ESAB Aluminium Welding Wire Aluminium Welding with regard to Quality & Cost
Which is the most popular aluminium product in the world? Aluminium is recyclable ESAB, Michael Spieß, Produktmanager Aluminium, Europa
Aluminium is the most common metal on Earth 47% Oxygen 27% Silicon common elements in Earth's crust 8% 5% 4% Aluminum Iron Calcium Feldspar Mica Clay 3% Sodium 2% Potassium 2% Magnesium
Total demand of Aluminum In 1000 to 2005 2006 2007 2008 2009 Europe 11.500 12.000 12.700 12.400 9.300 Asia 15.900 17.900 21.800 22.500 23.300 Africa 400 500 500 700 800 America 12.300 13.000 12.500 11.400 9.900 Oceania 600 500 500 500 500 Total 40.700 43.900 48.000 47.500 43.800 Quelle: GDA
Aluminium Market Segments
Aluminium Alloy Groups 1XXX Pure Aluminium 2XXX Copper 3XXX Manganese 4XXX Silicon 5XXX Magnesium 6XXX Magnesium/Silicon 7XXX Zinc 8XXX Lithium Main Alloying Elements of the Alloy Group
Aluminium Alloy Types heat treatable e.g. AlCu6Mn (2219) AlMgSi0,5 (6060) AlZn4,5Mg1 (7020) Non heat treatable e.g. AlMg3 (5754) AlMg4,5Mn (5083) AlMn1 (3103) ESAB, Michael Spieß, Produktmanager Aluminium, Europa
Aluminium Material with a Future Aluminium is the most abundant metal in the Earths crust and the third most abundant Element Light weight, 1/3 of the weight of Steel Low Melt point of pure (660 C for Al 99,99) Very high thermal conductivity High corrosion resistant and weatherproof No loss of toughness by low temperature (face centered cubic lattice) High solubility of hydrogen in the liquid state Increase in Strength through alloy of Mg, Cu, Mn, Zn
Aluminium is a very ductile material Perfect for crash management systems Car and train elements that are designed to fold and collapse like an accordion in a crash are capable of absorbing up to twice the crash energy of steel Michael Spiess, Product management, Aluminium, Europe
Aluminium Consumption rising steadly
and Aluminium is WELDABLE employing methods, equipment and skills similar to those used for welding other materials
Aluminium Welding Process FSW - Friction-stir welding (FSW) is a solid-state joining process (meaning the metal is not melted during the process) and is used for applications where the original metal characteristics must remain unchanged as far as possible
Aluminium Welding Process MIG GMAW is the most common industrial welding process, preferred for its versatility, speed and the relative ease of adapting the process to robotic automation.
Aluminium Welding Process TIG Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc welding process that uses a non consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by a shielding gas (usually an inert gas such as argon), and a filler metal is normally used
Aluminium Welding Difficulties What are the biggest problems for welding of aluminium? - soft welding wire - feedability of the aluminium welding wire - (hot) cracks in aluminium - porosity in the weld - aluminium storage and handling - lack of fusion - wrong parameter settings - etc..
Welding Difficulties Causes and corrections Difficulty Causes Corrections Dirty Welds Improper gas coverage Dirty electrode Dirty base material Check for leaks in hoses, air drafts, loose fittings wrong gas Proper storage or contact supplier Remove oils and grease before other mechanical cleaning. Remove oxides using clean stainless steel brush. Unstable Arc Connections, dirt, or wind Check all conductive surfaces for clean ground. Remove dirt from weld joint. Eliminate drafts from weld area where shield gas can be disturbed. Penetration and Fusion Problem Wrong weld parameters Wrong wire diameter Dirty base material Wrong gas type Wrong joint preparation Dirty electrode Adjust more amperage for more penetration and mor voltage for more width. Smaller wire will penetrate more. Larger wire will fill more Clean weld area prior fit up. Remove oxide. Use only enough gas to create coverage. Verify gas for operation Thicker welds require U-Type joint versus V-type or square. Store electrode in warm, dry enviroment at all times to prevent corrosion (it s cheaper to buy it once).
Welding Difficulties Causes and corrections Difficulty Causes Corrections Porosity Hydrogen in the weld Check gas dew point (reject gas above 20 C. Check for Gas leaks and defective hose conditions. Store electrode properly. Remove oils, grease and other hydrocarbons from base material. Remove oxides within 24 hours of welding. Preheat base material up to 65 C. Do not use torches to preheat (hot air guns work best!). Check gas flow. Use larger wire if puddle is turbulent. Weld cracking Poor feeding Improper filler alloy Joint or edge preparation Poor crater fill Bird-nesting Arc hunting Liner Build-up Drive rolls Refer to filler selection chart. Reduce dilution (more filler less base material). Increase joint spacing or increase bevel angle. Fill crater completely through technique or system device. Reduce drive roll tension. Use slow run-in start system. Check all surfaces where wire touches and reduce metal on metal areas. Check contact tip condition. Check liner condition. Check drive roll condition. Check for proper contact tip I.D. Use a liner material hard enough that does not cut easily. Check for wire galling items. Check drive rolls for proper size, shape and surface finish.
Welding Difficulties Causes and corrections Difficulty Causes Corrections Poor Arc Starting Improper ground Contact tip size No shielding gas Check that all grounds are well made. Use slow run-in or hot start features to assist start. Check that contact tip is not oversized for alloy and diameter. Use pre-purge feature for gas shield (also post purge to prevent oxides from forming on end of wire). Change welding parameters.
Quality Criteria for Aluminium Welding Wire - raw material quality and purity - shaving technology - welding wire surface - quality and maintenance of the drawing dies - tolerance of the wire diameter! - cast and helix - final cleaning and coating Helix Cast
Wire Surface Quality Al 5356 1,2mm 200 times magnification insufficient shaved insufficient shaved
Wire Surface Quality Would you like such an aluminium welding wire in your production?
Fume Test ESAB Peak value 0,206 mg/m³ Total 0,804 mg/m³ Alloy: 4043 Diameter: 1,60 mm Manufacturer: ESAB Pulse current 420 A Pulse time: 582 ms Date : 02.10.2009 Results Peak value: 0,206 mg / m³ Total: 0,804 mg / m³ Peak value: 0,776 mg/m³ Total: 7,513 mg/m³ Peak Value: 0,568 mg/m³ Total: 3,245 mg/m³ ESAB, Michael Spieß, Produktmanager Aluminium, Europa
Errors from Usage of Aluminium Welding Wire Fume Test What does the measurement of the residues from smoke tell us? Storage or Usage How long can you store aluminium welding wire until it is used? Is it one week, three months, one year or? ESAB, Michael Spieß, Produktmanager Aluminium, Europa
How do we test the quality of aluminium welding wire? We test the aluminium welding wire according the AWS Code 5.10 ESAB, Michael Spieß, Produktmanager Aluminium, Europa
Increase productivity by 40 % at a rail road car manufacturer Wire diameter Ø 1,60 mm Ø 1,80 mm Ø 2,00 mm Customer Rail Rail Rail Part Main carrier Main carrier Main carrier Parent mat. 6005A 6005A 6005A Filler mat. ER5356 Ø 1,60 mm ESAB OK Autrod 5356 ESAB OK Autrod 5356 Travel speed 36 38 cm /min 42 cm / min. 49 cm / min. No. of beads 3 2 2
WPS
Cross section
Welding Cost Calculation
Applications A weld without PAK TRAK and OK Autrod 5183 d= 1,60 mm A weld with the PAK TRAK and OK Autrod 5183 d= 1,60 mm
New Development If you like to: - pay off the welding wire, out of big bulk packages - get straight welding seams - prevent tangled wire - prevent twists in bulk packages - have a stable arc during welding - avoid disruption during welding process - transport the wire over a long length, up to max. 60 m - use standard PA wire conduits
New application for long straight welding seams and long wire conduits
Results with the PPT applications
What is special about the ESAB Aluminium Welding wire? - ESAB has the most comprehensive product portfolio of welding consumables for treatable alloys and also for harden able alloys. - ESAB is the biggest manufacturer of aluminium welding wire in the market. ESAB is continuously working on new developments to help our customers increase their productivity. - the ESAB Marathon Pac is the best, most reliable and most environmentally friendly packaging system in the global market. - the ESAB aluminium wire electrode has a unique surface and surface coating. This ensures non porous welds and a very good feeding behavior in the wire conduit. - ESAB has a wide range of accessories for welding without disruption and transporting the wire over long distances for use with our aluminium Marathon Pac products. Michael Michael Spiess, Spiess, Product Productmanagement, management, Aluminium, Aluminium, Europe Europe
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