Nya Svetsaren 1, 1999. - LuleÃ¥ University of Technology

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Fabricators pleased withincreased submerged arcproductivity from cored wiresImproved welding technique has now maturedBy Martin Gehring, ESAB GmbH, Solingen, and Shaun Studholme, ESAB UK Ltd.70In Svetsaren 1-2/96, wededicated an article tosubmerged arc weldingwith special cored wiresdeveloped by ESAB,in which we discussedindustrial applicationsfrom Finland where themethod was pioneered.In the meantime, thetechnique has maturedand has been adoptedby fabricators acrossEurope. They benefitfrom productivity advantagesresulting fromhigher deposition rates,as well as the avoidanceof plate edge bevelling,a smaller weld volumeand a reduced numberof layers. Before discussingindustrial applicationsfrom Germany, theNetherlands and theUnited Kingdom, theauthors re-introduce thetheme.Metal-coredAWSOK Tubrod 14.00S/OK Flux 10.71 CMn F7A2-EC1Basic flux-coredOK Tubrod 15.00S/OK Flux 10.71 CMn F7A4-EC1OK Tubrod 15.24S/OK Flux 10.62 1Ni F8A6-EG-GOK Tubrod 15.25S/OK Flux 10.62 2.5Ni F7A8-ECNi2-Ni2Table 1: ESAB OK Tubrod cored wires for the submerged arc welding of normaltemperatureand low-temperature steels.Svetsaren No.1 1999
Single Wire Deposition Rate ComparisonOK Tubrod 15.00S + OK Flux 10.71OK Autrod 12.20 (S2) + OK Flux 10.712018161412kg/hr1086420300358400450500550600650700750Current (A)80015.00S 2.4mm15.00S 3mm15.00S 4mm12.20 2.4mm12.20 3mm12.20 4mm8509009501000Figure 3. Fabrication of a cylinder forthe wood industry. Tube halves areattached to the inside of the cylinderwith the cored wire/flux combinationESAB OK Tubrod 14.00S/OK Flux10.81.Figure 1. Deposition rate increase obtainable with cored wires for submerged arcwelding.IntroductionSubmerged arc welding (SAW) iswidely recognised as a very productivewelding process, offeringthe following advantages:a high deposition rate due tothe use of high welding currentsa high travel speeda reduced incidence of coldlaps and slag inclusionsa smooth weld surface withgood tie-inno spatter, no fumesThe productivity of SAW isfurther optimised with variantssuch as twin arc, tandem andmetal-powder addition, but thesemethods normally require largescaleinvestments in equipment.The productivity of single-wireSAW can, however, be increasedsignificantly by substituting specially-developedcored wires forsolid wires. In the majority of applications,this requires no additionalfinancial expenditure as theexisting equipment is adequate.Product rangeThe range of ESAB OK Tubrodcored wires for submerged arcwelding is reviewed in Table 1.Both OK Tubrod 14.00S and15.00S are Grade 3 approved, incombination with OK Flux 10.71,by the major ship classificationsocieties, as well as TÜV and DB.OK Tubrod 15.24S and 15.25Sare designed for low-temperatureapplications in offshore fabrication,for example.They are usedin combination with OK Flux10.62.Both OK Flux 10.71 and 10.62are basic agglomerated fluxes.Figure 2. A single pass, double-sided I-joint made in 17 mm plate at 60 cm/min travel speed with the cored wire flux combinationESAB OK Tubrod 15.00S/ESAB OK Flux 10.71. Plates were not bevelled before welding. Middle: Meyer Werft Papenburg.Right: SSW Fähr- und Spezialschiffbau GmbH.Svetsaren No.1 1999 71
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A welding review published by The E
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Challenges for welding consumablesf
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used. One example of this comesfrom
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Consumable type Hydrogen content Co
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Steel type Chemical composition (%)
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alloyed consumables. It has alsobee
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tegration with the workpiece manipu
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Welding duplex chemical tankersthe
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Figure 4: Fabrication of a block se
Page 19 and 20: in duplex stainless steel3Figure 6:
Page 21 and 22: Figure 8: Welding of a corrugatedbu
Page 23 and 24: Figure 2.Typical hardness profile o
Page 25 and 26: Product R p0.2 R m A 5 (%) KV (J) a
Page 27 and 28: Hans Nyström has every reason to b
Page 29 and 30: Consumables for welding highstrengt
Page 31 and 32: solution hardening to strength.For
Page 33 and 34: In very rough terms, it can beassum
Page 35 and 36: Fig. 3. Special cyclone with double
Page 37 and 38: comparable table arrangementfor a d
Page 39 and 40: Stubends& SpatterTwo ESAB SuperStir
Page 41 and 42: FILARC PZ6105RThe robot-friendly co
Page 43 and 44: Laser weldingA mature process techn
Page 45 and 46: Laser:Robot:Material:Weld speed:2 T
Page 47 and 48: Accurate positioning using expensiv
Page 49 and 50: the melt zone temperature duringthe
Page 51 and 52: Energy efficiency in weldingby Klas
Page 53 and 54: Effect of interpass temperature onp
Page 55 and 56: Figure 4 Experimental CCT curve.The
Page 57 and 58: Figure 8 The similar appearance of
Page 59 and 60: “The technology of tomorrow”has
Page 61 and 62: mod.) for gas inlet sections,shell,
Page 63 and 64: Fig 10. MMC system weld parameterse
Page 65 and 66: Fig. 1. New range of medium machine
Page 67 and 68: Fig. 4. Laser cutting system with a
Page 69: Fig. 10. The most varied connection
Page 73 and 74: The total welding costs werereduced
Page 75 and 76: welding system, like the shieldingg
Page 77 and 78: Modern MIG welding powersourcesby p
Page 79 and 80: Control boxThe control box, see Fig
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Nya Svetsaren 1, 1999. - LuleÃ¥ University of Technology

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