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British Cataloguing in Publication Data A catalogue record for this book is available from the British ISBN I 855 73 088 X by Geoff Green (text) and Chris (jacket). Best-set Kong. St Suffolk, England.
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13
31 31 37
52
5
96
1
1 136 1 1 1
it.
a
to
its use.
tension
years,
to exorcise
--o-2 -
10
13
5
interest m gas mixture
wire
w1re.
Gas nder
Mains power
w1re.
Arc
Arc
extinction
l
1
m
currents.
w1res
w1res
to
over m
areas
w1re
user
nPI'lPTr:;c!TI
w1res.
Fig.
24
Tubular>..Vire welding
Even when basic components are not present in metal-cored wires, many are capable of matching basic wires in terms of weld metal hydrogen levels. The oxide film which surrounds the droplet, which is provided by designers mainly to encourage spray transfer; also inhibits hydrogen pickup. For this reason, some of the earliest high strength wires were of the metal-cored type. Other alloy types available include nickel-bearing wires for low temperature toughness, Cr-Mo wires for creep-resisting applications and copper bearing wires for weathering resistance, although the latter are being increasingly replaced by 1% Ni or 2.5/o Ni types. Metal-cored tubular wires even in their standard form may be used for submerged arc welding given a suitable flux and equipment and with some modification they can be made to perform even better. Some productivity advantages are described in the next chapter, but the ease with which a small quantity may be produced, rather than the minimum 20 tonne or so needed to
to
arc Wires
near
remains
mam
SIZe.
a new
it
i i;
Wire
(centre)
over-
'I
I'
Wires
concentric
Butt weld
Fillet weld
ac
ac
0-1 mm ~
12
t
4mm Pass No. Wire diameter, mm 1.2 1.2 Amps Volts Speed, em/min Shielding gas
1 2-8
140 180
21 24
6 21-27
Ar/20% C0 2 Ar/20%
wire.
oints
MMA
7
6
..c
----D-
-c
0
Ul
Cll .:;,:
w' +-' m ,_
4 3
2
:=:
0
Q.
Q)
L--------L--------~------~------~
100
200
300
Current, A
400
500
w1re
rates.
on
raise
a gaswire designed
wire
use
1
minimise mam
I,
'
;I
resource
I
I
!j
25-30 mm extension
transfer
a VISCOUS
slag-
see, or
lost or nse to
flux-
once claimed nearly UK Many of for deoxidation on manganese, a weak a strengthening agent, whereas 1 wires use a balanced mix of deoxidants the same without excessive increases in strength or loss of toughness. For welding over badly scaled plate, users should these wires T -2 types. extreme cases, especially give little away to the welding over primer, basic wires may needed. Nitrogen is an insidious contaminant of welds since its source, rust or grease, is Unless steps are taken to the nitrogen, porosity set in nitrogen level reaches 300-400 ppm. Unfortunately, needed to react this strong so far have use unwelcome therefore Gas-shielded
18
\
17
16
\ \
\
15
\ \
14
13
20
15 Gas
10
I/ min
200
400
600
gas
rate
to escapes. allowed,
to weld, long hose systems. Consideration to back-purging root in sensitive systems, though needed to effects
to ensure use, even out is generally a sign voltage has moisture can a or the wire has commonest
hydrogen came Core contained hygroscopic powders, although may been use, moisture once the w1re Traces were on the wire. levels above 30 23 were recorded. methods wire to porosity is a sign the wire has abused in some Manufacturers' packs are generally well enough sealed of pack, some wires absorb moisture . Even wires hydrogen can occasionally produce surface gas flats argon-rich gases at high currents Increase 1n should be enough to Special the
\--U.UHUU,
cracking, more specifically engmeers and m the 1960s diseases of the slums has been largely hygiene. Solidification cracking cooling weld act on intergranular films of phases. two most their effect is
'-'HHU.,U\..,
current as high as 2
was
i
I I
12
10
8
Hdiff, ml/1 OOg 6 4
2
stickout
Current
260 A
current
0
9
8
7
0
0
,---
6
5
4
::::::,
3
2
0
Wire A Wire B WireC
of
gas on
content.
as
'
''I. '
!
II
I!
Iii
j,l 1.111
::i
jt
i~ '
i.l
are.
I
,II
11
;,I' '!:.'' i
ansmg
gases, prEN
20/o
20
100 80
0
Ill
0
N
60 40
@J
Ill
'
Ill
Ill
20 0
50
100
Weld
150
200
ppm
250
300
on
140 120
II
-o--
Q. Q.
E 100
(!)
-co
""0
(!)
........
80
60
E
$
c
40
20 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
in gas, ppm
or as a
even
wires microstructures can also give designed though, to date, U.H.''-'"'"" types senous use strength
to remove 5 or 6 mm to remove
some these.
can be some
to
in damage to a clean tissue is needed in assessing wires surface is, may appear they are. graphite smce and torch graphite shows an excess Clogging of not have Most manufacturers often by meaa
users
or
arc
wear
excessive effects. common
wear.
Monitors on widespread use. Newer systems or use a solid-state one versiOn parameters can be interfaces conclusion feed speed
welding the parameters represet values monitoring the wire feed speed of effective is a good lS stickout is critical some installations
means
a gauge
over
lS
welders are used to other can produce some users have the process was more proper Some elements theory,
the starting wires are easiest to set because show no transition in transfer behaviour over a wide range of currents. 1.2 mm wire operate 140 to 300 m spray transfer. The by means of wire feed speed wire unit. The voltage
some
made in wires are at higher currents metal-cored wires come into own. more practical is to run possible at a high current, for example to ust 1.2mm produce high speed. be noted voltage he w1re m spray, so that an occasional crackle is feedback in response to be to provide a degree movements . Basic wires do not transfer and always be a slight crackle in most m setting up, however, is wires are to run m tolerance quite narrow spray areas. first stage in setting to m shortto set a wire speed hence range - perhaps 80 to 180 A
too
voltage recommendations are necessarily conservative. Makers w1res, perhaps more conscwus others particular generally not these, manu-
varymg or welds, a penetration and gas coverage. more 10 mm leg (7 mm throat thickness) is required, more than one pass be needed. first pass is made as before and aimed at toe of the
81
11
w1res.
technique
(gravity)
j!
weavmg across severe heat or no weaving must met or two or more runs each using a weave of technique,
necessary. welding vertically with most size 1 mm IS application calls a proportion a positional are used positionally in larger diameters, often between 1. 7 . . smce are to m have been optimised to give tenstics at densities voltages. wires are used vertically in may range to 250 on heavy IS more all-positional welding of 12mm
weave
weave
beads
sequences
ceramic backing tiles are one of . The root is weave pattern to ensure the joint edges are with a a side-to-side Subsequent passes are reg uiremen ts heat weave. Unless a single weave to a followed by a
~~
1st pass
Fill
~
Fill
and cap
and cap
basic
WireS.
on gas-shielded wires.
semifor being used to the on metre best economic argument have an economic process change has been briefly
. I
II
to
own
for 130 tonne capacity overhead cranes were fabricated large high recovery (E 7024) electrodes. Preheating was manually j took 5 hours '""'"u""' was mechanised using two beam
jackets were in steel to using E 7018 electrodes were re-dried before use. Extra supervision was required to maintain preheat ternperatures, electrode in general. change was to a basic gave a hydrogen weld heat increased and <5 /100 g preheat I 00 C. deposition rate also increased, supervision levels and overall saving was estimated at 36o/o. using both gasfurnace was successfully Wire. total all-positional wire and defect rate was 15 te of consumables were used
:.I
wires were used in assess relative economic performance and the following costing was welding parameters. 43 made to the
Diameter, mm kg/h efficiency, % Duty cycle, % Consumable $/kg Labour and overhead, $/h Deposition rate, kg/h Consumable cost, $ Labour cost, $ kg cost, $per kg
&4 L8 60 25 1.32 15
2 2.3 80 40 2.70 15 0.
wishbones
Weld
water
1000 mm
~I
500 mm
Water heater
water
9
a at
400
to give s, some 30% were use to speed was 11.8 m
Welding of boiler.
a
rnrrPn
processes seem based on companson of approaches fabricators suggests Ill 1971, some approaches 45 46 were described , but were also
wires electrodes can efficiencies ratio of coated types as measured the stub ends are not deposited to electrode consumed, of 50/o of deposited consumed have to be paid site. to electrodes
Consumable
cost
'%
Gas
Deposition rate
Arc time
Labour
Labour cost
cycle
cost
cost
sources can
too a change to
calculated as wL/11F.
the metre is nearly always be largest item the greatest savings wire welding.
ISm
VIeW.
0.l.U.U.H-l.l.
Digger
main mm this
5.2
Option 1 53 Solid E70S-6 1.6 mm 400 35 C02 50 1.30 1.15 0.08 13 0.46 7.7 95 0.413 0.435 3.23 6.46 0.57 0.09 0.06 1.40 0.05 2.17 9.29
Option 2 53
-500
wire 2.0mm
C02
1.74 1.15 0 13 0.46 11.4 95 3 0.435 2.18 3.96 0.76 0.06 0.06 0.86 0.03
L 15.17
50
\1
mm
AI8 l.6mm solid Voltage, Stickout, mm gas cycle,% . price, /kg Gas price, /m 3 pnce rate, /h Capital rate, /h Deposition rate, kg/h Deposition efficiency, % weight, kg/m Consumable weight, kg/m Arc Consumable cost, Gas cost, /m Electricity cost, cost, /m Capital cost, m/h cost, /m Productivity, 400 33 20 80/20 40 0.57 0.80 0.05 25 6.7 95 0.254 0.267 2.27 5.68 0.15 0.04 0.02 2.36 0.00 2.58 10.57
L6mm 400 38 20 40 2.01 0.05 25 7.8 85 0.254 0.298 1.95 4.88 0.60 0.02 0.03 2.03 0.00 2.67 12.31
1.89 0.80 0.05 25 8.8 95 0.254 0.267 1.73 4.32 0.50 0.03 0.02 1.80 0.00 2.36 13.89
85 0.254 0.298 2.08 5.21 0.55 0.02 0.03 2.17 0.00 2.77 11.52
..
sets was
w1re
amounts
sources. designed available even in only, wires are enough on AC, using an feeder as
were 2 mm
fi
Wire feeder
to feed wire over longer distances yet have not made the might seem to warrant. straightening effect rolls, is long stickouts or in robotic applications seam following is distance the power source to the cannot easily be reduced to a few metres, as for example in shipyards, repeater or wire feed may be , portable feeders the 'suitcase' type, a small wire spool inside, are increasingly popular. These can a facility for selecting the parameters at a pre-programmed range without the need to return to the power source.
or
prEN because tolerances 0.02-0.06 mm gas ,,,_.._..._,H."' the early days gas'"'-'-'-.... -'-'"'- as main design some might claim it taken second place to ergonomics in design. in 1960s 1 showed best shielding, it was necessary for the gas emerged simplest way to achieve is to torch is as long as possible mm long welding a
a new versiOn
IS
N/mm
digits 6 and each percentage
mcreases
......._.__ Gas
Suitable for
wire
spray
70 ksi tensile
w1re
13
single or use types can used positionally Self-shielded, giving 'spray good toughness Self-:shielded, As T-3 DC-, said to 6.4mm As 'spray toughness any
T-6
LU<'-"-H'-00
testing at
15
wires 10 T-11 types in 1979 issue. 10 wires in being designed for high-speed welding, instead of
users. been
Tubular wire
No gas
wire
EN
not be
g1ven
certain to use two digits to represent yield strength one strength. strength toughness common to for consumables processes. grades of strength appear in the existing
18
Metal-cored For high deposition rate, single run, high speed, flat and
u v
core
types
z
E
3 1
Standard
No.
Tubular wire
460
Hctiff<5 ml/1 00 g
Gas-shielded basic
1% Ni
u'"''-"'""'
Electrodes classed wires types 7 wires. and some chemistry and not MMA slags went into the and fact few people 'basic/fluoride' resulted in now embraces this class, the older wires main slag newer w1res contain fluorspar as Ill smaller amounts of fluorides in general and specific the self-shielded wires pass, description systems of is type single and basic/fluoride slag
12
In-
well as steels, of
w1re
8.1 The world's oldest all-welded ship was launched in 1920. Shipbuilding is the largest user of flux-cored wires today.
in terms
gas
127
conservatism used in
steel to 550, 690 550 N /mm 2 wires can levels, only basic wires are at wires offering
I i
use of
to
rates in 30 in (610-762
1985. 54
using the CRC process withE SIT-I Nil wire Pass No Process Travel direction Electrode diameter, mrn Wire feed speed, m/rnin Shielding gas Gas flow rate, !/min Wire extension, mm Current, A Voltage, V Travel speed, m/rnin Root MMA Downhill MMA Downhill 4 Fill I FCAW Downhill Fill 2 FCAW Uphill
1.4
2
FCAW
As req As reg
As reg As req
30
1.4mm
f----_____lT
l_
X
60 mrn pipe
w1re.
wires have scrap content the desired residual, mild steel long been a of high have wires for submerged arc increasingly seen in
represents a welding
section wue.
wires
mm wires are accurate processmg exceptionally corrosive, good so surface cannot food required.
practices change.
arc to recommends welding, grades appropriate to be chosen: Grade 1 Grade below l 75 A currents. levels are present, as practice, it is not workers passers-by who are most at risk from radiation. exposure to arc can give rise to a painful known as 'arc eye' which become apparent some eyes water as arc welding is at higher currents it is warn
arc
to Processes large to generate less ozone because is absorbed in the arc region. such as ozone to
In
welding can generate significant amounts IS tetrafluoride, disperse harmlessly since is remote Carbon monoxide can also evolved paints and coatings. arc welding processes can produce phosgene (OEL 1 chlorinated degreasing are not is usually preceded
2
3
gases', P
6 7 8
9 0
2
3 4 15 6
1
18
19
21
26
containing 0 Grong, Conference Proceedings Welding .Science and Technology', Tennessee, 1993, 569-571. 29 computer, developed and software documentation in welding', J Hoejgaard, J N E Proceedings ' International Conference on
Computer Technology Welding',
1990.
arc sensmg Crookall L
,J
31
' J
41
1971, 27-37.
terms, 'Economic Aspects of
1971, 227-235. 47 encountered in applying Proceedings 'Economic Aspects nology', The 1971, 21 21 'Self-adjusting arcs', J C Needham 19541 (2) 71-77.
51
m Proceedings Pipeline Technology Conference, of Sciences, 1990, 2.29-2. 73. 31 stainless steel', wire welding Metal Construction, 1987 JL
1978.
m
acicular 69- 71 alloyed wires, 29 aluminium in tubular 26, 29 American Welding Society, 10, 13 Specification A5-20, 13, 26 arc instability, 72-74 arc stabilisers, 12-13 argon mixtures, 20, 22, 44-45, 57-58 austenitic steels, 29-31 back-gouging, 71 barium compounds, 27 basic wires, 13-16 basicity, 14 British Standards BS 449,8-11 BS 5135, 60, 61, 65 BS 6693, 61 BS 7084, 61, 63 burn-o:lfrates, 45-47 carbonates, 13, 26-27 CEN (European Committee for Standardisation), lO C0 2 , 20, 22, 30, 44, 53, 57-58 cold cracking, 60-65 cold laps, 6 contact tip, 8 excessive wear, 74 copper, 60 29
soaps, 7 duty cycles, 3 electrode extension, II embrittlement, 68-72 European Standards EN lOll, 60, 65 EN 439,66 EN 729, 75 EN 758, 23, 63 filling ratio, 23, 31, 35-36, 65 fluorides, 13, 25-26, 28 guns, 8 heat 69 high strength steels, 29 hydrogen, 7, 14, 15, 17, 29, 58-65 41-43, 53 K-preparation, 68-69 Kjellberg, Oscar, l lack-of-fusion defects, 7, 52-53 lithium compounds, 28 lubrication, 37-38, 73-74 68-71 l, 2, 3, 6, 21, 66-67
61
oxygen,
55 66
23, 25 porosity, 7, 17,55-59 53 power sources, 8, 15, 48-50 welding over, 5, 21, 23, 43 production methods, 31-35 productivity, 3-5, 41-51 pulsed arc welding, 48-50 robotic rolling as a rutile, 16, 27-28 wires, 16-18, 29,41
61
77
11, 30 14, 15, 59-60, 66 30 17 41, 42 35 titanium dioxide, 16 torches, 8 toughness, 14,17,47 training of welders, 77-84 travel speeds, 21 underbead profile, 21, 22 undercut, 77
77-78
seamless wire, 34-35, 57 segregation of alloying elements, self-shielded 25-29 semi-automatic welding, 2, 8, 76 sheath materials, 31 shielding gases, ll, 20, 62, 66-67 shipyards, 21, 49 shroud, 8, 53, 77 slag, 12, 24 solid wires, 21, 53 solidification cracking, 59-60 spray transfer, 8, 16
66
61-,
voltage, setting up, 77-78 monitors, 75 welding speed, 47-50 wire feed speed, 5, 53 wire feeding difficulties, 73:_ 74 wire sections, 35-37