Download - SAT™ Swift Arc Transfer - BCZ Vamberkbcz.vamberk.eu/cd-dst-2015/images/PDF-prednasky/002_Flikweert.pdf · TEST RESULT, SAT™ TANDEM ... FCAW 2.4mm FCAW 1.6HS /h Amperage. SAT DEPOSTION

Peter FlikweertTransport Segment Mobile Machinery

ESAB CZ Customer days

19/05/2015

SAT™ Swift Arc TransferIntroduction, AristoRod, Applications, Solutions

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

ARISTOROD™

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

SAT™ (SWIFT ARC TRANSFER)

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


SINGLE WIRE

APPLICATION EXAMPLES

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


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


NON SYNCHRONIZED SAT™

TANDEM

APPLICATION EXAMPLES

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


Plate thickness: 12 mm (not shop blasted before welding)

Weld size: a= 5,5 mm


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


Plate thickness: 12 mm (shop blasted before welding)

Weld size: a= 5.3 mm


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


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


EQUIPMENT


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

SAT™ AND LIGHT

MECHANIZATION

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

SAT™ AND ROBOTIC

MECHANIZATION

ESAB MIG/MAG

CONFIGURATIONS ROBOTS

Standard robotic welding solutions for all mayor robotic brands

ESAB SWIFT ARC TRANSFER (SAT™)

HTTP://WWW.ESAB.COM/ARISTOROD/EN/SAT-PROCESS.CFM

SAT video volgt later

Apart hoofdstuk

Ook in navigatie

beeldvullend

Thank you for your Attention

Download - SAT™ Swift Arc Transfer - BCZ Vamberkbcz.vamberk.eu/cd-dst-2015/images/PDF-prednasky/002_Flikweert.pdf · TEST RESULT, SAT™ TANDEM ... FCAW 2.4mm FCAW 1.6HS /h Amperage. SAT DEPOSTION

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