The welding wire your robots have been waiting for.

Transcription

1 The welding wire your robots have been waiting for. OK ARISTOROD A NEW GENERATION OF BARE MAG WIRES By kind permission of ABB

2 We wanted to create a wire that takes MAG welding to new performance levels. New ASC wire surface technology! OK AristoRod MAG welding wires with Advanced Surface Characteristics technology resists corrosion during storage, improves feedability and arc stability and also reduces contact tip wear to a level equal to the very best copper coated wires. New OK AristoRod with ASC technology takes your MAG welding operations and systems to new levels of performance and all round efficiency in both robotic and mechanised welding. ESAB s development of Advanced Surface Characteristics (ASC) minimal post weld cleaning, and increased deposition rates. OK AristoRod wires can be safely stored for extended periods too. That s because the ASC surface technology creates a barrier that is highly resistant to corrosion. has enabled the creation of a whole new family of wires with outstanding properties. Taken together these deliver the potential for increased productivity in automated MAG welding facilities. With new OK AristoRod A dependable, high efficiency wire that will have a positive impact on reducing your overall welding costs. These new generation MAG wires are specifically designed to reduce your overall welding costs. What you ll gain is high quality, dependable production welding, time and time again. OK AristoRod is available you gain consistent, trouble-free feeding, with no clogging of the liners and guns, as well as low contact tip wear. The new generation of bare wires has excellent start properties too, with good arc stability at very high welding currents and producing extremely low spatter. Combined, these properties translate directly into reduced maintenance downtime, excellent weld finish with either on adapter-free basket spools or contained in Marathon Pac 250 and 475kg octagonal bulk drums. There s even an Endless Marathon Pac version for continuous, non-stop delivery of wire to the welding head. The Aristo name is synonymous with ESAB s highest quality traditions. That is why you can be certain that OK AristoRod with ASC technology will deliver clearly measurable performance and efficiency enhancements across your welding operations. So we developed ASC a major advance in wire surface technology.

3 A true innovation in MAG wire development. Voltage drop (mv) Common bare wire Current transfer diagram ASC treated bare wire High quality copper-coated wire Time (ms) The diagram above shows the current transfer from tip to wire for common bare wire, for ASC treated bare wire and for high quality copper-coated wire. ASC brings the current transfer to the level of the copper-coated wire but with a lower voltage drop and much improved current transfer stability. This results in greater arc stability and reduced spatter. A high-speed video recording revealed the smooth and spatter-free arc ignition process for OK AristoRod wires; a property that makes them extremely suited for MAG welding with many start-stop cycles, such as is common in robotic welding. OK AristoRod The benefits in a nutshell. + Very stable arc at very high welding currents. + Extremely low levels of spatter. + Excellent start properties. + Consistent trouble-free feeding, even at high wire speeds and lengthy feed distances. + Reduced contact tip wear. + Improved protection against corrosion of the wire. + Low fume emission level. What you ll gain is higher deposition rates, reduced maintenance downtime, and less post weld labour, all adding up to increased productivity and lower welding costs. High-speed video recording of arc ignition process for OK AristoRod wires. Improved corrosion resistance to the level of the very best coppercoated wire is another property of ASC technology. Here you see the results after 10 days Contact tip wear (mg/h) Tip wear diagram OK AristoRod Common bare wire Ar/CO 2 CO 2 Copper coated wire Contact tip wear, a traditional problem of bare welding wires, has been reduced to the level of exposure to tropical conditions. 0 of the best copper-coated wires (wire Ø 1.0mm).

4 OK AristoRod TM A steady force for robotic production processes. OK AristoRod productivity features highly at the Komatsu facility in Padua, Italy and one of four Komatsu Group production units in Europe. There they produce a wide range of earth moving equipment including mini-excavators, back hoe loaders and skid steer loaders. The main equipment structures and chassis are fabricated in-house on three highly automated production lines comprised of a multitude of robotic welding cells. The robots are programmed to recognise each component and then to carry out the related welding sequence. A high speed welding process is applied universally and with very demanding parameters. Welding currents reach in excess of 400A at wire feed speeds of over 20m/min., with frequent start-stop cycling. The weld wire is guided to the welding head through 20m long liners in the chain system of the robot gantry. In addition, they use a relatively long stick-out length imposing high demands on wire straightness. OK AristoRod mm is used throughout the production process and has already earned a good reputation at the Komatsu plant. Claudio Gallana, Production Manager at Komatsu, states The first and most important requirement for us is the consistency of the welding consumables. ESAB s OK AristoRod wire gives the same high performance time and again. It is a steady factor in our high efficiency welding. We ve experienced no feeding problems at all and the welds are always nice and clean and well positioned. Robotised production of earth moving equipment frame. OK AristoRod TM the complete range. AWS and EN classifications Product Classifications Wire Classification Weld Metal OK AristoRod TM AWS A5.18 AWS A5.28 EN 440 EN EN12070 M21 C ER70S-6 G3Si1 G 42 3 G ER70S-3 G2Si G 38 3 G ER70S-2 G2Ti ER70S-6 G4Si1 G 46 3 G ER70S-6 G4Si1 G 46 3 G ER80S-D2 G4Mo G 46 2 G ER80S-G G2Mo G MoSi G 46 2 G ER80S-G G CrMo1Si ER100S-G G Mn3NiCrMo G ER90S-G G CrMo2Si ER80S-G ER100S-G G Mn3Ni1CrMo G 62 3 OK AristoRod TM Approvals ABS BV CWB DB DNV GL LR Ü VdTÜV SA, 3YSA SA3YM CSA W III YMS 3YS 3 3YS / SA, 3YSA SA3YM III YMS 3YS 3 3YS / III YMS / II YMS/III YMS / /

5 Marathon Pac TM endless feedability. For many ESAB customers, Marathon Pac is key in maximizing production efficiency and quality. In fact, it can cut down time on spool changes and maintenance by almost 95%. Bulk supply Marathon Pac s are available charged with either 250 or 475 kg of welding wire. An Endless version combines the contents of a series of Marathon Pac s to form a continuous in-line supply source. As each drum empties, the subsequent drum takes over and a new drum is added to the line to form an uninterrupted supply. Perfect delivery to the welding head The special coiling technique used in packing the drum ensures that your OK AristoRod wire is never twisted or warped, or causes arc wander. Welds are always well positioned and perfectly straight. The unwind process from the drum is automatic, so no separate de-coiling equipment is needed and no additional forces are required as with turning a traditional revolving spool. For ease of recycling, Marathon Pac comes in octagonal cardboard drums that can be folded flat after use. The high quality board used will often fetch a price premium in the recycling market. Perfect delivery to the welding head. The unwind process from the drum is automatic and requires no additional feed force to pull the wire as is common with a traditional revolving spool. The high speed, robotised welding of thin sheet automotive components is an important application area for OK AristoRod wires. Marathon Pac endless wire delivery system feeds OK AristoRod to the robotic welding head for high volume production.

6 World leader in welding and cutting technology and systems. VBG, Sweden. This components manufacturer for Volvo passenger cars was among the first to recognise the advantages of OK AristoRod. Since 1904, ESAB has been both a pioneer and leader in welding and cutting development technology. Today ESAB combines world leadership with global applications expertise. By continuously improving and developing our products and manufacturing processes, we meet the challenges of technological advance in every sector and market we operate in. Delivering quality products and services remains at the heart of everything we do across all our global sales and production operations. ESAB customers enjoy local access to an unrivalled resource of technical and applications knowledge, service and support. Local representation close to our customers combined with central resources and a network of independent distributors bring practical expertise and solutions to challenges involving materials, welding systems and techniques, cutting and overall productivity enhancements. Wherever in the world quality and productivity in welding and cutting counts, ESAB is there to set the standard. ESAB AB Box 8004, SE Göteborg, Sweden. Phone: Fax: info@esab.se Reg. No: XA Printed in the United Kingdom