sat™ swift arc transfer - bcz...
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Peter FlikweertTransport Segment Mobile Machinery
ESAB CZ Customer days
19/05/2015
SAT™ Swift Arc TransferIntroduction, AristoRod, Applications, Solutions
Slide 2
Key
Account/
Segment
Managers
Local
Regions
Johan Elvander
Global Solutions
Alex Jirofle
Transport Segment
Manager
Gary Powell
Nickel based
Ken Konopa
Vice President
Dick Skarin
Global welding
applications group
Value Engineering
Daniella
Kasnecovic
Project Manager
Value Sell
TBA
Applications manager
Dennis Byrulin
Nuclear
Jens Ericsson
Senior Strategy
Analyst & Program
Manager
Anders Lindh
Director Of
Strategy
Peter Flikweert
Mobile Machinery
Tamas Sandor
Railcar/Rolling stock
TBA
Wind towers
Marcel Stemvers
Energy Segment
LNG
Lars Campbell
Global Product
Planner (VOC)
GLOBAL SOLUTIONS GROUP
Gordon Eadie
Pipelines
Cristiano Ferreira
Global Product
Planner (VOC)
Jose Roberto
Dominques
Shipbuilding and
OffShore
Transport Segment
Energy Segment
Shipbuilding & Offshore Segment
Strategy Team
Value Engineering Team
BENEFITSRESEARCH DATAOK ARISTOROD RANGE
• OK AristoRod™ is a family of
non copper-coated MAG wires
• Superior welding characteristics
for robotic, mechanised and
manual welding
OK AristoRod™ GMAW wires
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
Slide 8
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
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
ARC MODES AND WORKING
AREAS
Short Arc Globular Arc Spray Arc SAT™
Conventional
welding
15m/min
wfs
Unconventional
welding
Vo
lta
ge
WFS
PENETRATION THICK PLATE
SINGLE WIRE
▌ Heat input▌ Advantages ▌ Applications▌ Penetration ▌ Process requirements ▌ Recommendations ▌ Parameters▌ Arc type
Wire diameter (mm)
I (A) 210 260 316
Wfs (m/min) 20 20 20
Travel speed (cm/min) 75 95 125
Stickout (mm) 19 19 20
Plate thickness (mm) 10 10 10
Penetration profile
• Standing fillet weld a=3
• Shielding gas: 92%Ar/8% CO2
0.9mm 1.0mm
Good penetration with all wire diameters
0.8mm
PENETRATION THIN PLATE
SINGLE WIRE
Penetration profile
• Overlap joint/2mm plate
• Wire diameter 0.9mm
• Shielding gas: 92%Ar/8% CO2
▌ Heat input▌ Advantages ▌ Applications▌ Penetration ▌ Process requirements ▌ Recommendations ▌ Parameters▌ Arc type
Wire diameter (mm) 0.9 0.9
I (A) 266 236
Wfs m/min 25 20
Travel speed (cm/min) 155 140
Stickout (mm) 18 18
Plate thickness (mm) 2 2
Macro number 21 22
TEST EXAMPLE SAT SINGLE WIRE
Plate thickness: 12 mm (shop blasted before welding)
Weld size: a=5.5mm
Welding Speed: 7mm/sec or 42 cm/min
Wire Feed Speed: 20m/min
Welding parameters: 350A 31V
Net Deposition Rate: 7 kg/h
AristoRod 12.63 - 1,0 mm, in PB position
TEST RESULT, SAT™ TANDEM
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
Net Deposition Rate: 13 kg/h
AristoRod™ 12.63 - 1,0 mm x 2 in PB position
TEST RESULT, SAT™ TANDEM
Plate thickness: 12 mm (not shop blasted before welding)
Weld size: a= 5,5 mm
Welding Speed: 15 mm/sec or 90 cm/min
Wire Feed Speed: Wire 1: 22 m/min, Wire 2: 22 m/min
Welding parameters: Wire 1: 320A 28V, Wire 2: 320A 33V
Net Deposition Rate: 15,5 kg/h
AristoRod ™ 12.63 - 1,0 mm x 2 in PB position
TEST RESULT, SAT™ TANDEM
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
Net Deposition Rate: 18,7 kg/h
AristoRod™ 12.63 - 1,2 mm x 2 in PB position
CURRENT DENSITY
▌ Heat input▌ Advantages ▌ Applications▌ Penetration ▌ Process requirements ▌ Recommendations ▌ Depositionrate▌ Arc type
Diameter (mm) 0.8 0.9 1.0 1.2
Wfs 25 20 16 11
A 220 230 240 330
Wire diameter vs. deposition rate
Wfs 32 25 20 14
A 260 270 300 400
Wfs 35 27 22 15
A 255 285 330 450
Wfs 30 25 17
A 350 375 500 High Hi
5.9Kg/h
7.4Kg/h
8.1Kg/h
9.2Kg/h
DEPOSITION RATES FOR
DIFFERENT MIG/MAG
WIRES
0
2
4
6
8
10
12
14
16
0 100 200 300 400 500 600 700 800
AristoRod 0.9
AristoRod 1.0
AristoRod 1.2
MCW LS 1.2
FCAW 2.4mm
FCAW 1.6HS
Kg/h
Amperage
SAT DEPOSTION RATE
OVERVIEW
AristoRod 12.50 1.0mm
WfsM/min Amp Volt g/h
AristoRod 12.50 1.2mm
Wfs Amp Volt g/h
Stickout=20mm
4.4 100 17 1543
7 150 19.2 2571
10.6 200 22.5 3900
14.5 250 29.2 5250
18.7 300 32.7 6821
24.5 350 37 8880
32 400 39 11760
Stickout=20mm
4.2 150 17.5 2127
6.1 200 19 3130
8.6 250 23 4539
10.8 300 30 5635
13.5 350 33.5 7200
15.6 400 36 8147
Stickout=20mm
3.7 250 19.2 3462
4.7 300 27.5 4320
5.7 350 31 5328
6.8 400 33 6400
7.7 450 34.7 7200
AristoRod 12.501.6mm
Wfs Amp Volt g/h
(I²R)
400A 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!!
APPLICATIONS
SAT™ for industrial applications:
– Transportation segment
– General steel fabrication
– Bridge building, beams construction
– Tank- and vessel building
– Container- and equipment construction
Crane parts »
I-profiles »
Beams »
Road Compactors »
Compressor tanks »
Cranes »
▌ Heat input▌ Advantages ▌ End▌ Penetration ▌ Process requirements ▌ Recommendations ▌ Parameters▌ Arc type
Exhausts »
Tractor frames »
Tow bar frames »
CE Parts 1 »
CE Parts 2 »
SAT™ Process is especially suited for:
Mechanised- and robotic applications
Exhausts manifolds »
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
▌ Heat input▌ Advantages ▌ Applications▌ Penetration ▌ Process requirements ▌ Recommendations ▌ Parameters▌ Arc type
Equipment
– Aristomig 5000i,
– Aristomig 4004i Pulse
– Origo™ Mig 4002/5002/6502,
– Origo™ Mig4004i/5004i
– The Robofeed 3004w (HW) ELP encapsulated wire feeder
– The Aristo U82 and/or W82 control
PROCESS REQUIREMENTS
EQUIPMENT
▌ Heat input▌ Advantages ▌ Applications▌ Penetration ▌ Process requirements ▌ Recommendations ▌ Parameters▌ Arc type
PROCES REQUIREMENTS
(ROBOTIC) TORCHES
ESAB Aristo® Tandem – RT22 & RT 20
For double wire applications
ESAB Aristo® RT Infiniturn – for hollow
wrist robots
ESAB Aristo® RT standard
Slide 44
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
ESAB SWIFT ARC TRANSFER (SAT™)
HTTP://WWW.ESAB.COM/ARISTOROD/EN/SAT-PROCESS.CFM
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