welding economy elga ceramic backing · 2018-09-13 · elga ab, box 277, 433 25 partille, sweden...

is used to provide root pass support when weldingfrom one side only and is an extremely effective wayto rationalise welding procedures and reduceproduction costs. Welding of root passes is normallythe most critical part of the weld and hence the mostcostly. By using Elga ceramic backing, you canreduce production costs substantially.

Elga Ceramic Backing

Useful tips when using Elga CeramicBacking

Use relatively low current/welding speed. For Elgacore <200A and < 200 mm/min, for Cromacore < 160A.

Dirt, mill scale, coatings and other contamination to beremoved from the joint faces before welding

End craters should be fully ground out

Maximum 1 m root run at a time, before next pass applied

Reduced production costs:

Eliminates the need for back-gouging, grinding and rewelding opera-tions on the reverse side.

Significant savings in costs associated with turning large and heavyplates or structures in order to weld the second side in the flat position.

Increased productivity when welding root runs in position 1G/PA, 2G/PCand 3G/PF.

Simpler joint preparation and reduced set-up time because tolerances forthe root gap are greater.

Use of higher welding currents, which means higher deposition ratesand increased productivity.

Quality improvements:

Smooth, even root bead with slightly convex profile and excellent blend-in with base material.

The ceramic material does not emit fumes and contains no moisture.Ideal for low-hydrogen applications.

When welding in enclosed spaces the working environment is notpolluted by fumes from arc-air gouging, grinding and rewelding opera-tions.

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Welding economyThe use of ceramic backing offers significant economicadvantages. Take a look at a couple of examples based onlabour cost and time to complete the job.

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Switching from two-sided weldingto single-sided with flux coredwire and ceramic backing

Flux cored wire and backing (single-sided welding):Typical deposition rate is 2,5-3,0 kg/h.Welding speed 100-200 mm/min.Characteristic of flux cored wire with backing is a veryhigh arcing time factor. A 1 meter long root pass can bewelded non-stop.

Using a 2,5 mm electrode:Typical deposition rate is 0,6-0,7 kg/h.Welding speed 40-70 mm/min.Characteristic of MMA is a low arcing time factor. With a2,5 mm electrode, only a 50-70 mm weld length can beachieved between electrode changes.

Switching from MMA to FCAWwith Elga Ceramic BackingIn this example we have used an average welding speed(55 mm/min for MMA and 150 mm/min for FCAW withbacking) and a labour cost of 40€/h for the welder.

Total time comparison

Labour cost €/m

MMAFCAW with backing

Two-sided welding meansadditional time for:

1. Back-gouging

3. Rewelding on thereverse side, dependingon the construction.

Single-sided welding with fluxcored wire and backing:

Substantially higher productivity sinceall ”extra work” has been eliminated.

2. Grinding

Two-sided welding Single-sided weldingwith backing

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Elga AB, Box 277, 433 25 Partille, Sweden Tel: +46 (0)31-726 47 53, Fax: +46 (0)31-726 47 02

Reduce welding costs withElga Ceramic Backing

Note!NEW length perpiece 600 mm

d for all ceramic backing from Elga: ceramic backing on Alu-tape

ding positions: PA, PC, PF material: stainless and mild or low alloy steels

hoose the right backing

2005

06Part No: 86800600Typical application:Joint preparation: V-jointsWelding consumable: Rutileflux cored wireRoot gap: 3-8 mm

Technical specification:Tile width: 26 mmTile height: 8,5 mmGroove depth: 1,3 mmGroove width: 13 mmLength per individual tile:25 mm

Product data:Length per piece: 600 mmPieces per box: 30Pieces per pallet: 3360

Part No: 86650600Typical application:Joint preparation: X and K-jointsWelding consumable: Rutileand metal cored wireRoot gap: 4-6 mm

Technical specification:Diameter: 8 mmLength per individual tile:30 mm






Technical specification:Diameter:12 mmLength per individual tile:30 mm


Part No: 86990600Typical application:Joint preparation: V-jointsWelding consumable: Rutileflux cored wireRoot gap: 3-7 mm

Technical specification:Tile width: 26 mmTile height: 8 mmGroove depth: 1,3 mmGroove width: 12,5 mmLength per individual tile:25 mm


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welding economy elga ceramic backing · 2018-09-13 · elga ab, box 277, 433 25 partille, sweden...

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