been covered.
The shortage of skilled welders means that many companies are looking to automation for their welding tasks, and some experts say that robots could replace as much as 80% of all welding jobs.
Collaborative welding robots (cobots) are also becoming increasingly common as they allow people and robots to work safely alongside each other, offering the benefits of both automation and human adaptability and ingenuity to drive the future of Industry 5.0.
So, with all of these advantages, are robotic welders better than humans?
With all of the advantages offered by robotic welders, plus the current workforce skills gap for human welders, it is no surprise that there is an ongoing debate about the situation.
The main reason for companies exploring robotic welding solutions is a lack of qualified welders as well as a difficulty of keeping them.
Thousands of welding jobs need to be filled each year, but there is a lack of skilled welders available to do the work. Plus, with the average age of skilled welders being around 55-60, this problem is only going to get worse without more young welders being trained.
This has led to thoughts that robots may replace welders, but the fact is that robotic welders still rely on humans to operate. Although a robot can make a weld with a torch, it cannot understand the principles of producing a quality join, work in every environment, or deliver bespoke work.
It is true that robots can complete some welding tasks faster than humans, but they cannot do it alone. Instead, trained welders could be used as robot programmers, using their knowledge and expertise alongside robots to ensure weldments are done properly. This robotics training can be completed in a few short weeks, compared to the months of training and practice it takes to become a skilled welder.
To understand that robotic welding cannot be the answer on its own, we will take a look at the challenges associated with automation in welding.
Although there has been plenty of talk around humans being replaced by robots, that seems unlikely (at least at the moment), as there are plenty of challenges associated with automated welding. The first of these involve jobs that robots simply cannot do efficiently…
- Complex Welding Jobs: Welding robots (and cobots) are perfect for high volume, repetitive welding tasks, but they are not able to complete every type of complex welding job. Sophisticated designs, hard-to-reach welds, and highly customisable work are all types of welds that are challenging (if not impossible) for robots to perform, making human welders a more effective and efficient solution.
- Low Volume and High Mix Jobs: Industrial robots need to be programmed (and then reprogrammed) for each job they perform. This makes them an inefficient and expensive solution for companies who need to produce low volume or high mix welding jobs. The downtimes associated with reprogramming often means that human welders are far more cost-effective and efficient for these jobs.
Aside from the challenges associated with certain jobs, there is also the simple fact that robots cannot operate without people.
- Operation, Programming and Inspection: Robots cannot operate on their own – they still need people to set them up and program them to perform specific tasks. Qualified personnel are needed to input the welding parameters, operate the systems and inspect the machines themselves. This challenge is opening up opportunities to upskill welders so that they can work with robots and alongside cobots.
- Decision Making: Artificial intelligence has taken great strides in recent years and has been shown to allow for data to be collected so manufacturing performance can be improved and to increase productivity. However, data collection does not equal good decision-making, which still needs to be handled by people who can interpret the information and make the right choices to projects, workflows and more.
As hinted at above, developments such as artificial intelligence, machine learning and cobots have the power to change the scope of welding technology. These innovations should allow people and organisations to work smarter, getting the best out of both people and machines, so that they work in tandem to their strengths.
This paints a different picture to fears that human welders will be completely replaced by robotic welding technologies.
But, how does robotic welding affect human workers?
It seems that fears of robots or cobots leading to a large-scale decrease in human jobs in the welding industry are unfounded.
There are still lots of job opportunities available for welders and, while some businesses will look at robots or cobots for welding solutions, in many cases existing and new welding staff will be required to use the automated welding systems.
In fact, by allowing robots to take on the mundane and dirty welding tasks, human welders can use their knowledge and ingenuity to tackle more progressive projects.
With an increase in automation, could it be that there will be job losses for human welders? Experts believe not, as robots lack the ability for complex problem-solving, do not possess the dexterity needed for intricate welding work and need to be programmed and inspected by people.
Some of the tasks that are difficult, impractical or even impossible to automate include:
- Gas Tungsten Arc Welding (GTAW) / Tungsten Inert Gas (TIG) Welding: This arc welding process is used for metals including stainless steel, magnesium, copper and aluminium alloys, among others. It is difficult to automate because the filler wire is added to the melt pool separately from the arc. It is a complex process that requires skill to do properly, meaning that human welders are still the best option for this work.
- Weld Preparation: Weld preparation is important to ensure a good quality weld. This includes choosing the right products or process and preparing the base material for the weld (cutting, cleaning, etc). This still requires a skilled welder, even when a robot or cobot is to complete the actual weld.
- Complex Welding Projects: Some geometries, particularly 3D welding, or welding in the field are difficult to automate. It is usually much cheaper, efficient and effective to use a human welder for construction sites and pipelines (for example) than trying to move a robot and program it to complete the task.
- Small Batch Welds: Programming robots is useful when welding in high volumes, such as in an automotive manufacturing setting. However, it is far less cost-effective for small batches, where the robot will need to be programmed and reprogrammed. Often the time taken for a welding robot set-up is longer than getting a human welder to do the job.
While it doesn’t seem that robotic welders will replace humans, the landscape for welders is definitely changing as a result of technological advances. But, rather than replacing people, it may be more useful to see these advances as another tool in a welder’s arsenal.
Robots will help people avoid having to do monotonous, high volume work even as new responsibilities make themselves known to welders, with roles including:
- Robotic Welding Operator: Experts will be required to set-up, maintain, inspect and welding robots and cobots.
- Welding Robot Programmer: People will be needed to not only program robots for a particular task, but are also needed to test and develop the systems that robots rely on.
- Robotic Welding Manager: While robots may be able to complete many tasks (with the assistance of human operators and programmers), people will also be needed to manage the output of the robots, optimising production processes and creating new designs for welded parts.
Skilled human welders will still be an important part of the equation, even where much of the actual physical welding can be completed by robots.
Rather than fighting against the tide, it may be better to embrace the positive aspects of the robotic welding revolution, letting the machines handle the more mundane and undesirable work while people use their knowledge, skills and ingenuity to greater effect in designing processes, programming the robots, undertaking more complex tasks, and maintaining systems.
Given the right conditions and type of work, robots can complete more work than humans but, rather than replacing humans, robots allow people to do more interesting, complex or creative tasks.
There is also the potential of attracting more young employees with the promise of a technical role programming and operating robots.
When used correctly, automation delivers benefits including lower costs, consistent welds and greater productivity. Robotic welders don’t only complete more of the mundane work without a drop in consistency due to tiredness or disinterest, but can also positively impact employee safety and well-being.
Collaborative robots (cobots) take these advantages further than traditional industrial robots that can be dangerous for people, bulky, and only able to complete a single task. Instead of having to be housed in cages to avoid people from getting hurt, cobots have built-in safety systems that allow them to work alongside humans. As well as offering the same benefits of speed and repeatability, cobots tend to be smaller than industrial robots, making them better for smaller production units and capable of being moved across the production floor.
Cobots are also typically designed to be user-friendly, with clear control units or even apps being used to operate them. These controls can teach the cobot the welding positions and parameters it needs to use.
There is no doubt that a shortage of young skilled welders is a problem that will continue to be exacerbated as more welders retire – unless more young people are trained.
However, automation can step in and take up some of the burden - especially with monotonous, single application work – allowing human welders to work where they are really needed.
As with many other forward-thinking industries, welding seems to be coming to terms with automation. By allowing robots to work alongside humans, it is possible to take the strengths of both people and machines to create an even more efficient, cost-effective workplace.
An additional benefit from allowing humans to focus on decision-making, operation, design, programming, and the more complex welding tasks is greater employee well-being, with robots taking up the slack and doing the work people are less engaged with.
Businesses are taking advantage of the benefits of using robots and cobots, especially given the current lack of skilled welders in some nations. However, while technology offers a number of benefits, robots will not replace human welders.
There are lots of welding jobs that are still better being done by human welders for the sake of efficiency, ease, or simply because robots cannot perform the welds that are required.
Rather than replacing humans, robotic welding technologies are causing welders’ careers to develop to take on less of the mundane tasks and to instead focus on more complex welds and other tasks such as operation, programming, maintenance and inspection.
This change of focus will allow organisations to get the best out of both robotic and human welders while, at the same time, improving working conditions and the well-being of employees.
There is still a lot of work available for human welders, with robots assisting rather than replacing our human experts.
Are welders being replaced by robots?
There is no doubt that some welding jobs are now being done by robots rather than people, but these tend to be the more mundane, repetitive tasks, leaving the more complex jobs to human welders. But this does not mean that welders are being replaced by robots, as there are still many tasks that humans are required for. These include more complex jobs, decision-making, and the operation and setting up of the robots themselves. Added to this situation is a lack of welders, which has pushed some companies to look at robots as a means of supplementing their welding workforce. Despite recent technological advancements, skilled human welders are still required for many jobs.
Is there a future for welders?
There is definitely a future for welders, and the ageing population of skilled welders means that there is actually a need for more young people to enter the profession. Automation and robotics is certainly going to be part of the future of welding, but human experts will still be required to work with or alongside automated systems as well as on more complex jobs. Rather than looking bleak, the future for welders looks very bright.
Is robotic welding the future?
Robotic welding will certainly be part of the future of the profession as evolving technologies such as artificial intelligence, big data and machine learning continue to proliferate. A lack of welders in some regions has led companies to look to automated welding solutions to make up the shortfall in human welders as well as to save time and money on some tasks. However, this does not mean that robotic welding will completely replace the need for human welders.
Will welders become obsolete?
Although some prospective welding students have voiced concerns about the rise of automation in the industry, there is no reason to believe that welders will become obsolete. Instead, technology should help improve the working conditions and well-being of welders by taking away the more repetitive and mundane tasks. Welders will still be needed for certain tasks, such as more intricate or complex welding or where welds are needed in the field or in hard-to-reach places. In addition, knowledgeable welders will still find a place working with and alongside machines.