together we weld stainless! - bcz vamberkbcz.vamberk.eu/.../pdf/prezentace/esab-presentation.pdf ·...

Together we weld Stainless!

With a delivery from ESAB, your stainless consumable comes

with 80 years of built in experience

April 2012

Global Product Management

Page no 2

Stainless is growing…

Page no 3

Stainless is everywhere…

April 2012


What is stainless?

Carbon steel

• Iron with a controlled amount of carbon

• Small additions of other alloying elements

• No protection against corrosion

Stainless steel

• Iron and minimum 12% of Chromium

• A protective oxide film is formed on the surface

• The oxide film protects the steel from corrosion

Page no 4April 2012


Stainless steel main families

Ferritic grades

Austenitic grades

Duplex grades

Page no 5

• Magnetic

• Low thermal expansion

• Good creep resistance

• High yield strength

• Non-magnetic

• The ”common” stainless

• High strain

• Good low temp. properties

• The ”new” stainless type

• Very high yield & tensile

strength

• Excellent corrosion

resistance

April 2012


Alloying elements

Page no 6

•The base in all steelsIron (Fe)

•To make iron into steel

•Gives the steel strengthCarbon (C)

•”The stainless element”

•Promotes ferriteChromium (Cr)

•Provides impact toughness and elongation

•Promotes austeniteNickel (Ni)

•Provides corrosion resistance

•Promotes ferriteMolybdenum (Mo)

•Gives impact toughness and increased hot cracking resistance

•Promotes austeniteManganese (Mn)

•Improves weldabilitySilicon (Si)

•Niobium and Titanium are used as stabilizersOthers (Nb, Ti)

April 2012


Corrosion resistance

Page no 7

• A sample/product corrodes when its corrosion resistance is insufficient

in the surrounding environment.

• Corrosion can be very local on a sample or across larger areas

• Corrosion will start where the corrosion protection is the weakest, i.e.

• where corrosion preventing elements (eg. Cr, Mo, N) are locally

lower in concentration

• where surfaces are rough (eg. crevices, pores, corners, etc)

• where the environment is locally more aggressive

April 2012


Some types of corrosion

Page no 8

Intergranular corrosion

• Lower Cr content in grain boundaries makes this area susceptible to corrosion

• Prevented by adding stabilizing elements (Nb, Ti) to the alloy

Pitting corrosion

• Occurs at the weakest point of the surface

• The protective oxide film is damaged and not allowed to reform

• The ”pit” becomes increasingly sour and the corrosion accelerates

Crevice corrosion

• In deep crevices the protective film doesn’t reform due to lack of oxygen

• Similar to pitting corrosion, but normally occurs at lower temperatures

• Prevented by higher content of Cr, Mo, N

Stress corrosion cracking

• Occurs only when a combination of high tensile stresses and chlorides are present

• Often at elevated temperatures

• Prevented by higher alloying content as well higher ferrite content

April 2012


Health & Safety

Any welding process generated hazardous

substances

Pay attention to

warning texts on

labels and packaging

Read and understand Safety Data Sheets for the product being used

Use only products from a

supplier which

understands and explains

how to safely use

the products

Page no 9April 2012


Manual Metal Arc (MMA) Welding

Shielded Metal Arc Welding (SMAW)

Page no 10April 2012


MMA process and consumables

• Good welding performance (stable arc, good slag detachability, good tie in with base material etc) ensures high quality welds

• Supplied in VacPac. No need for redrying if package is intact before usage

• Large number of stainless grades are available

High quality welds and large range

• Easy to use and adjust welding parameters

• Easy to weld in all positions

• Less stringent demands on joint preparation

Easy and flexible process

• Low initial capital investment cost

• Low maintenance costs

• People who can weld are available everywhere

Economic and easy to get started

• No need for gas bottles or wire feeders

• Light weight machines

• Provides very good access even to narrow spaces

Provides good access



Gas Tungsten Arc Welding (GTAW)

Tungsten Inert Gas (TIG) welding

Page no 12

Power

source

1. Power source

2. Tungsten electrode

3. Shielding gas

4. Work piece

5. TIG rod

April 2012


GTAW consumables – Solid wires

• It is essential for a TIG consumbable that the alloy fits to the base material

• Low amount of trace elements

Accurate wire chemistry

• Any contamination on the wire surface may cause bad welding results

• A clean manufacturing and packaging process is key

Clean wire surface

• To avoid mix up and welding with the wrong consumable, each rod for TIG welding shall be stamped with unique ID, preferably in both ends

Wire identification



Gas Metal Arc Welding (GMAW)

Metal Inert Gas (MIG) welding



GMAW consumables – Solid wires

•The structure and roughness of the wire surface is the key to get a good grip on the wire and eliminate troublesome slippage.Stable feeding

•The stiffness of the wire helps in getting a constant contact in the contact tip

•Cast and helix

Consistent current transfer

•Cast and helix are important features

•Cleanliness of the wireStable arc

•The wire surface must be designed to enable lowest possible force required to push the wire through the conduit

•Wire stiffness is of great importance

•This is especially important in high efficiency intermittent welding

Low feeding force

•Spool or Marathon Pac

•Tangling free decoiling minimizes production downtime

Troublefree decoiling



SMAW consumables – Rutile cored wires

• Spray arc transfer allows fast travel speed in all welding positions

• Positional wire three times faster than MMA and two times faster than Solid wire

• Downhand types two times faster than MMA

Productivity

• Smooth arc transfer giving low spatter

• Reduces post weld cleaning

• Easy to use

Welder friendly

• No silica islands

• Reduced post weld cleaning time

Full self-releasing slag

• Excellent wetting

• Improved corrosion resistance and appearance

Superb weld appearance



GMAW consumables – Metal cored wires

• Stabilisers added to the core improve arc transfer

• Low current settings can be used on thin gauge material

• Low spatter levels, reduced post weld cleaning

Smooth, stable arc

• Larger gaps can be bridged, more tolerant to fit-up variations

• Reduced burn through problems on thin gauge material

Wide arc

• Wetting agents added to the core ensure smooth welds

• Improved corrosion resistance and appearance

Smooth weld profile



Submerged Arc Welding (SAW)



SAW consumables – Wires & Fluxes

• Low risk of undercut and porosity, no spatter

• Deep and safe penetration

• No lack of fusion

• Deslagging is easy

High weld bead quality

• Fully automated process

• High amperage is possible

• Simultaneous use of mulitple wires

High deposition rate

• High process performance and low repair rate

• Easy to operateLow repair costs

• No need for fume extractionNo radiation, low fumes and noise



Strip Cladding



Submerged arc strip cladding consumables

• Low risk of undercut and porosity, no spatter

• Flux produces a nice bead appearance and good slag detachability

• Deslagging is easy


• High deposition rate

• Fully automated process

• Low penetrating process resulting in lowdilution

High productivity

• No need for fume extractionNo radiation, low fumes and noise



Electroslag strip cladding consumables

• An arc-less method using ohmic heating to melt the strip, flux and parent metal

• Flux produces a nice bead appearance and good slag detachability


• High deposition rate in terms of kg/hours and areacoverage m²/hours the strip, flux and parent metal

• Result is specific chemistry in one pass

• Low penetrating process resulting in low dilution

High productivity

• Flux can be delivered in 1000 kg aluminium lined Big Bag

• Strip coil weight until 400 kg for 90 mm stripsBulk packaging

• No need for fume extractionLow radiation,

fumes and noise



Consumable selection

• A chain is only as strong as its weakest link

• The weld shall not be the weakest link

• The consumable needs to match the mechanical and corrosion properties of the base metal

• Matching corrosion resistance

• Matching mechanical properties



Consumable selection chart



Consumable selection help



Consumable selection -

Dissimilar metals welding

Welding of dissimilar stainless steels

• Choose a consumable with better corrosion resistance than the least corrosion resistant base material

Welding of stainless steel to carbon steel

• Avoiding cracking is key to success

• The weld metal needs to contain some ferrite

• Use the Schaeffler diagram to get the correct weld metal composition

Page no 26

1

2

3

4

5

1. Chemical composition of stainless grade

2. Chemical composition of carbon steel

3. 50% weld metal dilution from each base metal

4. Chemical composition of welding consumable (309L)

5. Weld metal composition based on a fixed dilution of

weld metal

April 2012


ESAB Consumables

Features and benefits

ESAB Consumables –

Products that you can trust

Complete product portfolio

•From austenitic to ferritic and duplex grades for all arc processes

•A variety of packaging solutions to fit customer needs

•The ESAB range includes :

•Coated electrodes

•Cored wires

•Solid wires

•TIG rods

•Submerged arc wire

•Flux

Highest product and company quality

ESAB is the first company in the world to achieve all-inclusive, external certification for the three key management standards –ISO 9001, ISO 14001 and OHSAS 18001.

The Environmental, Health and Safety Management System and certification covers all activities, people and units in ESAB globally.

Extensive set of approvals

•Majority of products comply with both EN and AWS classifications

•Majority of the products are CE approved.

•Many products have approvals from any of the marine societies ABS, BV, DNV, GL or LR

•Other common approvals are VdTÜV and DB



ESAB Covered electrodes -

Read more about the features and benefits

VacPac

• Factory fresh electrodes straight from the package. No redrying required before usage.

• Enables time and cost savings to be made

Small pack sizes

• More economic ordering levels

• Less stock

• Less risk of transport damage

• Easier to handle



http://www.esab.com/global/en/

ESAB Solid Wires -


Matt surfaced products

• Greater arc stability

• Excellent control of cast and helix

• Superior feedability

The Marathon Pac family

• Higher output

• Reduced downtime

• Three different sized to fit the customer volume requirement




Cored Wires


Ease of use

• Shield-Bright series of cored wires, both positional and downhand types, are very ”welder friendly” wires

• They both operate in the spray arc transfer mode which produces very little spatter

• Both Ar/CO2 and straight CO2 gas mixtures can be used

Productivity

• Higher current spray arc in position gives deposition two times greater than solid wire and three times greater than MMA

• Greater deposition rates in downhand position offer faster travel speeds

• Full, self-releasing slag cover reduces post weld cleaning time




ESAB SAW Welding consumables


BigBag for submerged arc welding fluxes

•1000 kg bulk package for the efficient handling of high quality submerged arc welding fluxes.

•BigBags are made from strong woven polypropylene material with an internal multi-layered aluminium lining, keeping the flux ”factory dry”.

Marathon Pac® for submerged arc welding wires

•Marathon Pac® is a bulk pack for 450 kg of SAW welding wire diameter 1,6 and 2,0 mm.

•The wire is straight and comes out of the welding head without twisting, making it ideal for SAW welding stations.

Productivity

•High speed welding fluxes for joining and electroslag strip cladding giving greater deposition rates .

•Alloyed and elements compensated fluxes for stainless and Ni based applications.

•Bulk pack of wires and fluxes.

•60x0,5 mm and 90x0,5 mm strips delivered as 200 – 400 kg coils for electroslag strip cladding.




Page no 33

ESAB – more than welding consumables

Take advantage of the ”one stop shopping” at

ESAB!

Consumables Equipment Accesories

April 2012


together we weld stainless! - bcz vamberkbcz.vamberk.eu/.../pdf/prezentace/esab-presentation.pdf ·...

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