NoN copper-coated solid gmaw wires with advaNced surface characteristics

Ok AristoRod™ Non-Copper-Coated Wire Welder Guidebook

2

Visit the oK aristorod microsite and learn why OK AristoRod wires bring

trouble-free, high productivity welding in robotic, mechanized, or manual operation

supported by unique video animation in 24 languages, scientific data and high

speed arc recording. Discover the quality and productivity benefits in detail and

review the full range of wire types for non- and low-alloyed steels.

www.esabna.com/aristorod

contents

introduction 2

Before You start welding 3

• ContactTipsandGasNozzle 3

• Liners 4

• GasandWater 4

• WireFeedUnit 4

• MarathonPac™Installation 5

• CheckDriveRollsandWireFeeding 7

• ShieldingGas 8

contact tip and gas Nozzle 9

• CorrectStick-OutLength 9

• GasNozzleDiameter 10

welding parameter setting 11

• HowtoGetanOptimumSetting 11

oK aristorod™ - the complete range 13

esaB swift arc transfer™ 14

3

introduction

OK AristoRod is a family of non copper-coated GMAW wires with superior welding

performance. The unique Advanced Surface Characteristics (ASC) increase

performance and efficiency, whether the process is manual, mechanized,

or robotic, helping reduce overall welding costs.

OK AristoRod non-copper-coated wires do not contaminate wire feeders, liners,

torches and contact tips with copper particles. This results in trouble free feeding,

high process stability, reduced consumption of wear parts, and superior welding

properties.

The unique features of OK AristoRod translate into clear user benefits which,

together, add up to increased productivity and lower welding costs.

To get the most benefit from using OK AristoRod welding wires, there are some

important steps to keep in mind, in particular compared to using copper-coated

wires. This guide provides practical step-by-step information on how to install and

use OK AristoRod non-copper-coated solid wires.

feature Benefit

Consistent welding performance Consistent weld results

Stable arc with low feeding forceHigh weld quality and reduced rework or post weld

cleaning

Excellent arc ignition Reduced post weld cleaning

High current operability Higher productivity

Extremely low spatter level Reduced post weld cleaning

Trouble-free feedability, even at high wire feed speeds and long feed distances

Higher productivity, reduced equipment downtime

Low fume emission Cleaner working environment

4

Before You start welding

To fully benefit from the excellent weldability of OK AristoRod GMAW wires, the welding equipment needs to be maintained in good condition. The following checklist serves as a guide.

contact tips and gas Nozzle

•Remove spatter and replace worn or

damaged contact tip.

•For the best welding performance and

longest tip life, ESAB contact tips are

recommended for use with

OK AristoRod wires.

•Grind the end of the liner conical for

optimal fitting of the contact tip.

•Ensure that the contact tip is the correct

size and fits tightly.

•Ensure the gas nozzle is free from

spatter.

correct incorrect

For contact tip sizes and packages, please contact ESAB or your local Distributor.

5

Before You start welding

liners

•Spiral steel liners are recommended.

•Never use liners which have been used for copper-coated wires. Copper residuals may stick onto the OK AristoRod wire and deteriorate its excellent wire feeding.

•Ensure that the liner has the correct inner diameter for the wire size to be used.

•Check liners regularly for kinks and excessive wear and replace when needed.

•Clean liners regularly using compressed air, removing the contact tip first.

gas and water

•Check gas and water connections for leaks.

•Check that the water cooler is filled and that the pump is operating effectively.

wire feed unit

•Position wire guide tubes as close as possible to the rollers to prevent kinking

of the wire.

•A substantial amount of fine metallic

shavings underneath the drive rolls

indicates misalignment.

Correct

Incorrect

6

Special cone for Jumbo Marathon Pac with 1050 lbs (475 kg) non- or low-alloyed wire.

ESAB's Marathon Pac is the most

advanced bulk wire packaging system

available to fabricators. The complete

Marathon Pac family consists of

(from left to right):

•Endless Marathon Pac

•Mini Marathon Pac

•Standard Marathon Pac

•Jumbo Marathon Pac

Before You start welding

The Marathon Pac is accompanied by

a full range of accessories for efficient

internal transport and handling and easy

installation.

Always make sure ESAB original

Marathon Pac accessories* are used

for best performance.

*For a complete list of Marathon Pac accessories, contact ESAB.

Use the Marathon Pac lifting yoke to handle the drum safely and to avoid damage to the drum or wire.

marathon pac installation

7

Step 6. Attach the wire conduit to the wire feeder. Avoid liner bends or point pressure on the liner.

Step 1. Remove the rubber strap and VCI paper.

Step 4. Place the carton or plastic lid (Standard and Mini Marathon Pac) or cone (Jumbo Marathon Pac) on top of the Marathon Pac.

Step 2. Place the wire conduit attachment or “spider” on top of the Marathon Pac.

Step 5. Attach the wire conduit to the lid or cone with the quick connector.

Step 3. Feed the welding wire through the centre of the spider.

Before You start welding

marathon pac installation

8

check drive rolls and wire feeding

•Use drive rolls with smooth, double

V-grooves. U-shaped grooves or knurled

rolls may damage the welding wire

surface.

•Check that the groove size is correct for

the wire diameter.

•Apply the correct pressure on feed rolls.

Too much pressure flattens the wire,

resulting in feeding problems and higher

liner and contact tip wear. Insufficient

pressure may cause wire to slip in the

feed rolls, resulting in irregular feeding

and possible wire burnback.

•A good approach is to set the roll

pressure so it is possible to stop a bent

wire at the gas nozzle by applying light

pressure.

•Check that the wire is feeding correctly

from the contact tip.

•Never use felt pads or liquids to clean

the wire surface. This may damage

the advanced surface condition of

OK AristoRod wires.

Before You start welding

Smooth Knurled

9

shielding gas

•Check that the appropriate gas is used.

Adjust gas flow rate to between 0.5-0.7

cfm (15-20 l/min) or according to gas

nozzle size.

•Check the gas flow rate again if the gas

nozzle diameter is changed. Always

check the gas flow on the gas nozzle

as well.

Before You start welding

10

contact tip and gas Nozzle

It is essential to fit the gas nozzle and

contact tip at the right distance relative

to each other. The ideal distance of the

contact tip is 0.080 in. (2 mm) recessed.

A longer distance will force the welder to

use too long a stick-out, resulting in poor

weldability. This may lead to lack of fusion,

particularly in narrow joints. Contact tips

protruding beyond the gas nozzle can

result in insufficient gas shielding.

correct stick-out length

The stick-out is the distance between the

contact tip and workpiece and must be

kept between 1/2 in. and 3/4 in. (12 and

20 mm ) ø 0.040 in. and 0.047 in. (ø 1.0

and 1.2 mm). Excessive stick-out results

in too short an arc length, larger droplets,

an unstable arc and spatter leading to poor

weldability. Additionally, it may reduce the

gas protection which can lead to porosity.

When welding in spray arc with too short of

a stick-out, the arc length can become too

long. The weldpool will get hotter and more

difficult to control.

Incorrect. Contact tip too recessed.

Incorrect. Contact tip protruding beyond gas nozzle.

2 mm

Correct positioning of contact tip.

1/2 - 3/4 in. (12-20 mm)

Ideal stick-out for wire diameters 0.040 and 0.047 in. (1.0 and 1.2 mm.).

11

contact tip and gas Nozzle

gas Nozzle diameter

Various nozzle diameters must be available

to allow adequate access to the joint, to

maintain the above recommended stick-

out, and to ensure proper shielding gas

protection. Small diameter gas nozzles

are used for the first layers only. Revert to

the standard gas nozzle diameter when

access to the weld joint allows, so full

gas protection can be assured.

Incorrect. Use of standard gas nozzle restricts access to narrow joints, resulting in too long a stick-out.

Correct. Use a smaller diameter nozzle or a conical nozzle for the 1st layers in the root area.

Correct. Use of standard gas nozzle for completing the joint ensures good gas protection and correct stick-out.

When welding in short arc transfer, the arc stability and start properties will improve

when reducing the stick-out.

1/2 - 3/4 in. (12-20 mm)

> 3/4 in. (> 20 mm)

12

Incorrect. Arc length too long. Arc becomes too wide, with insufficient penetration. Also a risk of burnback to the contact tip. This may be caused by the arc voltage being too high, the wire feed speed too low or the stick-out being too short.

Use positive polarity for OK AristoRod

solid welding wires. A given welding current

requires a specific arc voltage for optimum

weldability. The welding current is set by

adjusting the wire feed speed control. The

arc voltage is regulated by the open circuit

voltage (OCV) setting of the power source.

how to get an optimum setting

For the following procedure, it is critically

important to keep the stick-out constant

within the correct range for each welding

position.

•Select a welding current which suits your

application from the graph on page 12.

•Start welding with the lowest voltage

value from the given range. This may

result in stubbing, however wire

burnback will be avoided.

• Increase the arc voltage in steps of 1

or 2 V until the arc becomes stable,

smooth and spatter free, with a slightly

crackling sound. Ensure the correct

stick-out length is maintained.

welding parameter setting

Correct. Correct arc length. Stable and concentrated arc with a quiet spray droplet transfer.

Incorrect. Arc length too short. Wire dips into weld pool (stubbing) caused by too low an arc voltage, too high a wire speed or too long of a stick-out.

13

welding parameter setting

Note: As mentioned, stick-out control is very important. If the recommended

stick-out length is not constantly maintained, weldability will fluctuate. Shortening

the stick-out will result in an increasing current and a longer arc. Lengthening the

stick-out will result in a lower current and the arc being too short.

•Due to OK AristoRod’s Advanced

Surface Characteristics (ASC) the

optimal voltage is typically 5-10%

higher than with a copper-coated

wire at the same arc length.

• If a different current is required,

i.e change of welding position, the

procedure described on the previous

page needs to be repeated.

50

38

36

34

32

30

28

26

24

22

20

18

16

14

12

100 150 200 250 300 350 400

3

3

2

2

4

4

1

1 Welding in short arc area. Use for thin plate, tack welding or positional welding.

When arc length is tooshort increase voltage.

When arc length is toolong decrease voltage.

Welding in spray arc transfer. High productivity, thick plate, downhand welding, low spatter.

Excessive weld metal. Di�cult to control.

Welding in globular area. Unstable arc and excessive spatter.Try to avoid.

Amperage

Volta

ge

OK AristorodTM

0.040 in.(1.0 mm)

0.047 in.1.2 mm

14

oK aristorod - the complete range

aws and eN classifications

oK aristorod

classification wire

classification wire and weld metal shielding gassteel type

aws eN-iso eN-iso 14175

a5.18 a5.28 14341-a 16834-a 21952-a /-B m21 c1

12.50 ER70S-6 G3Si1 G 42 4 G 38 2Normal strength

12.57 ER70S-3 G2Si G 38 3 G 35 2Normal strength

12.62 ER70S-2 G2Ti G 46 4 G 42 3Normal

strength

12.63 ER70S-6 G4Si1 G 46 4 G 42 2Normal strength

12.65 ER70S-6 G4Si1 G 46 4 G 42 2Normal strength

13.08 ER80S-D2 G4Mo G 50 4 G 46 0Creep

resistant

13.09 ER80S-G G2Mo G MoSi /G 1M3

G 46 2 G 38 0Creep

resistant

13.12 ER80S-GG CrMo1Si / G 55M 1CM3

Creep resistant

13.16 ER80S-B2Z CrMo1Si / G 55A 1CM

Creep resistant

13.22 ER90S-GG CrMo2Si /

G 62M 2C1M3Creep

resistant

13.26 ER80S-G G Z 3Ni1Cu G 46 4 G 42 0 Weather resistant

55 (13.13) ER100S-G G Mn3NiCrMo G 55 4High

strength

69 (13.29) ER110S-G G Mn3Ni1CrMo G 69 4High

strength

79 (13.31) ER120S-G G Mn4Ni2CrMo G 79 4High

strength

89 (1B96) ER120S-G G Mn4Ni2CrMo G 89 4High

strength

15

oK aristorod - the complete range swift arc transfer™

Swift Arc Transfer is a high productivity

GMAW process using OK AristoRod

non-copper coated welding wires at

very high wire feed speeds. The SAT

process produces flat welds with good

penetration and no undercut.

the ultimate high productivity process.

ESAB’s Aristo™ U82 robotic package

enables SAT welding. It is a complete

set of welding consumables and

equipment, based on ESAB’s latest

digital power source technology.

The package consists of:

•The Aristo MIG 5000i inverter power

source or ESAB's MIG 4002c, 5002c

and 6502c chopper power sources.

•The Aristo U82 control unit with SAT

synergic lines or The Aristo U82

interface for different robot brands.

•The Robofeed 3004w ELP

encapsulated wire feeder with up to

98.4 ipm (30 m/min) wire feed speed.

•Cable packages.

•The Marathon Pac bulk wire drum

with robot quality welding wire and

optional bobbin holder.

SATTM

Sho

rt a

rcM

ixed

arc

Sp

ray

arc

Forced short arc

Wire feed speed (m/min)A

rc v

olta

ge

Rotating arc

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NOTICE:Test results described above were obtained under controlled laboratory conditions, and are not guarantees for use in the field. Actual use of the product may produce varying results due to conditions and welding techniques over which ESAB has no control, including but not limited to plate chemistry, weldment design, fabrication methods, wire size, welding procedure, service requirements and the environment. The User should confirm by qualification testing, or other appropriate means, the suitability of any welding consumable and procedure before use in the intended application.

CAUTION:Users should be thoroughly familiar with the safety precautions referenced in the product label for the relevant product and the Safety Data Sheet for the product. Safety Data Sheets are available at www.esabna.com or by calling 1-800-ESAB-123.