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

Contact Tips and Gas Nozzle

Liners

Gas and Water

Wire Feed Unit

Marathon Pac Installation

Check Drive Rolls and Wire Feeding

Shielding Gas

Contact Tip And Gas Nozzle

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

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.

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.

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.

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.

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.

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 ) 0.040 in. and 0.047 in. ( 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 AristoRods 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.

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

0.040 in.
(1.0 mm)

Welding in globular area. Unstable arc and excessive spatter.

Try to avoid.

0.047 in.
1.2 mm

Welding in spray arc transfer. High productivity,

thick plate, downhand welding, low spatter.

OK AristorodTM

Excessive weld metal. Difficult to control.

38

36

34
32
30

Voltage

28

26
24
22
20

When arc length is too

short increase voltage.

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 Classications

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)

ESABs 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 ESABs 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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