SAT Swift Arc Transfer Introduction, AristoRod, Applications, Solutions

Transcription

1 SAT Swift Arc Transfer Introduction, AristoRod, Applications, Solutions ESAB CZ Customer days 19/05/2015 Peter Flikweert Transport Segment Mobile Machinery

2 GLOBAL SOLUTIONS GROUP Transport Segment Shipbuilding & Offshore Segment Energy Segment Ken Konopa Vice President Strategy Team Value Engineering Team Johan Elvander Global Solutions Key Account/ Segment Managers Local Regions Alex Jirofle Transport Segment Manager Peter Flikweert Mobile Machinery Tamas Sandor Railcar/Rolling stock Marcel Stemvers Energy Segment LNG TBA Wind towers Gordon Eadie Pipelines Gary Powell Nickel based Jose Roberto Dominques Shipbuilding and OffShore Anders Lindh Director Of Strategy Jens Ericsson Senior Strategy Analyst & Program Manager Lars Campbell Global Product Planner (VOC) Dick Skarin Global welding applications group Value Engineering TBA Applications manager Daniella Kasnecovic Project Manager Value Sell Dennis Byrulin Nuclear Cristiano Ferreira Global Product Planner (VOC) Slide 2

3 ARISTOROD Slide 3

4 OK AristoRod GMAW wires OK AristoRod is a family of non copper-coated MAG wires Superior welding characteristics for robotic, mechanised and manual welding OK ARISTOROD RESEARCH DATA BENEFITS RANGE

5 OK ARISTOROD Advantages Very stable arc at very high wire feed speed low level of spatter Consistent, low friction feeding at high wire speeds and long feed distances Good starting properties Reduced fume emission rate Good wire surface corrosion resistance Less sensitive to drive-roll pressure damage

6 SAT (SWIFT ARC TRANSFER) Slide 7

7 DEFINITION ESAB SAT GMAW welding at very high travel speed The ultimate Single wire and Tandem Double wire GMAW high productivity welding process Suited for thick and thin plate Slide 8

8 BASES OF ESAB SAT Unconventional welding parameters giving the modified spray arc AristoRod non copper-coated MAG wire ESAB digital power sources & wire feeders Standard shielding gases

9 Voltage ARC MODES AND WORKING AREAS Short Arc Globular Arc Spray Arc SAT WFS Conventional welding 15m/min wfs Unconventional welding

10 SAT (SWIFT ARC TRANSFER) SINGLE WIRE APPLICATION EXAMPLES Slide 12

11 PENETRATION THICK PLATE SINGLE WIRE Penetration profile Standing fillet weld a=3 Shielding gas: 92%Ar/8% CO 2 Good penetration with all wire diameters 0.8mm 0.9mm 1.0mm Wire diameter (mm) I (A) Wfs (m/min) Travel speed (cm/min) Stickout (mm) Plate thickness (mm) Arc type Advantages Heat input Penetration Process requirements Recommendations Parameters Applications

12 PENETRATION THIN PLATE SINGLE WIRE Penetration profile Overlap joint/2mm plate Wire diameter 0.9mm Shielding gas: 92%Ar/8% CO 2 Wire diameter (mm) I (A) Wfs m/min Travel speed (cm/min) Stickout (mm) Plate thickness (mm) 2 2 Macro number Arc type Advantages Heat input Penetration Process requirements Recommendations Parameters Applications

13 TEST EXAMPLE SAT SINGLE WIRE AristoRod ,0 mm, in PB position Net Deposition Rate: 7 kg/h Plate thickness: Weld size: Welding Speed: Wire Feed Speed: Welding parameters: 12 mm (shop blasted before welding) a=5.5mm 7mm/sec or 42 cm/min 20m/min 350A 31V

14 SAT (SWIFT ARC TRANSFER) NON SYNCHRONIZED SAT TANDEM APPLICATION EXAMPLES Slide 16

15 TEST RESULT, SAT TANDEM AristoRod ,0 mm x 2 in PB position Net Deposition Rate: 13 kg/h Plate thickness: 12 mm (not shop blasted before welding) Weld size: a= 5,0mm Welding Speed: 18 mm/sec or 108 cm/min Wire Feed Speed: Wire 1: 20 m/min, Wire 2: 17 m/min Welding parameters: Wire 1: 290A 27V, Wire 2: 330A 30,5V

16 TEST RESULT, SAT TANDEM AristoRod ,0 mm x 2 in PB position Net Deposition Rate: 15,5 kg/h Plate thickness: Weld size: Welding Speed: Wire Feed Speed: Welding parameters: 12 mm (not shop blasted before welding) a= 5,5 mm 15 mm/sec or 90 cm/min Wire 1: 22 m/min, Wire 2: 22 m/min Wire 1: 320A 28V, Wire 2: 320A 33V

17 TEST RESULT, SAT TANDEM AristoRod ,2 mm x 2 in PB position Net Deposition Rate: 18,7 kg/h Plate thickness: 12 mm (shop blasted before welding) Weld size: a= 5.3 mm Welding Speed: 18 mm/sec or 108 cm/min Wire Feed Speed: Wire 1: 18,5 m/min, Wire 2: 18,5 m/min Welding parameters: Wire 1: 400A 30V, Wire 2: 400A 36,5V

18 CURRENT DENSITY Wire diameter vs. deposition rate Diameter (mm) Wfs A Wfs A Wfs A Kg/h 7.4Kg/h 8.1Kg/h Wfs Kg/h A High Hi Arc type Advantages Heat input Penetration Process requirements Recommendations Depositionrate Applications

19 Kg/h DEPOSITION RATES FOR DIFFERENT MIG/MAG WIRES AristoRod 0.9 AristoRod 1.0 AristoRod 1.2 MCW LS 1.2 FCAW 2.4mm FCAW 1.6HS Amperage

20 SAT DEPOSTION RATE OVERVIEW (I²R) AristoRod mm Wfs M/min Amp Volt g/h Stickout=20mm AristoRod mm Wfs Amp Volt g/h Stickout=20mm AristoRod mm Wfs Amp Volt g/h Stickout=20mm A is about the maximum the 1.0 and 1.2mm wires can handle, difference is 2Kg in deposition rate! For the AristoRod 1.6mm at 450A difference is 4.5Kg in compare to a 1.0mm!!

21 APPLICATIONS SAT for industrial applications: Transportation segment General steel fabrication Bridge building, beams construction Tank- and vessel building Container- and equipment construction SAT Process is especially suited for: Mechanised- and robotic applications Exhausts» Exhausts manifolds» Cranes» Crane parts» Road Compactors» Beams» I-profiles» Compressor tanks» Tractor frames» Tow bar frames» CE Parts 1» CE Parts 2» Arc type Advantages Heat input Penetration Process requirements Recommendations Parameters End

22 SAT (SWIFT ARC TRANSFER) PROCESS REQUIREMENTS Slide 38

23 PROCESS REQUIREMENTS CONSUMABLES Consumables: AristoRod non copper-coated solid wire: From Mild Steel (E70S-3) To Low Alloyed (ER120S-G) (890Mpa) High Alloyed Ferritic stainless (GZ18LNb-Ti) (GZ 17 LNB) Cored wires: Coreweld 46LS (E70C-6M H4) Marathon Pac bulk drum Arc type Advantages Heat input Penetration Process requirements Recommendations Parameters Applications

24 PROCESS REQUIREMENTS EQUIPMENT Equipment Aristomig 5000i, Aristomig 4004i Pulse Origo Mig 4002/5002/6502, Origo Mig4004i/5004i The Robofeed 3004w (HW) ELP encapsulated wire feeder The Aristo U8 2 and/or W8 2 control Arc type Advantages Heat input Penetration Process requirements Recommendations Parameters Applications

25 PROCES REQUIREMENTS (ROBOTIC) TORCHES ESAB Aristo RT standard ESAB Aristo RT Infiniturn for hollow wrist robots ESAB Aristo Tandem RT22 & RT 20 For double wire applications

26 SAT AND LIGHT MECHANIZATION Slide 43

27 ESAB MIGGYTRACK ENTRY LEVEL AUTOMATION SOLUTIONS Miggytrack B501 Efficient simple battery operated tractor Miggytrack 2000 Solution with weaving capability Miggytrack 3000 Solution with wire feeder Slide 44

28 SAT AND ROBOTIC MECHANIZATION Slide 45

29 ESAB MIG/MAG CONFIGURATIONS ROBOTS Standard robotic welding solutions for all mayor robotic brands

30 ESAB SWIFT ARC TRANSFER (SAT ) SAT video volgt later Apart hoofdstuk Ook in navigatie beeldvullend

31 Thank you for your Attention Slide 49