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Solutions for Submerged Arc Welding

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Solutions for Submerged Arc Welding www.lincolnelectric.eu THE FULL SOLUTION FOR SUBMERGED ARC WELDING GLOBAL LEADER FOR SUBMERGED ARC WELDING KNOWN WORLDWIDE FOR QUALITY, PERFORMANCE AND PRODUCTIVITY NETHERLANDS UNITED KINGDOM POLAND CANADA FRANCE RUSSIA GERMANY UNITED STATES SPAIN JAPAN ITALY CHINA UAE MEXICO INDIA LOCATIONS COLOMBIA SINGAPORE Global Headquarters PERU Solution Centers BRAZIL SOUTH AFRICA CHILE AUSTRALIA ARGENTINA 11 000 Employees worldwide 325+ Global R&D Team 125 Years of experience 38 Solution Centers 3.0 Billion USD revenue SUBMERGED ARC WELDING FOR EVERY INDUSTRY TECHNICAL EXPERTISE • PRODUCTIVITY SOLUTIONS GLOBAL APPLICATION SUPPORT GO TO WEB PAGE 2 SUBMERGED ARC WELDING www.lincolnelectric.eu GLOBAL LEADER FOR SUBMERGED ARC WELDING KNOWN WORLDWIDE FOR QUALITY, PERFORMANCE AND PRODUCTIVITY TABLE OF CONTENTS MOVING YOUR SUBMERGED ARC SOLUTION TO THE NEXT LEVEL 4 THE SUBMERGED ARC WELDING PROCESS 8 WELD COST STUDIES 11 SUBMERGED ARC EQUIPMENT 14 SUBMERGED ARC CONSUMABLES / PACKAGING 16 POWER WAVE® SOFTWARE SOLUTIONS: CHECKPOINT™ 17 SOLUTIONS FROM ONE HAND 18 SUBMERGED ARC WELDING 3 MOVING YOUR SUBMERGED ARC SOLUTION TO THE NEXT LEVEL MOVING YOUR SUBMERGED ARC SOLUTION TO THE NEXT LEVEL ● High quality welding results Lincoln Electric is the submerged arc process specialist. Together we will ● Excellent bead appearance develop the best solution while maximizing your savings through highest ● Highest deposition rates deposition rates, highest quality and optimized parameters with your actual ● Deep penetration equipment and potential investments. Rate yourself on the next graph and ● Increased productivity let's move together to the next step. Tandem Twin Triple Arc MULTIPLE MULTIPLE Tandem Arc POWER SOURCES POWER Investment Investment Tiny Twin Arc SINGLE SINGLE Long Stick Out POWER SOURCE POWER Single Wire 150 200 250 300 350 400 100 Deposition Rate (%) vs Single Electrode 50 40 (kg/h) Tandem Long Stick Out (Ø3.2-4.0) e t 30 a Tiny Twin Arc (Ø2.0-2.4) R n o i t Triple Arc (Ø3.2-4.0) i Long Stick Out (Ø2.0-4.0) s 20 epo D Tandem Arc (Ø3.2-4.0) 10 Single Arc (Ø2.0-4.0) 300 600 900 1200 1500 1800 2100 2400 Total Welding Amperage (A) 4 SUBMERGED ARC WELDING www.lincolnelectric.eu MILD STEEL WIRE DEPOSITION RATES IN SUBMERGED ARC WELDING Average Deposition Rate in (kg/h) Improvement versus standard Single Arc in [ %] DC+ AC Standard Long Standard Long Stick Out Stick Out Stick Out Stick Out Single Wire 10.0 kg/h 8.0 kg/h 15.0 kg/h 6.5 kg/h 4.0 mm +54% +23% +130% Single Arc Tiny Twin Arc 9.6 kg/h 13.8 kg/h – – 2 x 2.0 mm +48% +112% DC+/AC AC/AC Standard Long Standard Long Stick Out Stick Out Stick Out Stick Out Tandem Arc 18.7 kg/h 23.5 kg/h 20.7 kg/h 29.0 kg/h 2 x 4.0 mm +188% +262% +218% +346% Tandem Twin 23.2 kg/h 26.0 kg/h – – 4.0 + 2 x 2.0 mm +256% +300% Multiple Arcs AC/AC/AC Standard Stick Out Triple Arc 32.0 kg/h 3 x 4.0 mm +392% ● High Lincoln quality Electric welding supports results you to select: ● Excellent● Optimum bead process appearance ● Highest● Ideal parametersdeposition rates ● Deep● Consumables penetration that guarantee the required ● Increased mechanical productivity properties customized to your application GO FOR NEXT www.lincolnelectric.euSTEP SUBMERGED ARC WELDING 5 MOVING YOUR SUBMERGED ARC SOLUTION TO THE NEXT LEVEL DEPOSITION RATES – SINGLE POWER SOURCE The single power source configuration panel D S EPOSITION RATE Single Wire Long Stick Out Tiny Twin Arc ● Standard platform ● Low additional investment ● Very low additional investment ● Easy to upgrade ● To be used over 700 A ● High deposition rate ● Deposition rate up to 10 kg/h ● High deposition rate and high speed weld ● Low heat input (less distortion) ___________ ● To be used on fillet or filling weld ● Flux / wire ratio reduction 1 – Power source ● Reduced penetration ● Deposition rate up to 30 kg/h 1 – Wire feeder ● Deposition rate up to 20 kg/h ● Recommended with Power Wave® 1 – Wire ___________ AC/DC 1000® SD 1 – Power source __________ 1 – Wire feeder 1 – Power source 2 – Wire 1 – Wire feeder 1 – Drive roll kit 1 – Wire 1 – Long Stick Out kit TYPICAL STANDARD DEPOSITION RATES FOR SINGLE POWER SOURCE DC+ AC Single Wire 4.0 mm Tiny Twin Arc 2.0 x 2.0 mm Single Wire 4.0 mm Tiny Twin Arc 2.0 x 2.0 mm Standard Stick Out Long Stick Out Standard Stick Out Standard Stick Out Long Stick Out Standard Stick Out Typical Deposition Rate 6.5 kg/h 10.0 kg/h 9.6 kg/h 8.0 kg/h 15.0 kg/h 13.8 kg/h Improvement vs. Single Wire 4.0 mm 100% 154% 148% 123% 230% 212% 250 +130% 200 +112% 150 + % DC+ 54 + 48% +23% 100 AC 50 Hz 50 25% balance -25% offset Productivity Improvement Percentage % 0 Single Wire Single Wire, Tiny Twin Arc Single Wire Single Wire, Tiny Twin Arc DC+ Long Stick Out DC+ AC Long Stick Out AC DC+ AC 6 SUBMERGED ARC WELDING www.lincolnelectric.eu DEPOSITION RATES – MULTIPLE POWER SOURCES The tandem and triple arc configuration panel D S E E Triple Arc T ● High productivity P ● High welding speed O A Tandem Tiny Twin ● High deposition rate up to 35 kg/h R ● SIT ON Versatile process with Power Wave® I AC/DC 1000® SD __________ ● High productivity and high speed weld 3 – Power source ● High deposition rate up to 30 kg/h Tandem __________ 3 – Wire feeder 2 – Power source 3 – Wire ● 2 – Wire feeder Favourable weld geometry pass/cap pass 3 – Wire ● High deposition rate up to 25 kg/h 1 – Drive roll kit ● Long stick out option with all benefits on demand __________ 2 – Power source 2 – Wire feeder 2 – Wire TYPICAL STANDARD DEPOSITION RATES FOR MULTIPLE POWER SOURCES DC+/AC AC/AC AC/AC/AC Single wire Tandem Tiny Tandem Arc + Tandem Tiny Tandem Arc Triple Arc 4.0 mm Tandem Arc Twin Long Stick Out Tandem Arc Twin + Long Stick Out 3 x 4.0 mm Typical Deposition Rate 6.5 kg/h 18.7 kg/h 23.2 kg/h 23.5 kg/h 20.7 kg/h 26.0 kg/h 29.0 kg/h 32.0 kg/h Improvement vs. Single Wire 4.0 mm 100% 288% 356% 362% 318% 400% 446% 492% 500 + 392% 450 + 346% + 287% 400 + 300% DC+ 350 +262% + 256% AC/AC 300 + 218% 50 Hz 25% balance + 188% -25% offset 250 AC/AC/AC 200 50 Hz 25% balance -25% offset 150 100 Productivity Improvement Percentage % 50 0 Single Wire Tandem Arc Tandem Tiny Tandem Arc Tandem Arc Tandem Tiny Tandem Arc, Triple arc DC+ DC+/AC Twin Long Stick Out AC/AC Twin Long Stick Out AC/AC/AC DC+/AC DC+/AC AC/AC AC/AC www.lincolnelectric.eu SUBMERGED ARC WELDING 7 THE SUBMERGED ARC WELDING PROCESS THE SUBMERGED ARC WELDING PROCESS The arc being shielded and hidden under the flux, high current density can be considered with the following benefit: ● Operator protection from arc ray and heat radiation ● High deposition rate and high quality welds ● Versatile welding process with combination of wire diameter, flux type, single or multiple electrodes, welding current wave shape and welding mode WELDING PARAMETERS (VARIABLES) WIRE DIAMETER/AMPERAGE The submerged arc wire standard portfolio includes different wire sizes, mainly between 2.0 and 4.0 mm wire diameter. The choice of wire size is made in accordance with the welding procedure parameters in order to maximize the current density and increase the melt off rate, without exceeding the wire current carrying capacity as shown in the following table. Amperage Used Wire Diameter 200 300 400 500 600 700 800 2.0 mm kg/h 1.9 3.0 4.5 6.7 2.4 mm kg/h 2.9 4.4 5.9 8.0 3.2 mm kg/h 2.5 3.8 5.2 6.7 8.5 4.0 mm kg/h 3.5 5.0 6.5 8.3 10.0 10 12 8 10 6 8 64 2.02.0 mm mm kg/h kg/h 4 2.4 mm kg/h (kg/h) Deposition Rate 2.4 mm kg/h (kg/h) Deposition Rate 2 3.2 mm kg/h 3.2 mm kg/h 2 4.0 mm kg/h 4.0 mm kg/h 0 0 200 300 400 500 600 700 800 200 300 400 500 600 700 800 900 Amperage Used Amperage Used 8 SUBMERGED ARC WELDING www.lincolnelectric.eu POLARITY In most of the submerged arc applications it is possible to work in DC current with the electrode being either positive or negative. Thanks to Lincoln Electric Waveform Control Technology®embedded in the new Power Wave® AC/DC 1000® SD power source and the new MAXsa® Controllers and Feeders, we can now take over the full area between DC+ and DC-. DC + DC- AC ● Most common mode ● Improves deposition ● A compromise between ● Deep penetration and rate (25%) the two DC modes ● stable arc Limits penetration ● The optimum choice with ● Limited arc stability Power Wave® AC/DC 1000® SD Waveform Control Technology® capability provides precise control over: ● Frequency ● Balance ● Offset (Number of switch per (Percentage of time in (Positive/Negative second from positive to the positive polarity Amplitude) negative polarity) portion of one cycle) Offset : Positive Current Level = Penetration AC Frequency Cycle Balance = Penetration/Deposition Current, Voltage, or Power Current, Voltage, Offset : Negative Current Level = Deposition Stick-out: 32mm 15 DC- ) h 13 / g AC Square wave k ( 25% balance, -20 offset e t a 11 R AC Square wave n o 25% balance i t i s 9 AC Square wave epo 50% balance D 7 DC+ 5 3 200 400 600 800 Current (A) 1000 www.lincolnelectric.eu SUBMERGED ARC WELDING 9 THE SUBMERGED ARC WELDING PROCESS ELECTRICAL STICK OUT Electrical Stick Out setting: The electrical stick out or CTWD (contact tip to work distance) is the distance set between the contact tip end and the work piece.
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