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Ok AristoRod Non-Copper-Coated Wire Welder Guidebook Flipbook PDF
NoN copper-coated solid gmaw wires with advaNced surface characteristics Ok AristoRod™ Non-Copper-Coated Wire Welder Gui
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Ok AristoRod™ Non-Copper-Coated Wire Welder Guidebook
Non copper-coated solid gmaw wires with advanced surface characteristics
Contents Introduction 2 Before You Start Welding
3
•
Contact Tips and Gas Nozzle
3
•
Liners
4
•
Gas and Water
4
•
Wire Feed Unit
4
•
Marathon Pac™ Installation
5
•
Check Drive Rolls and Wire Feeding
7
•
Shielding Gas
8
Contact Tip And Gas Nozzle
9
•
Correct Stick-Out Length
•
Gas Nozzle Diameter
Welding Parameter Setting •
9 10 11
How to Get an Optimum Setting
11
OK AristoRod™ - The Complete Range
13
ESAB Swift Arc Transfer™
14
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
2
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. Feature
Benefit
Consistent welding performance
Consistent weld results
Stable arc with low feeding force
High 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
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.
3
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
correct
incorrect
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.
For contact tip sizes and packages, please contact ESAB or your local Distributor.
4
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
Correct
• 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.
Incorrect 5
Before You Start Welding
Marathon Pac Installation 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
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.
6
Special cone for Jumbo Marathon Pac with 1050 lbs (475 kg) non- or low-alloyed wire.
Before You Start Welding
Marathon Pac Installation
Step 1. Remove the rubber strap and VCI paper.
Step 2. Place the wire conduit attachment or “spider” on top of the Marathon Pac.
Step 3. Feed the welding wire through the centre of the spider.
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 5. Attach the wire conduit to the lid or cone with the quick connector.
Step 6. Attach the wire conduit to the wire feeder. Avoid liner bends or point pressure on the liner. 7
Before You Start Welding
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.
8
Smooth
Knurled
Before You Start Welding
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.
9
Contact Tip and Gas Nozzle
It is essential to fit the gas nozzle and contact tip at the right distance relative 2 mm Correct positioning of contact tip.
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
Incorrect. Contact tip too recessed.
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 Incorrect. Contact tip protruding beyond gas nozzle.
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
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.).
10
long. The weldpool will get hotter and more difficult to control.
Contact Tip and Gas Nozzle
When welding in short arc transfer, the arc stability and start properties will improve when reducing the stick-out.
Gas Nozzle Diameter Various nozzle diameters must be available to allow adequate access to the joint, to maintain the above recommended stickout, 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
1/2 - 3/4 in. (12-20 mm)
Correct. Use a smaller diameter nozzle or a conical nozzle for the 1st layers in the root area.
gas protection can be assured.
> 3/4 in. (> 20 mm)
Incorrect. Use of standard gas nozzle restricts access to narrow joints, resulting in too long a stick-out.
Correct. Use of standard gas nozzle for completing the joint ensures good gas protection and correct stick-out.
11
Welding Parameter Setting
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
Correct. Correct arc length. Stable and concentrated arc with a quiet spray droplet transfer.
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.
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.
• 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.
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.
Welding Parameter Setting
• 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. 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.
1
Welding in short arc area. Use for thin plate, tack welding or positional welding.
0.040 in. (1.0 mm)
2
Welding in globular area. Unstable arc and excessive spatter. Try to avoid.
0.047 in. 1.2 mm
3
Welding in spray arc transfer. High productivity, thick plate, downhand welding, low spatter.
OK AristorodTM
4
Excessive weld metal. Difficult to control.
38
4
36
3
34 32 30
Voltage
28
2
26 24 22 20
When arc length is too short increase voltage.
1
18
When arc length is too long decrease voltage.
16 14 12 50
100
150
200
250
300
350
400
Amperage 13
OK AristoRod - The Complete Range
AWS and EN Classifications OK AristoRod
Classification Wire
Classification Wire and Weld Metal Shielding Gas
AWS A5.18
A5.28
EN-ISO 14341-A
16834-A
Steel Type
EN-ISO 14175 21952-A /-B M21
C1
12.50
ER70S-6
G3Si1
G 42 4
G 38 2
Normal strength
12.57
ER70S-3
G2Si
G 38 3
G 35 2
Normal strength
12.62
ER70S-2
G2Ti
G 46 4
G 42 3
Normal strength
12.63
ER70S-6
G4Si1
G 46 4
G 42 2
Normal strength
12.65
ER70S-6
G4Si1
G 46 4
G 42 2
Normal strength
G 50 4
G 46 0
Creep resistant
G 46 2
G 38 0
Creep resistant
13.08
ER80S-D2
G4Mo
13.09
ER80S-G
G2Mo
13.12
ER80S-G
G CrMo1Si / G 55M 1CM3
Creep resistant
13.16
ER80S-B2
Z CrMo1Si / G 55A 1CM
Creep resistant
13.22
ER90S-G
G CrMo2Si / G 62M 2C1M3
Creep resistant
13.26
ER80S-G
55 (13.13)
ER100S-G
G Mn3NiCrMo
G 55 4
High strength
69 (13.29)
ER110S-G
G Mn3Ni1CrMo
G 69 4
High strength
79 (13.31)
ER120S-G
G Mn4Ni2CrMo
G 79 4
High strength
89 (1B96)
ER120S-G
G Mn4Ni2CrMo
G 89 4
High strength
14
G MoSi / G 1M3
G Z 3Ni1Cu
G 46 4
G 42 0
Weather resistant
Swift Arc Transfer
™
The ultimate high productivity process.
very high wire feed speeds. The SAT process produces flat welds with good
arc Mixed arc Spray a rc
non-copper coated welding wires at
ting
Rota
arc
Short
GMAW process using OK AristoRod
Arc voltage
Swift Arc Transfer is a high productivity
Forced short arc
SAT
TM
penetration and no undercut. Wire feed speed (m/min)
ESAB’s Aristo™ U82 robotic package
• The Robofeed 3004w ELP
enables SAT welding. It is a complete
encapsulated wire feeder with up to
set of welding consumables and
98.4 ipm (30 m/min) wire feed speed.
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
• Cable packages. • The Marathon Pac bulk wire drum with robot quality welding wire and optional bobbin holder.
and 6502c chopper power sources.
• The Aristo U82 control unit with SAT synergic lines or The Aristo U82 interface for different robot brands.
15
Unrivaled Service and Support Every ESAB product is backed by our commitment to superior customer service and support. Our skilled customer service department is prepared to quickly answer any questions, address problems, and help with maintenance and upgrading of your equipment. Our products are backed with the most comprehensive warranty in the business. With ESAB, you can be sure that you purchased equipment that will meet your needs today and in the future. Product and process training is also available. Ask your ESAB sales representative or distributor for a complete ESAB solution.
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.
ESAB Welding & Cutting Products / esabna.com / 1.800.ESAB.123
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