MIG-MAG PROCESS. Global solutions for automatic welding: innovation, quality, productivity.

Transcription

1 MIG-MAG PROCESS Global solutions for automatic welding: innovation, quality, productivity.

2 THE MIG-MAG PROCESS Single wire or double wire (TOPMAG), two process variants guaranteeing an excellent result and high-performance welding. Single wire process* 1 - electrode wire 2 - gas nozzle 3 - contact tube 4 - protection gas 5 - electric arc 6 - molten pool 7 - part to be welded Performance Deposition rate (kg/h) Spray+ MAG standard Short-arc+ TOPMAG (double wire) MAG TGV flux-cored wire Welding speed (m/min) * see page 11 for double wire process. Various transfers for high productivity Arc voltage (volts) Globular Rotating liquid vein Rotating vein Axial atomisation (Spray-arc) Spray Short-arc Pulsed Globular Spray Short-arc Short-arc Arc current (amperes) 2

3 MIG-MAG : SAF global solutions for automatic welding Drawing on its long experience of MIG/MAG welding, SAF can propose the best automation solution for your application. In a partnership guaranteeing your success, SAF can support your manufacturing process: process control, welding equipment, consumables (wires and gas), services (training, maintenance, etc.) Welding armoured cabinets. Carbon steel or stainless steel. - Thickness: 4 to 12 mm. - Solid wire diameter: 1.0 and 1.2 mm - Part dimensions L x W x H: 800 x 800 x 1200 mm. - Welding speed: 0.5 m/min Equipment Consumables Services Various ranges of power sources, torches and wire-feed units on basic standard machines or highly automated equipment (including robots) and engineering machines. SAF 03 The combination of the welding gas with the filler metal plays a determining role in achieving quality, productivity and ergonomic objectives. AIR LIQUIDE group proposes a major asset in the form of its global solution: shielding gas, high-quality and reliable filler products, packaging that allows higher productivity. The welding performance information in this document is given as a guide and may vary according to process implementation and the quality of part preparation Are you looking for ways to improve productivity? In addition to high-performance equipment and consumables, you can benefit from the experience of our experts. As your partners, we can assess your situation and propose innovating solutions: advice on your process and welding procedures, preventive or after-sales maintenance, logistics for managing consumables and wearing parts, training. 3

4 "Uncomplicated and economic" mechanisation solutions for single wire applications You manufacture all types of steel, stainless steel, aluminium and light alloy parts for light boilermaking and basic parts for mid-range boilermaking. As a first step to automation, these uncomplicated machines deploying mechanisation equipment from the SAF catalogue (slides, supports, etc.) are usually fitted with welding facilities based on manual equipment. They provide a considerable productivity increase over manual welding for a reasonable budget. They feature user-friendly controls and reduced, low-cost maintenance Welding machine for pressure tank bottoms (1 or 2 simultaneous welds depending on application) - Carbon steel. - Thickness: 1.2 to 3 mm. - Solid wire diameter 1.2 mm or TGV flux-cored wire diameter 1.2 mm. - Part dimensions: diameter 550 x 500 mm (length). - Welding speed: 0.8 m/min to 1.5 m/min with solid wire up to 2.8 m/min with flux-cored wire. The OPTIMAG range of power sources features: fast access to the correct welding parameters; reduced spatters; full welding cycle with hot start and crater filler; arc extinction system for better striking; optional torch-cooling system OPTIMAG 300S OPTIMAG 400S Primary specifications Three-phase power supply 230/400 V Hz 230/400 V Hz Primary power consumption 12.6 kva 20.2 kva Maximum current 19 A 29.1 A Secondary specifications No-load voltage 38.5 V 45 V Welding current mini 40 A 50 A at 60 % 280 A 350 A maxi 280 A 400 A Welding wires steels/stainless steel mm mm aluminium mm mm flux-cored wires mm mm Welding cycle 2 T/4 T/4 T with crater filler 2 T/4 T/4 T with crater filler Net weight 114 kg 144 kg Protection factor IP 23 IP 23 4

5 Rotating electrode machine for circular welding (drain tap or flange on tank bottom) with stationary part and rotating torch. Machine for welding drain taps at the bottom of boiler shells. Carbon steel or stainless steel. - Thickness: 1.8 mm to 3.5 mm. - Solid wire diameter 1.0 or 1.2 mm. - Welding speed: 0.5 to 1 m/min Circular welding of small pressure tanks. Stainless steel 304 L. - Thickness: 2 mm. - Solid wire diameter: 1.0 mm. - Part dimensions: diameter 400 x 350 mm (length). - Welding speed: 1.2 m/min The STARMATIC 650 DC has a full use range: solid wires flux-cored wires dia. 0.8 to 1.6 mm, steel stainless steel light alloys up to dia. 2.4 mm. Smooth welding possible up to 650 A, full duty cycle Name STARMATIC 650 DC Full duty cycle 650 A - 44 V Welding range 1 Primary power supply 230/400/440 V Hz tri* Technology thyristors Maximum current input at primary 72 A Power consumption 34,5 kva Characteristics: - horizontal - vertical Protection factor IP 21 Insulation class H Cooling driven air Net weight 247 kg * contact us for other primary three-phase power supply ratings. 5 Machine for welding household gas cylinders. Carbon steel. - Thickness: approx. 2 mm. - Solid wire diameter: 1.0 mm or 1.2 mm. - Part dimensions: diameter 285 or 365 mm - Welding speed: 0.8 m/min.

6 "High productivity" automatic solutions for single wire applications. You manufacture mechanicallywelded framework, casing, civil engineering materials, agricultural equipment, construction vehicles, hot water tanks, fire extinguishers, home radiators, structure stiffeners, vehicle axles... TM15 torch mounted directly in the powered wire-feed unit. Joint monitoring by laser device Constructed in compliance with all safety standards and EC standards, these machines with basic through to sophisticated automation systems, are fitted with powerful STARMATIC A450 power sources. Welding of low pressure tanks - Carbon steel. - Thickness: 2 to 3 mm. - Solid wire or TGV flux-cored wire: diameter 1.2 mm. - Part dimensions: diameter 600 x 1000 mm (length). - Welding speed: 1.2 to 1.8 m/min depending on wire used STARMATIC A450 power source using transistor chopper technology for welding steel and light alloys. Synergic - Pulsed Built-in hot-start 50 storable programs Crater filler Burn back Display of welding parameters Monitoring of welding parameters Loading/unloading of welding parameters to/from PC. Type of welding Standard MIG-MAG - current range 20 to 450 A - voltage range 10 to 44 V - wire speed range 1 to 20 m/min Pulsed MIG-MAG - current range 20 to 350 A - voltage range 20 to 40 V - wire speed range 1 to 20 m/min MIG-MAG Short-arc+ - current range 20 to 360 A (steel wire 1.6 mm) - wire speed range 1 to 20 m/min - arc height fine adjustment Main specifications Welding current 45 to 450 A Duty cycle 450 A at 100% Welding voltage 14 to 44 V No-load voltage 70 V Pulse frequency 10 to 500 Hz Primary voltage 230/400/415/440 V + 20% -15% Hz Weight 230 kg Dimensions (h x l x d) mm 1010 x 625 x

7 Welding centrifuge screws (purification station) - Stainless steel 304L. - Thickness: 3 to 4 mm. - Solid wire diameter 1.2 mm.. - Part dimensions diameter 450 x up to 6000 mm (length). - Welding speed: 0.45 m/min. Welding control unit on remote MIGMATIC console TR400 torches mounted apart with coaxial beam and fitted with fume extractor unit. QB Horizontal welding of stiffeners on flat panels - Coated steel. - Thickness: 6 to 15 mm. - Solid wire diameter 1.2 mm.. - Part dimensions: length 12 m maximum. - Welding speed: up to 1.2 m/min depending on thickness. Functions Control: - gas yes - blowing yes - suction yes - wire-feed yes - wire lifting yes - on/off yes - error cancellation yes - pulsed yes - synergy yes Safety: - water yes - gas yes - torch yes - end of coil yes Setpoint: - wire speed yes - voltage yes Welding cycle storage yes (50) Remote program change yes Program stringing (any order) yes RS 232 interface: - for printer yes - for PC option Remote start-up option Process control: - for current yes - for voltage yes Contact - ready to weld yes - movement authorisation yes - removal authorisation yes - error yes - gas control yes - blowing control yes - suction control yes - current relay (adjustable threshold) yes - voltage relay yes Display: - wire feed speed yes - voltage yes - current yes Pre-set internal synergies 100 Possible additional external synergies 5 7

8 Robotic solutions for single wire applications. Improved productivity for welding of all types of steel, aluminium and light alloys. Robotic handling of welding operations is one of the possibilities available to industrialists looking to improve their productivity. SAF, your welding partner, proposes its current range of economic and easily-implemented robotic welding solutions. STARMATIC R450 Robotic cell DR X 100. Multiple welding of vehicle oil gauge tubes - Carbon steel. - Thickness: 1.5 mm - Solid wire diameter 1.0 mm. - Tack welding and bead segment welding. STARMATIC R450 power source Like the STARMATIC A450, the STARMATIC R450 takes its current from a power transistor source delivering a smooth or pulsed current up to 500 Hz and maximum intensity of 450 A at full duty cycle. It is designed to adapt to all types of robotic cell (SAF and others). Cycle management by the power source or robot. Monitoring and management of robot inputs/outputs and the various safety devices of the facility. Storage of up to 50 welding programs. Torches and wire-feed Welding facilities fitted with a range of liquid-cooled torches with coaxial beams of various lengths. A powerful motor-driven wire-feed unit with 4-roller plate and wire straightener for perfect electrode wire feed. For improved traceability: Basic process control built into the power source software with parameter stop processing (current, voltage and wire speed) as a percentage of a value or as an absolute value. Wire-feed motor current monitoring (option). Loading and unloading of welding programs by direct link to PC or remote link via PCMCIA card

9 PRODUCTOR 7X cell. Welding of agricultural gates. Square tubes, 40 x 40 mm, thickness 2.5 mm - Carbon steel - Solid wire diameter: 1.2 mm. - Part dimensions: length 5000 mm - height 2000 mm. - Welding speed: 0.7 m/min. - Galvanisation after welding. Welding of hospital equipments. Carbon steel. - Thickness: 0.8 to 2 mm. - Solid wire diameter 1.0 mm. - Tack welding and bead segment welding. - Chromium plating after welding. Functions of the STARMATIC R450 Control: - gas yes - blowing yes - suction yes - wire-feed yes - wire lifting yes - on/off yes - error cancellation yes - pulsed yes - synergy yes Safety: - water yes - gas yes - torch yes - end of coil yes Setpoint: - wire speed yes - voltage yes Welding cycle storage yes (50) Remote program change yes Program stringing (any order) yes PCMCIA interface option RS 232 interface: - for printer yes - for PC yes Remote start-up yes Process control: - for current yes - for voltage yes - wire feed speed yes - wire-feed motor current option Contact - ready to weld yes - movement authorisation yes - removal authorisation yes - error yes - gas control yes - blowing control yes - suction control yes - current relay (adjustable threshold) yes - voltage relay yes Display: - wire feed speed yes - voltage yes - current yes Pre-set internal synergies 100 Possible additional external synergies 5 9

10 MIG-MAG double wire processes: TOPMAG TOPMAG: TANDEM or TWIN is the Air Liquide Welding solution combining process assistance (specific double wire synergies), complete fittings, specific gases and consumables for considerably increased productivity (welding speed and deposition rate). Depending on the application, single wire welding speeds are multiplied by 2, 3 or more. TOPMAG TANDEM - Pulsed/pulsed configuration Carbon steel Double wire test conditions: ARCAL 14 (M 14) gas - NERTALIC 70S (ER 70 S 3) solid wire, diameter 1.2 mm Example A B Thickness 2 mm 6 mm Position lap joint flat fillet weld Single wire welding speed 0.8 m/min 0.45 m/min Double wire welding speed 2.4 m/min 1.0 m/min (4.5 mm channel) TOPMAG TANDEM - Spray/pulsed configuration Carbon steel Double wire test conditions: ARCAL 14 (M 14) gas - NERTALIC 70S (ER 70 S 3) solid wire, diameter 1.2 mm Example C D E Thickness 2 mm 4 mm 6 mm Position flat lap joint flat fillet weld flat butt on support on support on backing bar Single wire welding speed 1.1 m/min 0.5 m/min 0.35 m/min Double wire welding speed 3.2 m/min 2.8 m/min (2.8 mm channel) 3.2 m/min TOPMAG TANDEM - Pulsed/pulsed configuration Austenitic stainless steel Double wire test conditions: ARCAL 12 (M 12) gas - NERTALIC 50 (ER 308 L Si) solid wire, diameter 1.2 mm Example F G Thickness 4 mm 4 mm Position lap joint butt joint Single wire welding speed 0.9 m/min 0.7 m/min Double wire welding speed 2.4 m/min (4.5 mm channel) 2.4 m/min TOPMAG TANDEM - Pulsed/pulsed configuration ( H & I ) or spray/pulsed ( J ) Light alloys Double wire test conditions: ARCAL 1 (I 1) gas - NERTALIC 10 (ER 1100), 20 (ER 5183) or 30 (ER 5356) solid wire, diam. 1.2 mm Example H I J Material AG 3 AG 4 Aluminium Thickness 1.5 mm 3 mm 8 mm Position butt (special butt joint on profile) butt (special profile) reinforcing flange Single wire welding speed 0.85 m/min 0.9 m/min 0.6 m/min Double wire welding speed 1.7 m/min 1.5 m/min (2.8 mm channel) 1.2 m/min TOPMAG TWIN - pulsed/pulsed configuration 10 Carbon steel Double wire test conditions: ARCAL 14 (M 14) gas - NERTALIC 70S (ER 70 S 3) solid wire, diameter 1.2 mm Example K L Thickness 2 mm 8 mm Position butt joint - inserted lap joint flat fillet weld Single wire welding speed 1.15 m/min 0.3 m/min Double wire welding speed 3 m/min 0.8 m/min

11 TOPMAG TWIN For use with carbon steels The 2 electrode wires are at the same potential electrode wire 2 - gas nozzle contact tube shielding gas electric arc molten pool part to be welded 4 STARMATIC R450 TOPMAG slave STARMATIC R450 TOPMAG master TOPMAG TANDEM For use with all types of steel and light alloys The 2 electrode wires are electrically isolated. Independent welding parameter setting for each electrode wire. 1 - electrode wire 2 - gas nozzle 3 - contact tubes 4 - shielding gas 5 - electric arc 6 - molten pool 7 - part to be welded STARMATIC R450 TOPMAG master STARMATIC R450 TOPMAG slave 2 mm 6 mm A Welding speed : 2.4 m/min B Welding speed : 1.0 m/min 2 mm 4 mm 6 mm C D E Welding speed : 3.2 m/min Welding speed : 2.8 m/min Welding speed : 3.2 m/min 4 mm 4 mm F Welding speed : 2.4 m/min G Welding speed : 2.4 m/min 1,5 mm 3 mm 8 mm H I J Welding speed : 1.7 m/min Welding speed : 1.5 m/min Welding speed : 1.2 m/min 2 mm 8 mm K Welding speed : 3 m/min L Welding speed : 0.8 m/min 11

12 Automatic or robotic solutions for TOPMAG double wire applications: welding speeds that increa The TOPMAG offer in automatic and robotic double wire welding: fast welding speed, two to three times standard single wire speeds, high-quality bead, excellent penetration, versatile (depending on your application, these facilities can be used in single wire mode), easy to implement. Your application: fire extinguishers, small tanks, metal framework, automotive and railway construction, construction vehicles, mechanicallywelded casing, welded composite girders and metal framework. Welding of aluminium silo panels. Edge-to-edge assembly on reinforcement flanges. - Thickness: 8 mm. - Solid wire diameter 1.2 mm. - Double wire Tandem welding speed (2 wires of 1.2 mm): 1.2 m/min Construction of aluminium railway carriage roofs. Construction of metal framework and construction vehicles Fire extinguisher body - Carbon steel. Vehicle engine support cradle. Coated carbon steel. Thickness: approx. 3 mm.

13 se productivity Boiler body welding. Carbon steel. - Thickness: 4 to 6 mm. - Solid double wire diameter 1.2 mm. - Circular welding, bead segment and tack welding. - Jacket and heat insulation applied after welding. - Welding speed variable from 0.6 to 1.8 m/min Double wire torch Tandem TTA 900 (2 x 450 A %). Tandem double wire machine. Longitudinal and circular welding. Solid stainless steel wire or flux-cored wire. Welding speed: - circular welding > 3 m/min - longitudinal welding > 2 m/min. Comprises: 2 STARMATIC R450 - TOPMAG (450 A %), an interface controlling process and cycle, 2 wire feeders, 1 double wire torch TTA Double wire welding facility for truck side members - Carbon steel. - Thickness: core 5 mm, wing 10, 12 or 16 mm. - Flux-cored wire diameter 1.2 mm. - Welding speed: 2 m/min. Double wire welding of fire extinguisher body - Thickness: 1.8 to 2.2 mm. - Solid wire diameter 1.2 mm - Part dimensions: diameter 165 x 350 (length). - Welding speed: 2.7 m/min. 13

14 Consumables: wires. The choice of a welding consumable for MIG/MAG processes depends mainly on the material to be assembled. For aluminium and light alloys, only solid wire is used. On the other hand, for non-alloy, low-alloy or stainless steels either solid wire or flux-cored wire can be chosen. Welding speeds, deposition rates and the bead quality obtained are generally better with flux-cored wires, but these wires are more expensive. To get a clear picture of the advantage of flux-cored wires, a cost calculation needs to be drawn up taking into account all the parameters influencing the cost price of a welding operation. The tables to the right show a selection of the most common grades in the SAF range. Getting the right combination of welding gas and filler metal is a determining factor in achieving quality, productivity and ergonomic objectives. Solid wires for non-alloy or low-alloy steels and stainless steels Grade to be Grade of filler metal SAF name Packaging assembled as per (homogeneous) EN 440 AWS Non-alloy steels G 3 Si 1 ER 70S-6 STARMAG 16 kg coil and 250 or 300 kg ENDURO barrel. Ø and 1.6 mm Low-alloy steels G 4 Mo ER 80S-D2 NERTALIC kg coil and 250 kg ENDURO barrel. Ø and 1.2 mm stainless steels steels ER 308 L Si NERTALIC kg coil. Ø and 1.6 mm stainless steels ER 316 L Si NERTALIC kg coil. Ø and 1.2 mm Flux-cored wires for non-alloy or low-alloy steels and stainless steels* Grade to be Grade of filler metal as per SAF name Packaging assembled (homogeneous) EN AWS Non-alloy steels T 42 2 R M 3 H 10 E 70 T1 SAFDUAL kg or 20 kg coil and 200 kg ENDURO drum, 300 kg PENELOPE reel. Ø and 2.4 mm T 42 2 MM 2 H 10 E 70 C 3M H8 SAFDUAL 206A 18 kg coil and 230 kg ENDURO drum or 230 kg reel Ø and 1.6 mm T 3T Z MM 3 H 10 E 70 C GS SAFDUAL TGV 18 kg or 20 kg coil and 230 kg ENDURO drum, 170 kg PENELOPE reel. Ø et 2.4 mm stainless steels 304 T 19 9 L R M5 E 308 LT 0-4 SAFDUAL kg coil. Ø 1.2 and 1.6 mm Stainless T R M5 E 316 LT 0-4 SAFDUAL kg coil steels 316 Ø 1.2 and 1.6 mm * for double wire process use only metal cored wire (SAFDUAL serie 200 or TGV). Solid wires for welding aluminium and light alloys Grade to be Grade SAF name Packaging assembled of filler metal (homogeneous) as per AWS A ER 1100 NERTALIC 10 6 kg coil. Ø and 2.4 mm 3000 ER 4043 NERTALIC 15 6 kg coil. Ø 1.2 and 1.6 mm 5000 ER 5356 (5183) NERTALIC 30 (26) 6 kg coil. Ø and 1.6 mm 6000 ER 4043 NERTALIC 15 6 kg coil. Ø 1.2 and 1.6 mm Large volume packaging For automatic welding of non-alloy and low-alloy steels, the use of large volume packaging has several advantages that will help you to increase productivity: machines do not need to be stopped so frequently to change the wire coil (16 kg for coils, 200/250 kg for large volume packaging); the wire is cleaner because the packaging is protected against ambient dust; better wire feed, especially with ENDURO drums and PENELOPE reels, and therefore less risk of stoppage; wire impact point more accurate and repeatable SAF-03 14

15 Productivity through qualified services. QEOPS Service - Advice and testing Take advantage of our personnel's expertise, come and test our processes and equipment on the materials you actually work with PHENIX Service - Equipment upgrading With this service you can retrofit or upgrade your current facilities.a low-cost way of modernising your work tool. Training Our training teams are available to refresh your operators' skills, optimise the use of the equipment, prepare and qualify your operators.training can be carried out at your site or in an SAF centre. We can also supply a vast range of teaching material on welding-cutting technologies. Logistics You would like to optimise stock and procurement management of welding consumables, you are looking for supply continuity at the place where you use support products, accessories or wearing parts.we can propose "made-to-measure" solutions, already tested and successfully set up with other customers. SESAME - After-Sales Service Various arrangements are possible for repairing your facilities. Our after-sales team will put your equipment back in working order in the shortest possible time. ALLIANCE - Maintenance Contract ALLIANCE or PPM (programmed preventive maintenance) contracts are your insurance policy guaranteeing permanent use of your facilities at peak performance. Full Service Rental or Finance Leasing These solutions allow you to acquire high-performance equipment without capital expenditure. Very flexible terms are available with the possibility of including a maintenance contract. LOC'SAF Service - Equipment Rental Rental of welding-cutting equipment. Diversify your production for automatic applications without excessive machinery stock, test the equipment before purchasing it. CAP Productivity and CAP Partner Service - Auditing CAP Productivity and CAP Partner Service - Auditing You would like to optimise your manufacturing process and improve productivity. Our experts can "audit" your welding operations, calculate real costs and propose a global savings program.we can also inspect the safety level of your facilities. 15

16 Imagine what your performance could be SAF reserves itself the right to embody modifications without prior notice. The illustrations, descriptions and characteristics are given for information only and do not engage the responsibility of the constructor. SAF - 13, RUE D'EPLUCHES - SAINT-OUEN L'AUMÔNE CERGY-PONTOISE - CEDEX FRANCE TEL. : FAX : SAF WELDING PRODUCTS LTD - LOW MARCH LONDON ROAD - DAVENTRY - NORTHANTS NN 11 4 SD TEL. : TELEFAX : E mail : info.saf@airliquide.com Internet : DISTRIBUTOR S STAMP SAF S 01 Ed. 01 QB : 1789 Photos : François, JSR, Rocskay