2011- Submerged arc welding catalogue

Transcription

1 2011- Submerged arc welding catalogue

2 LULEÅ OSLO STOCKHOLM HELSINKI TALLINN CLOSE TO EVERYTHING AND EVERYONE. ALINGSÅS RIGA COPENHAGEN MALMÖ

3 IT IS YOUR WELD THAT COUNTS LET US HELP YOU OFF FROM THE THIN ICE The secret of our success is your success! Bayrock company slogan states it is your weld that counts, and our customers have welding as part of their business. Our business is to help you to become better in welding, and to improve and optimize your welds and welding work. If we are not able to increase your profitability, you are not able to pay us. Simple as that. Environment, ergonomics and economics - the 3E - are shaping modern welding work. It is not easy - especially for smaller and mid-sized companies - to keep in pace with development of joining technologies, new welding standards, process development or even to follow market trends and activities. Welding is too often seen just as something that needs to be done and nothing else. And that is where you are hiding a lot of savings and earnings potential. Get your welding KPI s in place and release the potential. Core business of Bayrock is sales and rental of equipment for mechanised sub-merged arcwelding. Submerged arc welding represents 5-8% of the total welding market and is used primarily in joining of materials thicker than 8 mm. Shipyards, pressurevessels, windtowers, bridges, construction beams for buildings are typical application areas for this process. In order to lower the threshold to start utilizing SAW process, AB Bayrock has in collaboration with a major Chinese welding equipment manufacturer introduced a modern inverter sub-arc welder to the market. Now it is no more question of investment, but of willingness to work better. AB Bayrock has a vision to make it profitable to weld in Europe. If your company is welding today, but not so sure about tomorrow - take contact with us now. Let s have a look together if there is money hidden in your welding production. AB Bayrock was founded 2010 and has its site in Alingsås, Sweden. the 3E Environment, ergonomics economics -

4 THINK ENVIRONMENT THINK SAW Submerged arc welding (SAW) has been used since 1930 s as part of productive welding production. It represents approximately 5-8% of total welding market and is mainly used in heavy-duty applications with thick materials. That is area where you can get most out of the process, but it is not uncommon to see submerged arc welding in joining of 3-4 mm thick materials either, where high power can be transferred to higher welding speeds and lower distortions. Recent developments in electronics and control technology have given new birth to efficient use of this ergonomic and environmentally sound process. ADVANTAGES OF SUBMERGED ARC WELDING Deposition rates of 6-8 kg/h are typical in mechanised SAW applications. This equals roughly to manual metal arc welders working days output! In applications where amount of deposited weld metal is the key, investment will have short payback time. Submerged arc welds have deep penetration and homogenous, robust structure. Due to welding currents higher than those in manual arc welding, welds will have deeper penetration profile allowing for smaller throat sizes and in some cases use of thinner materials without reduction in structural strength. Heavier welding gives lighter structures. One-sided single pass weld can be reliably done up to 10 mm material thickness. Welding arc burns under flux bed. Therefore there is no visible light from the weld, very little fumes present, and no spatter. Also noise level is very low contributing to SAW being very ergonomic and environmentally sound choice for welding process. Healthy welder is profitable for business! Modern inverter technology is energy efficient and used power is effectively used for melting the wire and flux. Almost 100% of the generated heat is utilised in melting of parent material, wire and flux and very little energy is wasted. Additionally, unused flux can be re-used! What you hear during welding is a low humming sound of the air-cooling fans in the powersource placed some ten meters away from the welding location. Noise level during welding operation is low and you can effortlessly have conversation in normal voice when welding.

5 THINK ENVIRONMENT THINK PANDAWELD R Pandaweld is a product that is developed to address the needs of the industry: Increased welding economics and improved quality. Pandaweld combines modern technology with robust functionality that contributes to ease of use and allows operators to focus on the essential: The weld. The heart of Pandaweld is IGBT inverter providing stable, well-controlled welding current up to 1250 This allows increases in productivity and welding quality at minimal efforts. A lot of complexity and hence cost has been reduced in the equipment in order to make submerged arc welding process easier to adopt in industry of any size. Mechanization of welding process should not be privilege of big companies only! That has been the guiding principle in putting the product together, and it is continuously improved based on user input and experience. This product is for welders! Pandaweld welding package consists of power source and welding trolley with embedded control unit. Equipment can be used for welding with either constant current (CC) or constant voltage (CV), depending on application requirements. Pandaweld is suitable even for stick-electrode welding and arc-gouging. This makes it possible to use same equipment for tack-welding, rootopening and filling of the joint. Reduced investment costs to equipment contribute to profitability. Wellding of heavy-duty beams is a perfect job for Pandaweld. Printed with permission from Levator Oy, Finland

6 PANDAWELD PRODUCTS POWER PACKAGE Pandaweld 1250 is a powerful machine for demanding welding applications. It delivers 1250A of welding current at 60% duty cycle making it strong enough for twin-wire welding and even for coarse wire diameters of Ø5 and Ø6 mm. In high-duty cycle applications like multipass welding of vessels, or in cladding applications Pandaweld will be your tool for higher productivity. Let Pandaweld melt 5 mm wire instead of Ø4 mm and you have opened potential for 50% increase in hourly melt-rate. This is possible with powerful, yet compact, welding powersource. Pandaweld 1250 is easily converted to stick-electrode welding or arc gouging if needed. This reduces the number of machines you need to have in your workshop. A true multi-talent this Pandaweld is SMALL AND CAPABLE Pandaweld 630 is so compact that you probably want to take it home after your work-day is over. Powersource consists of one powerful inverter-block that delivers 500A of welding current at 100% duty cycle. This is enough for many submerged applications where Ø3 mm wires are used. For short fillet- and butt welds this can be the right machine for you. 63A fuse requirement for mains power makes it possible to use the machine almost anywhere, and wheels under the 60 kg powersource makes it unnecessary to use cranes or forklifts to move the machine around in the factory. Just like its big brother, Pandaweld 630 can also be used for stick electrode welding.

7 ACCESSORIES FOR YOUR PANDAWELD R T R O LL E Y THE TRANSPORTER With good tools you truly open the possibilities in your submerged arc welding. A robust trolley in cast steel body and wirefeeder body in cast aluminium are made to last. Accurate control and adjustment of both travel speed and wirefeed speed are basic elements when taking steps towards mechanised welding production. Wire feed speed is from between 0,3 and 3 m/min, depending on the application. Travelspeed on Pandaweld trolley can be adjusted freely between 0,2 and 2,2 m/min which makes it possible to use high welding speeds on thinner materials where submerged arc welding can be a good alternative to MIG/MAG welding. In industrial environment it is important that the tools you use are robust and reliable. That is why Pandaweld is using steel rims for wirespools or for bands. Springloaded arms are adjustable to various spool widths making the wire rim suitable for most wire spools available in the market. Welding torch in Pandaweld trolley uses contact tips similar to those used in MIG/MAG welding. Changing the tip reqularly guarantees uninterrupted flow of welding current and secures good weld. Tips are available for Ø3.0, Ø4.0, Ø5.0 and Ø6,0 wires. Double wirefeed rolls provide a good grip at the wire and enable quick automatic adjustment of wirefeed speed during welding. One set covers two wire diameters reducing additional work between wire changes. Air-operated fluxrecovery system is a standard in feature in Pandaweld trolley, but there may be need to upgrade your other stations with this robust steel bodied equipment. System requires 4 bars of pressure for proper operation.

8 IT IS YOUR WELD THAT COUNTS Bayrock submerged arc projects for windtower production cells, bridge and construction beam manufacturing, pressurevessel fabrication, welding of road and rail transport equipment frames and components, dry-docks ans shipyard on-site welding, production of offshore platforms and monopiles, manufacturing of rectangular steelframes and beams for buildings and support structures, construction of lifting and loading cranes and machinery, mechanized solutions for pipe and pipelines welding, and cladding, surfacing and hardfacing solutions. TAKE CONTACT TODAY IT IS YOUR WELD THAT COUNTS. Göteborgsvägen 16, Alingsås Tel. +46 (0)