Update on

PIPE WELDING
Tips for using pulsed GMAW
for the root pass on smaller-diameter or thinner-wall pipe. Operators consistently can produce X-ray-quality welds with SMAW electrodes, although the process can be slow, labor-intensive, and dirty. Sometimes, though, quantity is as important as quality, and a faster, more continuous process, such as pulsed gas

By Tommy Caver, David Almy, and Nicholas Peterson

abricating pipe for marine, offshore, and petrochemical applications traditionally involves welding all passes on all joints with shielded metal arc welding (SMAW) or using gas tungsten arc welding (GTAW)

metal arc welding (GMAW), should be considered. Based on the assumptions shown in Figure 1, it costs $49.20 and takes 1.85 hours to weld an 8-inch-diameter Schedule 40 pipe using SMAW for the root, hot, two-fill, and cap passes. It costs $24.48 and takes 0.85 hour to make the same weld with pulsed

Article reprinted with permission from the November 1999 issue of The FABRICATOR.

GMAW for the fill and cap and SMAW for the root. Common objections to adopting pulsed GMAW include the increased cost of consumables and equipment. However, labor contributes 80 percent to the cost of a weld, and consumables contribute less than 20 percent. Because of its speed, pulsed GMAW can yield a return on equipment cost in less than a year, and it may allow fabricators to increase production without adding personnel.

Summary of Cost Study for 8 Inch Schedule 40 Pipe With a 30 Degree Bevel
Processes Used
MCAW Root Pass With MCAW Balance SMAW Root Pass With MCAW Balance MCAW Root Pass With FCAW Balance SMAW Root Pass With FCAW Balance GTAW Root Pass With MCAW Balance GTAW Root Pass With FCAW Balance MCAW Root Pass With SMAW Balance SMAW Root Pass With SMAW Balance GTAW Root Pass With SMAW Balance

Time to Complete a Weld (Hours)

0.79

Cost of Consumables

Cost of Labor

Total Cost Per Joint

$3.83

$19.65

$23.48

0.85

$3.21

$21.28

$24.48

0.94

$3.30

$23.40

$26.70

Pulsed Applications for Pipe

Of the wire welding processes, pulsed GMAW provides the most complete set of characteristics required for welding marine pipe. Short-circuit GMAW does not meet American Bureau of Shipping (ABS), Det Norske Veritas (DNV), or Lloyds Register approval because incomplete fusion (cold lap) and spatter may be a concern with this process. Spray transfer GMAW provides good fusion and low spatter, but its high current density causes meltthrough on thinner metals. The 0.050-inch nickel width land commonly found on beveled pipe cannot support the current density from spray transfer, nor can an approximately 0.125-inch-thick SMAW or GTAW root bead. Pulsed GMAW works well for pipe because it is a modified spray transfer process. In pulsed-spray transfer, the power source rapidly switches the output from high peak current to low background current. The peak current pinches off a spray transfer droplet and propels it toward the weldment for good fusion. The background current maintains the arc but is too low for metal transfer to occur. This reduces overall heat input. For example, the minimum

1.00

$2.67

$25.04

$27.71

1.33

$4.22

$33.32

$37.54

1.48

$3.68

$37.08

$40.76

1.79

#3.54

$44.66

$48.20

1.85

$2.91

$46.29

$49.20

2.33

$3.93

$58.33

$62.26

Assuming 2.25 feet of root pass per joint, 1.14 pounds of fill pass per joint, and $25.00 per hour labor rate. All welds were performed in the 1G Rolled Position. FCAW wire was 0.052" in diameter, MCAW was 0.045" in diameter, and SMAW was 0.125" in diameter. This report gives a comparison of the welding processes. We do recommend that studies on actual jobs be performed to increase the accuracy of the cost analysis. We believe you will find that the actual costs with pipe in a fixed position will prove to be higher than this study reflects. However, the proportions will remain the same.
The above calculations involve a number of variables, some more definite than others. This information is to aid and assist you in making the right decision and should be checked by your engineering department to assure that these figures are correct. The use of the information is solely at your own choice and the authors are not responsible for any errors or miscalculations based on or generated by this data.

Figure 1

spray arc current for a 0.045-inchdiameter carbon steel electrode is 220 amps, compared to the minimum pulsed-spray average current of 68 amps. Pulsed-spray transfer also permits all-position welding and welding of thick and thin metals and produces low spatter, higher travel speeds (up

to 35 percent faster than short-circuit transfer), high deposition rates, and potentially lower fume emissions. Pulsed-spray transfer lets users manipulate waveform components to develop beads with desirable width-todepth ratios and tailor the arc characteristics and burnoff rate to satisfy operator preferences.

FABRICATORS & MANUFACTURERS ASSOCIATION, INTL. 833 FEATHERSTONE RD. ROCKFORD, IL 61107-6302 815-399-8700 Fax: 815-484-7700 Web Site: www.fmametalfab.org E-mail: info@fmametalfab.org

Adjusting Pulse Variables

Because different conditions affect characteristics of the pulsed GMAW arc, it is difficult to recommend standard settings for every application. Therefore, it is necessary to understand the variables used to adjust the waveform and the effects of changing these variables. Variables include wire feed speed, peak current, background current, pulse width, and pulse frequency (see Figure 2). Wire Feed Speed. Of all the variables, wire feed speed has the most effect on average amperage and deposition rate. If the weld bead burns through the joint, the operator should decrease wire feed speed. For a weldment requiring a faster fill, the wire feed speed should be increased. Peak Current. Peak current is the highest welding amperage. It must be high enough to pinch droplets from the wire and propel them across the arc. Arc length directly reacts to peak currents; it increases as the peak current increases and vice versa. The operator should adjust peak current to increase penetration. Background Current. Background current helps to control puddle fluidity and penetration. At background level, the weld puddle cools to a semisolidified formation, allowing allposition welding with minimal puddle sag. Increasing the background current increases penetration and fluidity. Pulse Width. Pulse width is the time period during each pulse that the peak current is on. Adjusting the pulse width affects droplet size and arc cone width but has a more pronounced effect on the average amperage (wider pulses carry more amperage and increase arc length). On a scale of 1 to 5 milliseconds, a ballpark starting point would be between 1.2 and 2 milliseconds. Pulses Per Second (or Pulse Frequency). The pulses per second, or pulse frequency, controls the burnoff

rate of the wire as it is fed into the arc, and it affects average amperage, overall heat input, and arc length. To shorten arc length, the welder should lower the frequency. If the wire speed is higher than the burnoff rate, the frequency should be increased to lengthen the arc. Increasing the frequency also permits increased travel speeds. Setting pulsed GMAW parameters is not complex. Welders who are not familiar with the process should practice adjusting the variables and observing the effects. They should adjust one variable at a time and document the results. Figure 3 shows how changes to waveform components affect the burnoff rate and arc characteristics. During the learning process, supervisors and managers should provide individuals adequate time to conduct their own tests.

Pulse Variables
Amperage (Current) D

C Time

A. Peak Current
1. The higher of the two current levels in the pulsing waveform. 2. Current level where spray transfer is achieved.

B. Background Current
1. The lower of the two current levels in the pulsing waveform. 2. Current level well below the level at which spray transfer occurs.

C. Pulse Width (or Peak Time)

1. Duration of the peak current level. 2. Defined as the beginning of current rise to the beginning of current fall during a pulse.

Synergic Control
When working with pulsed GMAW, operators must understand that wire feed speed cannot be adjusted independently of voltage as it can be with conventional GMAW. When an operator wants more wire for a more driving, focused GMAW arc, increasing the wire feed speed will not produce the desired result because wire feed systems for pulsed GMAW provide synergic control. Synergic control means that as one variable changes, others shift accordingly. Thus, as an operator adjusts the wire feed speed control, the feeder automatically provides new settings for the pulse variables so that they deliver compatible welding conditions. If a welder feels he or she needs more wire, the trim control should be used. Reducing trim shortens the arc length, which gives a welder the feel of more wire. For pipe welding, operators usually want a narrower arc cone and stiffer arc. Welders report that it gives them better directional control over

D. Pulses Per Second (PPS or Pulse Frequency)

1. Number of peak current pulses that occur in one second. 2. Adjusting pulse frequency inversely adjusts the duration of the background time (time spent at lower current value).

Figure 2 Process variables include wire feed speed, peak current, background current, pulse width, and pulse frequency.

the weld puddle and may allow them to increase travel speed. As noted, changing arc characteristics requires changing the pulse variables. Until recently, this would require connecting a PC to the wire feed system or using the wire feed systems programming controls and an LCD screen. The task typically is left to someone with in-depth knowledge of the equipment and not the line operator. However, some pulsed GMAW power sources include a second synergic control that a line operator can use to sharpen the arc, eliminating or minimizing the need for reprogramming.

This control lets line operators increase the number of pulses per second. For narrower arc cone, stiffer puddle, and faster travel speeds, the operator can increase the number of pulses per second. For a wider arc and more fluid puddle, the operator can decrease the number of pulses per second. As the operator adjusts the pulse frequency, this synergic control automatically shifts the other variables to maintain relatively consistent weld characteristics such as heat input and depth of penetration.

Equipment and Consumables

Standard equipment for pulsed GMAW of pipe includes an inverterbased power source with a 400-amp, CC/CV output and a programmable, microprocessor-controlled wire feed system. Commonly used consumables include 95 percent argon/5 percent CO 2 shielding gas and metal-cored wire (tubular electrode) conforming to class E70C-6C/E70-6M of AWS A5.18 and ASME SFA 5.18. Inverters and microprocessors provide the high-speed power switching and control capabilities necessary to tailor the pulsed waveform. Depending on the application, obtaining the best weld bead and arc may involve making minute adjustments. Conventional power sources and pulsing pendants cannot provide this type of control. Power sources need CC/CV output capabilities because developing a qualified procedure may involve using SMAW or GTAW for the root pass. For example, some companies use SMAW (E-6010 or E-6011 electrode) for the root pass on pipe with 5-inch and larger diameters and the DCGTAW process for the root pass on smaller-diameter or thinner-wall pipe (especially stainless steel). Pulsed GMAW can be used for fill and cap passes to reduce welding time.

A programmable feeder is the operators connection to the welding arc. It provides the welding power source with instructions on how to pulse. These feeders have factory-set pulsing programs that typically work with six, eight, or 10 common combinations of wire size, type, and gas mixture. However, programs for the metalcored wire recommended in this article for pipe welding have yet to be included in the feeders memory. A solidsteel-wire program provides a good starting point, but adjustments will need to be made to fine-tune performance for the specific application. Metal-cored wire produces little spatter and almost slag-free welds, and out-of-position welding can be performed by pulsing. Metal-cored wire also meets offshore and marine standards.

Preparation Is Paramount
For tough pipe welding jobs, writing a pulse program is not enough to obtain good results. It also involves proper joint preparation, operator comfort, and correct weldment positioning. Good joint preparation includes cleaning the metal at least 1 inch back from the weld (usually with a wire brush), machining effective bevels, and machining saddles for tight fit-up. Pipe comes from the factory with a lessthan-perfect bevel around its circumference, and saddles usually are cut by oxyfuel or plasma and finished with a hand grinder. As with any welding process, a better fit-up makes it easier to create a better weld. While poor fit-up is no problem in SMAW, poor fit-up can lead to cold lap and undercut problems in short-circuiting GMAW. When using pulsed GMAW, fit tolerances can be overcome except on the root pass. In this case, fit-up is critical when the pipe cannot be rolled. Operators should ensure close fit-up by machining bevels and saddles with

CNC pantograph equipment that holds tolerances of about 0.05 inch. (Using CNC pantograph equipment for cutting pipe to length also is a good idea.) Good torch positioning is needed to produce consistent welds. While automation may ensure good torch positioning, it is not feasible for companies fabricating a pipe with a wide variety of configurations. For example, a 6-foot spool might have five headers saddled into it at 90 degrees and one at 45 degrees. Companies often order spools with three or four different diameters of pipe or may want an unusually large 22inch-diameter flange. Such jobs require the flexibility of a human operator. The key to good torch positioning in manual operation is rolling the pipe. Without a positioner, the operator can fatigue and weld defects occur. Thus, operator comfort also is essential. One way to increase comfort in the shop environment is to let the operator sit in a chair equipped with an armrest. This allows the operator to brace himor herself on the rest and hold the torch steady as the weldment turns. To account for varying heights of weldments, the chair can be fixed to a small platform that can be elevated with a scissors-type hydraulic lift. No matter the process, welding pipe to meet marine and offshore standards is not easy. Increasing productivity with SMAW depends not on equipment but on the skill of available workers. Using pulsed GMAW with metal-cored wire may allow companies to increase productivity without having to hire a greater number of skilled personnel. s
Tommy Caver is President of Industrial Maintenance & Machine, Inc. David Almy is a Welding Engineer with Miller Electric Manufacturing Co. Nicholas Peterson is a Welding Engineer with Welding Engineering Supply Company, Inc.

How Waveform Affects Arc and Burn-Off Rate

Changes to Arc
A A Electrode extension (stickout) C A B B Arc length C Contact tube-to-work distance should be 38 inch to 3 4 inch. Recommended gun angle is 10 to 20 degrees from vertical Increasing peak amperage only: Increases burnoff rate, which directly affects arc length Increases average amperage slightly Increase Peak Amperage Only A T Increases heat input slightly

Comments

T Reference Waveform A

Note: A good fine-tuning parameter for arc length. Assuming a constant pulse width (peak time), peak amperage should be high enough to achieve a spray transfer. Too low of a peak current often results in a globular transfer.
T Decrease Peak Amperage Only

High peak amperages result in smaller droplets and a more forceful or driving arc.
Increasing background amperage only: Increases arc length Increases average amperage

Increase Background Amperage Only A

Increases heat input and penetration Increases puddle fluidity

T Decrease Background Amperage Only A

Note: This current level is largely responsible for arc stabilization and must be high enough to maintain the arc between peak current pulses.

Increasing pulse width (time) only: Increases arc length T Increase Pulse Width (Time) Only A Increases heat input and penetration Increases arc cone width Increases average amperage

Decrease Pulse Width (Time) Only A

Increasing pulses per second only: Increases arc length Increases average amperage Increase Pulses Per Second Only A T Increases heat input

Note: A good fine-tuning parameter for arc length.

T Decrease Pulses Per Second Only

Typically, this variable is adjusted to control the burnoff rate of the wire as it is fed into the arc.

Figure 3

Industrial Maintenance & Machine, Inc., 4401 Sermetel Drive, Moss Point, Mississippi 39563, phone 228-475-0512, fax 228-4750569, provides specialty fabrication, field machining, in-plant maintenance, and other services to the oil, chemical, and paper industries.

Miller Electric Manufacturing Co., 1635 W. Spencer Street, P.O. Box 1079, Appleton, Wisconsin 54912, phone 800-4AMILLER, email dalmy@MillerWelds.com, Web site www.millerwelds.com, is a worldwide manufacturer of arc welding and plasma cutting equipment and related systems for metalworking, construction, and maintenance.

Welding Engineering Supply Co., 940 M.L. King Drive, Prichard, Alabama 36610, phone 334-457-8681, fax 334-457-9353, Web site www.wescoweld.com, is a full-service welding supply distributor.

Visit our website at www.MillerWelds.com or call us at 800-4-A-MILLER (800-426-4553)