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R.

BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Fronius Schweißmaschinen
Vertrieb GmbH & Co KG
GF II - Automation
Buxbaumstraße 2
A-4600 Wels
INFORMATION ON TIG-HOTWIRE
WELDING PROCESS
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
SCHEMATIC SKETCH
-
+
-
+
TIG-
power source
Hotwire-
power source
Control unit
PA8000 /
FPA 9000
Wirefeeder
unit
Shielding gas
TIG-
torch
Hotwire-
torch
+
-
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
ECONOMY
Overlay welding 100% duty cycle (kg/h)
Filler metal: Alloy 625-IG, ø1.2
Deposition rate
kg/h at 100% duty cycle (overlay welding)
0
1
2
3
4
5
6
100 200 300 400 500A
kg/h
Hotwire
Coldwire
ø3.2
ø4
Tungsten
0
1
2
3
4
5
6
kg/h
Electrode
Hand
ø4mm
TIG
COLD-
WIRE
ø1.2mm
390A
TIG
HOT-
WIRE
ø1.2mm
390A
GMAW
ø1.2mm
Corgon 18
SUB.ARC
ø4mm
400A
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
ADVANTAGES
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
ADVANTAGES
over manual electrode welding:
• no need to change electrodes
• no need to remove slag
• higher deposition rate
over MAG-welding:
• higher welding quality
• all high-grade materials are weldable
• no spatter
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
over TIG cold-wire welding:
• higher deposition rates (up to 60%)
• higher welding speeds (up to 100%)
• reduces the dilution percentage (by up to 60%)
• larger deposition volume (30% - 50%) at same
welding speed and amperage
over submerged-arc welding:
• no need for costly flux powder
• maintains sight-contact to weld pool
• no elaborate accessories
ADVANTAGES
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
AREAS OF USE
• Joint welding • Overlay welding
MATERIALS
Carbon steel
Cr-Ni
Ni-based alloys
Duplex and Superduplex
Aluminium
Hard-facing with Stellite 6/21
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Welding is possible
in all positions
WELDING POSITIONS
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Power-station construction
Project: Lippendorf / Germany
Flue-gas desulphurisation plant:
Welding of 4 absorbers, D = 16 m
Internal overlay welding with Alloy 59
USAGE EXAMPLES
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Power-station construction
TIG-HOTWIRE multilayer-circular seam welding
horizontal:
with 50 m driving rail - for coupling and with vacuum-carrier
Welding- and
monitoring unit:
- TT 450 power source
- TP 200 Hotwire power
source
- electron. sequencing
control
- camera-monitoring of
the arc
USAGE EXAMPLES
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Power-station construction
TIG-HOTWIRE Vertical-
welding unit:
- With manual adjustable
trolley (load capacity up to
40 kg)
- Welding length 3 m
- with camera-monitoring of
the welding sequence
USAGE EXAMPLES
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Flue-gas desulphurisation plant
Wallpapering in pure-gas passages:
Alloy C276, Alloy 59
Lap welds
Material thickness: s=1,6mm
Welding speed: v=1,0m
USAGE EXAMPLES
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Automatic overlay welders - 2 double stations:
Valve body material: Alloy 625
Offshore - engineering
USAGE EXAMPLES
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Offshore - engineering
Valve bodies:
Repair overlay welding with Alloy 625
Internal overlay welding of
valve blocks:
Cladding material:
Nickel-based Alloy 625,Ø=1,2mm
USAGE EXAMPLES
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Intersection zones in valve blocks:
The control system computes the exact
location of the intersecting edges and
controls arc ignition and cut-off. This ‘bore-
to-bore’ fuction enables these weldments
to be welded automatically.
USAGE EXAMPLES
Offshore - engineering
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
External overlay welding:
Filler metal: Stellite 6/21 or Alloy 625
External- / floor welding: with automatic
speed adjustment
Overlay welding:
Basic material: Alloy 625
Surfacing material: Stellite 6
USAGE EXAMPLES
Offshore - engineering
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Joint-welding station: (Dual-head station)
Welding of cast housing halves and flanges
Material thickness: 5 - 15 mm ; Diameter: 50 - 200mm
Shutoff valve
Material: C22/8 forged or
13CrMo44
USAGE EXAMPLES
Fittings - engineering
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
USAGE EXAMPLES
Longitudinal seam welding unit:
Material:
St37 - 6mm - Length-carrier underprofile
1.4003 - 2mm - Sidewall-plate
Features: Arc Voltage Control, Inductive seam
tracker system
Railway vehicle construction
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Overlay welding:
Ship components
USAGE EXAMPLES
Ship - building
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Pressure-pipeline construction:
Assembly seams
Material thickness: 10-50mm
USAGE EXAMPLES
Pipeline construction
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Circular seam - ,
Longitudinal seam - and
overlay welding
Material: Cr-Ni / Duplex
USAGE EXAMPLES
Pipeline construction
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
Tube to tube welding:
Orbital vehicle POLYCAR 130
with Systemcontroller FPA 2003
USAGE EXAMPLES
Pipeline construction
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
TIG-HW-PLASMA
Cicular seam welding:
Joint welding
Thickness: 4 - 40mm
Pipe length: 2x15m
Material: C-Steel /
CrNi - for chemical plants
Features:
automatic in- and out-
transport of the pipes
USAGE EXAMPLES TIG-HW-PLASMA
Pipeline construction
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
TIG-HOTWIRE-PLASMA-EQUIPMENT
TIG-PLASMA
Power Source PT450:
- switchover between
TIG and Plasma
Mains voltage:
3x380V/400V/415V 50-60Hz
Welding current:
450A bei 60% duty cycle
HW-Power Source TP200-HD
Cooling unit FK6:
Fluid quantity: 6,5l/min
PLASMA-HW-Torch:
- with wire-guide-unit FWH4
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS
REFERENCE LIST
ABB ATOM AB Västeras - S 2 KHS Bad Kreuznach - D 1
ABB KENT LTD. West Yorkshire - GB 1 KVAERNER NATIONAL Aberdeen - GB 1
ABB VETCO GRAY LTD. Douglas - GB 4 METALURGICA PROGRESSO Vale de Cambra - P 1
ABB VETCO GRAY LTD. Singapore 3 MOTHERWELL BRIDGE LTD. Motherwell - GB 2
ABB VETCO GRAY LTD. São Paulo - Brazil 1 NUOVO PIGNONE Massa - I 1
ALLIED TEK Bangkok - Thailand 1 PREUSSAG ARMATUREN GMBH Peine - D 1
AMAG Ranshofen - A 1 QA WELDTECH LTD. Middlesbrough - GB 2
ARROWELD Zane - I 1 RICHARDS & ROSS LTD. Wolverhampton - GB 1
BOOTHAM ENGINEERS York - GB 1 ROLLS ROYCE Derby - GB 1
BUTTING Knesebeck - D 3 SLV HALLE Halle/Saale - D 1
CAMERON Beziers - F 2 T.K. VALVE Dunfermline - GB 1
DRIL QUIP Aberdeen - GB 3 TEMEC SRL. Brindisi - I 2
FLOW CONTROL TECHNOLOGIE St. Juéry - F 1 THYSSEN SCHWEISSTECHNIK Bochum - D 1
FORTH TOOL AND VALVE LTD. Glenrothes - GB 1 VENTURE OILFIELD LTD. Glenrothes - GB 1
FRONIUS DEUTSCHLAND Kaiserslautern - D 1 VOEST-ALPINE GMBH Linz - A 1
HEAD ROBINSON ENGINEERING Bristol - GB 2 VOEST-ALPINE MCE Linz - A 3
HOPKINSON VALVE Huddersfield - GB 1 WEIRS PUMPS Glasgow - GB 2
IHC HOLLAND Kinderdijk - NL 1 WOOD GROUP ENGINEERING Peterhead - GB 1
R. BRUNMAIER ‘ 99
TIG-HOTWIRE WELDING PROCESS