ESAB OK AristoRod welding wire

Transcription

1 ESAB OK AristoRod welding wire Ten arguments: Excellent feeding properties and very stable welding arc. Wide range of welding parameters, amperage to 400A with diameter 1,2mm. Excellent start and stop characterisation - very important for robotic applications. Excellent current transfer with minimum deflections. Welding fume contains very low copper volume. Consumption of contact tips with CO 2 shield is comparable with copper coated wires. Consumption of contact tips with Ar/CO 2 shield is comparable with copper coated wires. New design of spool with stronger construction and no need for use of adapter. Very high corrosion resistance of the wire. Simply the best global non-coppered welding wire available that has all the advantages of copper coated-but none of the disadvantages. TS BCZ, CDWD - PCZ

2 1. Excellent feeding properties and very stable welding arc The welding equipment: ESAB LUD 450W, Feed unit MEK 44C, PSF402W 4,5m steel wire conduit, contact tip - Binzell Cu-Zr. All wires were from spools. The gas flow for 1,0 of 12 l/min. The gas flow for 1,2 of 15 l/min. The conditions: a Mix gas Ar/20CO 2 without loop - the test time 30 min and with loop diam. 300mm the test time 30min (table 1. 3., b Pure CO 2 without loop - the test time 30 min and with loop diam. 300mm the test time 30min (table Table V, 160 A, 4m/min, g Ar/20CO 2 No loop Loop Feedability Dim. Avr. (N (N (m/s 2 Avr. (m/s 2 Feedability Avr. (N (N (m/s 2 AristoRod 1,0 mm ,5 AristoRod 1,2 mm , OK Autrod ,0 mm , OK Autrod ,2 mm OK Autrod ,0 mm ,5 OK Autrod ,2 mm Feed test at short arc transfer with mixed gas. Avr. (m/s V, 260 A, 9 m/min Ar/20CO 2 No loop Loop Feedability Dim. Avr. (N (N (m/s 2 Avr. (m/s 2 Feedability Avr. (N (N (m/s 2 AristoRod 1,0 mm , AristoRod 1,2 mm OK Autrod ,0 mm OK Autrod ,2 mm OK Autrod ,0 mm ,5 OK Autrod ,2 mm Feed test at globular transfer and mixed gas. Avr. (m/s 2.

3 35 V, 340 A, 12 m/min Ar/20CO 2 No loop Loop Feedability Dim. Avr. (N (N (m/s 2 Avr. (m/s 2 Feedability Avr. (N (N (m/s 2 AristoRod 1,0 mm , AristoRod 1,2 mm OK Autrod ,0 mm OK Autrod ,2 mm OK Autrod ,0 mm OK Autrod ,2 mm Feed test at spray arc transfer with mixed gas. Avr. (m/s 2. Table V, 160 A, 4m/min CO 2 No loop Loop Feedability Dim. Avr. (N (N (m/s 2 Avr. (m/s 2 Feedability Avr. (N (N (m/s 2 AristoRod 1,0 mm AristoRod 1,2 mm OK Autrod ,0 mm OK Autrod ,2 mm OK Autrod ,0 mm OK Autrod ,2 mm Feed test at short arc transfer with pure CO 2. Avr. (m/s V, 260 A, 9 m/min CO 2 No loop Loop Feedability Dim. Avr. (N (N (m/s 2 Avr. (m/s 2 Feedability Avr. (N (N (m/s 2 AristoRod 1,0 mm AristoRod 1,2 mm OK Autrod ,0 mm OK Autrod ,2 mm OK Autrod ,0 mm OK Autrod ,2 mm Feed feed test at globular transfer with pure CO 2. Avr. (m/s V, 340 A, 12 m/min CO 2 No loop Loop Feedability Dim. Avr. (N (N (m/s 2 Avr. (m/s 2 Feedability Avr. (N (N (m/s 2 AristoRod 1,0 mm AristoRod 1,2 mm OK Autrod ,0 mm OK Autrod ,2 mm OK Autrod ,0 mm OK Autrod ,2 mm Feed test at long arc transfer with pure CO 2. Avr. (m/s 2.

4 The comparison Feed force and s for bare and copper coated wires OK Autrod OK Autrod OK Autrod OK Autrod AristoRod Spray Arc s Spray Arc Feed Force Globular Arc s Globular Arc Feed Force Short Arc s Short Arc Feed Force AristoRod The time behaviour of the tests Feed force (N blue chart (1 red chart

5 2. Wide range of welding parameters, amperage to 400A with diameter 1,0 and 1,2mm The welding equipment: Aristomig 400, Aristofeed 48, Binzell torch and Binzell Cu-Zr contact tip. The mixed gas (80Ar/20CO 2 and a gas flow of 15 l/min. All welding was performed in position PB. Spray Arc Start Dim. Wfs (m/min I (A U (V Remark AristoRod 1,0 mm 10, ,5 Highest start parameters AristoRod 1,2 mm 7, ,5 OK Autrod ,0 mm 9, ,7 OK Autrod ,2 mm 7, ,2 OK Autrod ,0 mm 9, OK Autrod ,2 mm 7, ,7 Spray Arc Start Optimal Spray Arc Dim. Wfs (m/min I (A U (V Remark AristoRod 1,0 mm AristoRod 1,2 mm ,7 OK Autrod ,0 mm 13, OK Autrod ,2 mm OK Autrod ,0 mm 13, OK Autrod ,2 mm ,2 Optimal Spray Arc Highest Possible Arc Start Dim. Wfs (m/min I (A U (V Remark AristoRod 1,0 mm ,7 AristoRod 1,2 mm ,5 OK Autrod ,0 mm OK Autrod ,2 mm ,2 OK Autrod ,0 mm ,5 Silicates on the. below this setting no arc pressure. Max machine wfs still good feedability. Max machine amp still good feedability. Some small silica islands Max machine wfs still good feedability. Max machine amp still good feedability. Max machine wfs poor feedability (pumping OK Autrod ,2 mm ,5 Max machine amp poor feedability Highest Possible Arc Start The major difference between the tested wires at spray arc transfer is the feeding properties at really high wire feed speeds or amperages. The copper coated wires tend to start pumping at really high parameters meanwhile the bare wire maintain stable.

6 3. Excellent start and stop characterisation - very important for robotic applications The welding equipment: ABB irb1400 Arcitec robot with standard torch and contact tips (Dinse, the gas used was 80%Ar/20%Co2, and welding on DC+. For all the tests a standard synergic setting was used, without any special start or stop data like craterfill etc. For the 1,0mm wires For the 1,2mm wires Travelling speed = 72 cm/min Travelling speed = 90 cm/min Wfs = 12,0 m/min Wfs = 11,0 m/min Voltage = 31,0 V Voltage = 31,0 V Burn back = 0,18 sec Burn back = 0,18 sec Dynamic = 80% Dynamic = 85% Final pulse = 60% Final pulse = 60% Stick-out = 15mm Stick-out = 15mm Repeated start and stop performed on a plate.

7 A close up of the picture above. All the wires where able to conduct 120 start and stops without interruption. They all gave quite a lot of starting spatter. With a final pulse synergic setting of 60% (standard for the ABB robot some wires still had a big droplet or bullet at the wire end after completed welding. The 1,2mm gave a slightly smaller droplet. From experience, a big droplet equals poor starting features. It is the impression that the influence of the power source has a larger importance to this test than the wires examined. A less professional power source will probably give a more pronounced result.

8 4. Excellent current transfer with minimum deflections The current transfer of the wires was measured in Vamberk using an equipment called LOLA. A pick-up is slide along the wire surface and a current is passed through the wire and the resistance is recorded. The average voltage drop (mv is measured together with the voltage drop standard deviation. See the result charts below. All the 1,2 mm wires among the investigated wires where tested. AristoRod Less resistance between the wire and tip equals stable arc at high amperages. OK Autrod The same wire, but AristoRod surface treated. As can be observed from the results above, there are differences between the bare and copper coated wires. In general the copper coated wires gives less contact resistance due to the copper. In this case the obtains 277 mv meanwhile the standard obtains 403 mv and the New AristoRod 360 mv. The standard deviation goes more or less hand in hand with the voltage drop and becomes lower for the copper coated wire and higher for the bare. Even though the bare wire does not match the current transfer of a copper coated wire, the AristoRod has been much improved from its predecessor. See also the result below: The middle part of this wire sample examined has been treated in accordance with the AristoRod manufacturing process. As can be seen the voltage drop drastically goes down and becomes more stable, which gives a lower standard deviation. Especially the SD when it become stable reveals the consistency of the surface coating and if the surface coating is consistent the arc becomes stable.

9 5. Welding fume contains very low copper volume The welding equipment: ESAB LAW 500 on DC+. The voltage and current used are presented in the table below. The test was carried out with both a mixed Ar/CO 2 gas (80/20 and with pure CO 2. % wt Dim. Gas I (A U (V Fe Mn Pb Cu Ni Cr AristoRod 1,2 mm 80/ ,7 57 8,5 0,02 0,14 <0,01 0,03 AristoRod 1,2 mm CO ,5 53 9,6 0,02 0,18 <0,01 0,03 OK Autrod ,2 mm 80/ ,1 0,02 0,26 <0,01 0,07 OK Autrod ,2 mm CO ,3 0,03 0,25 <0,01 0,06 OK Autrod ,2 mm 80/ ,9 0,03 0,55 <0,01 0,06 OK Autrod ,2 mm CO , ,02 0,50 <0,01 0,07 Fume analysis. All results are given in %. Cu-content in the welding fume (wt% 0,6 Mix gas CO 2 0,5 0,4 0,3 0,2 Mix gas CO 2 Mix gas CO 2 0,1 0 AristoRod AristoRod OK Autrod OK Autrod OK Autrod OK Autrod The only obvious difference between the fume results was the level of copper. The copper is one of the elements in the welding fume that is highly detrimental to the health and should be kept as low as possible.

10 6. 7. Consumption of contact tips with CO 2 and Ar/20CO 2 shield is comparable with copper coated wires The welding equipment: ESAB LUD 450W, Feed unit MEK 44C, PSF402W 4,5m steel wire conduit, contact tip - Binzell Cu-Zr. All wires were from spools. The gas flow for 1,0 of 12 l/min. The gas flow for 1,2 of 15 l/min. The feedability test in Vamberk was combined with a tip wear study. One hour of welding was carried out and approximately 6-7 kg of wire was used. The tips were cleaned and weighed before the welding. After finalised the test period the tips were cleaned again in weak acid and alcohol to remove spatter and other residuals from the welding and wires. Finally the tips were weighed again and that result was subtracted from the first result, which gives the tip wear per hour. Diam Ar/CO 2 CO 2 AristoRod 1,0 mm 5,9 4,8 AristoRod 1,2 mm 6,9 6,2 OK Autrod ,0 mm 16,5 10,8 OK Autrod ,2 mm 21,7 16,6 OK Autrod ,0 mm 5,1 8,9 OK Autrod ,2 mm 1,7 12,0 All results are given in mg/h Ar/CO2 CO2 5 0 AristoRod AristoRod OK Autrod OK Autrod OK Autrod OK Autrod The tip wear have been reduced with about half compared with the regular OK Autrod and is on the same level as the copper coated wires, with one or two milligrams advantage still for the copper coated wires when welding with mixed gas. However, when changing to pure CO 2 the tip wear for the AristoRod is even below the results with the OK Autrod

11 8. New design of spool with stronger construction and no need for use of adapter 8 Spokes = Rigid Side Wall Assists Wire Feed No Plastic Adaptor needed Successful introduction of Stainless Steel and Aluminium MIG wires in Customer Benefits : No Plastic Inserts / Quick change over 18kg on 1.0mm & 1.2mm / Fewer changes Rigid Side Wall Construction / Assists Feeding Plastic Spools / Landfill costs Adaptorless Baskets / Reusable Resource The type of spool BS 300

12 9. Very high corrosion resistance of the wire Small coils of the wire are prepared and placed in an exicator with water on the bottom. The relative humidity in the vessel reaches about 84% at 24 C. The wires are checked every second day for corrosion. A final evaluation is made after 10 days. The result of this test gave the following: Dim. Comment AristoRod 1,0 mm No visible corrosion after 10 days AristoRod 1,2 mm No visible corrosion after 10 days OK Autrod ,0 mm No visible corrosion after 10 days OK Autrod ,2 mm No visible corrosion after 10 days OK Autrod ,0 mm No visible corrosion after 10 days OK Autrod ,2 mm No visible corrosion after 10 days Corrosion test AristoRod OK Autrod OK Autrod 12.51