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Hipbuilding: The Esab Welding and Cutting Journal Vol. 58 No.1 2003
Hipbuilding: The Esab Welding and Cutting Journal Vol. 58 No.1 2003
1 2003
SHIPBUILDING
THE ESAB WELDING AND CUTTING JOURNAL VOL. 58 NO.1 2003
Efficient production of Stiffeners for Secure downhill MAG welding of butt- and
fillet welds with ESAB OK Tubrod 14.12
9 Shipbuilding
ESABs new IT-100 automatic T-beam weld- 26 The article reports on highly productive
ing machine offers highly productive, auto- downhill welding procedures used by German
mated welding in an unmanned production shipyards for thin-walled applications using
environment to shipbuilders and other fabri- OK Tubrod 14.12 metal-cored wire.
cators with a need to produce beams.
The article describes recent developments in the construction of fast patrol and
transportation vessels for the US military by Bollinger/Incat Inc., applying the latest
higher strength varieties of the 5083 aluminium marine alloy. The section on weld-
ability addresses the open-end questions that surround these very new alloys.
The creation of this article was promoted by current The more recent 98m Evolution 10B range has a dead-
activities within the United States military, the extraor- weight four times that amount. While Incat-built ferries
dinary developments in aluminium shipbuilding that initially revolutionized transport links around the
have been taking place in Australia, and the creation United Kingdom, today its ships operate in North and
of new high strength aluminium alloys, primarily in South America, Australasia, the Mediterranean, and
Europe, for the shipbuilding industry. throughout greater Europe. Incats extensive shipbuild-
ing activity is conducted from a modern facility with
I was fortunate enough recently to visit Incat Tasmania
over 32,000 m2 under cover, located at Hobarts Prince
Pty Ltd. (Shipbuilding) off the southeast coast of
of Wales Bay Tasmania.
Australia. This manufacturer has over the years taken
aluminium shipbuilding to exciting new levels. In 1977
they launched their first high-speed catamaran, and Aluminium Welded Ships Within The United
today they are manufacturing the new generation of 98- States Military.
metre (100 plus yards) wavepiercers that are being eval- In response to great interest from the US military in
uated by the United States military (see figure 1). high-speed craft, a strategic alliance has been formed
Incat has constructed more than 50 vessels of varying between Incat, the premier builder of the worlds fastest
lengths. The companys first passenger/vehicle ferry was vehicle/passenger ferries, and Bollinger, a proven
delivered in 1990, a 74-metre Wave Piercing Catamaran builder of a variety of high speed, reliable and efficient
with a maximum deadweight capacity of 200 tonnes. patrol boats for the US Navy and Coast Guard.
The US government has awarded Bollinger/Incat USA New Developments in High Strength
the charter for a High Speed Craft (HSC) for a multi- Aluminium Alloys for Marine Applications
service program operated by various arms of the US Until fairly recently, the most popular base material
military. The HSC Vessel, now known as Joint Venture used for aluminium shipbuilding, 5083, has had very lit-
HSV-X1, is being used for evaluation and demonstra- tle rivalry from other alloys. The 5083 base alloy was
tion trials in order to assess the usefulness of such tech- first registered with the Aluminium Association in 1954,
nology in US military and Coast Guard applications. and while often referred to as a marine aluminium alloy,
Another charter, the USAV TSV-1X Spearhead is the US has been used for many applications other than ship-
Armys first Theater Support Vessel (TSV) and is part of building. The popularity of the 5083 alloy within the
the Advanced Concept Technology Demonstrator shipbuilding industry has been largely based on its avail-
(ACTD) program by the Office of the Secretary of ability and also its ability to provide an aluminium alloy
Defense and the US Army. TSVs promise to change the with excellent strength, corrosion resistance, formabili-
way the US Army gets to the fight by allowing person- ty and weldability characteristics. Other lower strength
nel to quickly deliver intact packages of combat-ready alloys, such as 5052 and 5086, have been used for the
soldiers and leaders with their equipment and supplies. manufacture of usually smaller, lower stressed and typi-
cally inland lake boats, but 5083 has been predominant
Another order, from Military Sealift Command, in the manufacture of ocean-going vessels.
Washington, D.C., calls for the lease of a 98m craft
from Bollinger/Incat USA, LLC, Lockport, La., to In recent years, progress has been achieved by alu-
support US Navy Mine Warfare Command. The ship minium producers in the development of improved
will be capable of maintaining an average speed of 35 aluminium alloys specifically targeted at the shipbuild-
knots or greater, loaded with 500 short tons, consisting ing industry. In 1995 the aluminium manufacturer,
of 350 personnel and military equipment, have a mini- Pechiney of France, registered the aluminium alloy
mum operating range of 1100 nautical miles at 35 5383 and promoted this material to the shipbuilding
knots, and a minimum transit range of 4000 nautical industry as having improvements over the 5083 alloy.
miles at an average speed of 20 knots. The craft will be These improvements provided potential for significant
capable of 24-hour operations at slow speeds (3-10 weight savings in the design of aluminium vessels and
knots) for small boat and helicopter operations. included a minimum of 15% increase in the post-weld
How to proceed?
Friction Stir Welding is much easier to implement than
most other welding processes. The welding operator
does not need any special skills, since the parameters
are repeatable and high quality is easily achieved time
after time. You dont need to be big and powerful to
invest in Friction Stir Welding the modular way. It
may, however, make You big and powerful by shorten- About The Author:
ing cycle times and improving the quality of Your
Mr. Kari Erik Lahti graduated from Helsinki
products. Just dare to do it! University of Technology, Finland, 1994 with a
M.Sc. degree in welding technology. After working
References: as a research scientist in the field of welding metall-
Larsson H., Karlsson L., Svensson L-E, 2000. Friction lurgy, he joined Oy ESAB in Finland 1997 and star-
ted as product manager for welding automation.
Stir Welding of AA5083 and AA6082 Aluminium. In:
In 1998 Kari Lahti finalised his Ph.D. in "nominal
Svetsaren 2(2000). 5 pp. stress range fatigue of stainless steel fillet welds"
Midling O.T., Kvle, J.S. 1999. Industrialisation of the Since 2002 he has been working at ESAB AB
friction stir welding technology in panels production Gteborg, Sweden, currently as marketing manager
for the maritime sector. In: The 1st International for advanced engineering products.
Symposium on Friction Stir Welding. Thousand Oaks,
CA, USA 14-16 June. 7 pp.
ESABs new IT-100 automatic T-beam welding machine offers highly pro-
ductive, automated welding in an unmanned production environment to
shipbuilders and other fabricators with a need to produce beams.
Optimum welding speed, beyond 1m/min., is provided by double-sided
tandem submerged arc heads. Web and flange are automatically longi-
tudinally centered in the in-feed conveyor, whereas on-line straightening
of the beams is provided by inductive heating, avoiding time-consuming
post-weld straightening procedures.
4. Welding Process
The IT-100 submerged-arc welding (SAW) configura-
tion uses two single wires (DC+ AC) on each side of
the web (Figure 7). The torch arrangement uses a lead-
ing DC wire and a trailing AC wire. Offset between the
wires is 12 mm. Power sources include the LAF 1250
and TAF 1250. The welding controller is an Allan
Bradley PLC type Control Logic 5550 Figure 7. DC-AC Torch arrangement in ESAB`s T- beam welder.
Where
= Camber in mm.
PW = Shrinking force in N.
L = length of beam in mm.
E = modulus of elasticity in N/mm2.
I = moment of inertia in N/mm4.
b = distance from flange to neutral axis.
Figure 8. Cross section of welded T-beam. Shrinking force Pm per mm2 for different welding
methods has been determined by Malisius (see refer-
ences below). Typical shrinking forces for fillet welds
5. Theoretical analysis of the distortion after are 6300 N/mm2
welding a symmetrical T-beam
The intense heat input from the welding process and With this formula, an approximate camber value can be
the molten steel, which is deposited into the joint, con- easily calculated. For a beam web size, flange size, and
tribute to thermal expansion and contraction of the total length of 475 x 13mm, 125 x 25mm, and 16m,
heated parts. Also residual stresses released in the respectively, a resultant camber of 53mm is calculated
rolled and raw-cut material will have some influence on assuming a fillet weld on each side (leg length =8mm).
the final shape of the beam.
If the welding is done on only one side of the web the The result in this case seems to be too small compared
plate will bend upwards and sideways (sweep and cam- with empirical data found in the field. The difference
ber). If two welds are done simultaneously, one on each can perhaps be explained by considering additional
side of the web, the beam tends only to exhibit beam- forces associated with the shrinking effect of the
camber due to the shrinkage produced after welding. flange. One effect could be attributed to the tempera-
ture difference between the web and the flange meas-
Distortion can be minimized in symmetrical designs by ured at the welding site. The temperature difference
applying the heat into the material in a symmetrical seems to be the reason why the flange (but not the
manner. The remaining distortion on the final part can web) length increases by l during welding. The heat
rarely be tolerated in subsequent assemblies and must will enter into the flange much faster than the Web
be eliminated with thermal or mechanical methods because the cross sectional area of the flange is much
(see part 3 above). smaller than the webs.
Camber Bending distortion by longitudinal shrinkage upwards. Can be neutralized by applying heat on
top of the T-beam (see point 3 above).
Sweep Bending distortion by longitudinal shrinkage upwards. Perpendicularity (see below) needs to be
Unsymmetrical heat input from the welding process corrected.
(different weld parameters in fillet welds. Big longitudinal Change setting of weld parameters and
offset between torches). reduce offset of torches.
Perpendicularity Different weld parameters in fillet welds, big longitudinal Change weld parameters and reduce
(between Web and offset between torches. torch offset.
Flange)
Angular change Caused by different temperatures between top and bot- Use mechanical "pull down" straightening
(of flange) tom of flange. Bending distortion by transversal shrinkage feature of T-beam welder.
sideways and upwards.
Release of residual Releasing of residual stresses from earlier heat treatment Use heat treated material, use cutting
stresses and rolling operations of raw material. process with lower heat input.
6 References
1996, Andersen N.
High deposition welding with sub-arc forgotten and
overlooked potential, Svetsaren Vol. 51, No.3, p. 12 19.
1987 Conner L. P.
Welding Technology, Welding Handbook, Eighth
Edition, Vol. 1, American Welding Society, p. 241 264.
1989, ESAB
Krympning, Deformationer, Spndinger.
ESABs handbgsbibilitek 9 (in danish).
Figure 14. Heat distribution in a T-beam during the welding
operation. 1991, Gustavsson J.
Automatic production machinery for the fabrication
of welded steel beams and profiles. Svetsaren Vol. 45
No.2, p. 46-30.
5.2 Straightening by line-heating
By applying heat to the top of the beam during the 1977 Malisius R.
welding process it is possible to produce straight beams Schrumpfungen, Spannungen und Risse beim
(see point 3.4). The theory behind this is to achieve a Schweissen 4. Auflage, 154 p, DVS Verlag,
balance between the heat applied by the welding ISBN 3-87155-785-4.
process (below the neutral axis of the T-beam) and by
the heat applied by the proposed straightening process 1996, Persson M.
(above the neutral axis of the T-beam). Manufacture of welded beams. Svetsaren Vol. 51,
No.3, p. 20-21.
The best way to predict the required heat input of the
straightening process is to create an empirical table
with data derived from full-scale experiments. The
final condition of the beam is usually obtained after
approximately 1 hour after welding was finished.
Theoretical calculations require a lot more data. Heat
distribution in a beam can be measured and then be
used as part of these calculations. The heat distribution
in a T-beam (same size as used in above calculations) is
shown in figure 14.
or expressed by formula:
About The Author:
(4) w Xb x (xweldtemp) dx = H Xa x (xheating) dx Herbert Kaufmann, M. El. Sc. and M. Mech. Sc., joi-
(Temperature x length to neutral axis) ned ESAB in 1988 as Technical Director at ESAB
Automation Inc., USA. He is currently working as
Where Project Manager within the Engineering
Xb = distance to neutral axis (welding). Department of ESAB Welding Equipment in Lax
(xweldtemp) = heat distribution in the T-beam from Sweden.
welding process.
Xa = distance to neutral axis (heating).
(xheating) = heat distribution in the T-beam from
heating process.
Svetsaren no. 1 2003 15
ESAB Railtrack FW 1000 aids
fabrication efficiency of the
worlds largest aluminium yacht
Translation of an article first published in Laswijzer,
the customer magazine of ESAB The Netherlands.
By: Guus Schornagel, ESAB, The Netherlands.
Improved welding efficiency has been a major consideration for Dutch boatbuilder, Royal
Huisman, in the planning, design and construction of The Athena the worlds largest
aluminium yacht. This has been achieved by implementing mechanised MIG welding with
Railtrack FW 1000 for horizontal and vertical butt welds on the yachts hull.
The welding
The construction of a ship hull requires an enormous
amount of welding. Traditionally, manual MIG welding
was applied for horizontal and vertical butt joints in the
hull. However, the scale of this project made higher
welding efficiencies and economies very important.
Production experience
Huismans production manager, Henk Petter, is very
satisfied with the results so far. He cites "reduced arc
time, the consistent weld quality, the absence of lack of
fusion defects, and, very importantly, the fact that the
work has become less strenuous for the welders" as the
most appealing improvements.
The mechanical properties of welded joints and, in particular their quality in pro-
duction welds, is amongst the most important considerations when developing
welding procedures. High heat input (welding energy), in particular, weakens the
toughness properties of welded joints.
Figure 1 shows schematically the effect of cooling time When the issue is that of impact toughness requirements
on the hardness and impact toughness of the heat- at -40C or lower, for example when applying thick
affected zone. Optimal properties will be obtained for welds in submerged arc welding applications, then the
the joint when the cooling time is within range II. upper limit for heat input is of the order of 3-4 kJ/mm.
The lower the heat input, the more passes have to be Table 1. Maximum values for cooling time t 8/5 as issued for
made, and the lower, generally, is the deposition rate. Rautaruukki steels.
This has the effect of diminishing the productivity of
welding. The general aim is to use high heat inputs,
which is restricted by the heat-input limits issued by
the steel mill on a particular steel grade. Rautaruukki
has published heat input restrictions on its steels in the
form of welding energy or heat input graphs, e.g. in the
booklet Hitsaajan opas (Welding guide), Figure 2.
Rautaruukki repeats research
Heat Input (kJ/mm) EN 10025 Since the publication of the first heat input graphs, in
6.0 S355N 1972, Rautaruukki has conducted many studies into
5.6 S355J2G3 the effects of heat input - most recently in 2001-2002.
5,2 On the basis of these tests, the heat input recommen-
4.8 EN 10113-2 dations for the foremost Rautaruukki hot-rolled steels
4.4 S420N will be reviewed and where necessary the instructions
4.0 will be reformulated. By applying the heat input rec-
S355NL
3.6 ommendations it will be possible to ensure maximum
3.2 S420NL productivity of welding joints along with the impact
2.8 toughness and tensile strength firmness requirements
2.4 imposed on joints.
2.0
1.6 The plate thicknesses used were 12mm (two-run welds,
1.2 not reported in this shortened article), 20mm and
0.8 40mm. Submerged arc welding, which readily enables
10 20 30 40 50 60 high heat inputs, was the process applied. The heat
Plate thickness (mm) input in the tests varied between 20 and 80 kJ/cm.
Figure 2. Heat input limits for Rautaruukki steels when weld- The first group comprises conventional and commonly
ing butt joints. used steels, fine-grained steel RAEX Multisteel
(corresponds to EN 10025: S355J2G3 and S355K2G3)
and the general structural steel S355J2G3 (EN 10025):
Restricting heat input can also be indicated by means of
cooling time t 8/5. Rautaruukki presents the maximum Strength properties: ReH = min 355 N/mm2
allowable cooling times for various steel grades in the ( 16mm) and min 345 N/mm2 (s1640mm),
booklet, Table 1. The booklet also sets out the instruc- Rm= 490-630 N/mm2.
tions for determining cooling times, which can be done Impact toughness (RAEX Multisteel): min 40 J/-20C.
by calculation, or graphically by means of a nomogram. Impact toughness (S355J2G3): min 27 J/-20C.
Plate Joint Heat Cooling time Number of Impact test: Impact Impact Impact
thickness preparation input t 8/5 passes location energy energy energy
(mm) Q (s) -20C -40C -50C
(kJ/cm) (J) (J) (J)
20 45-1/2-V 31 35 6 Wm - 110 62
Fl - 101 31
Fl+1 - 225 196
Fl+5 - 104 45
37 45 5 Wm - 129 55
Fl - 136 88
Fl+1 - 207 160
Fl+5 - 108 66
43 60 5 Wm - 84 61
Fl - 109 56
Fl+1 - 167 144
Fl+5 - 91 91
55 98 4 Wm - 100 57
Fl - 111 39
Fl+1 - 179 136
Fl+5 - 79 70
60-V 50 81 2+1 Wm 42 25 17
Fl 101 66 35
Fl+1 115 78 37
Fl+5 183 134 52
Parent material: - 114 64
Requirement: - min 40 -
40 60/90-X 70 40 3+3 Wm 72 69 35
Fl 111 63 35
Fl+1 80 53 27
Fl+5 105 51 27
45-K 71 43 3+4 Wm - 40 38
Fl - 109 70
Fl+1 - 90 79
Fl+5 - 175 174
Parent material: - 186 165
Requirement: - min 40 -
ing time for the weld is the same (60 s) even though the requirements set on the parent material (not reported
heat input is only one-third of the above, i.e. 25 kJ/cm. in this shortened article). Even the highest heat inputs
Thick plates withstand considerably higher heat inputs of 70-80 kJ/cm did not soften joints to such an extent
than thin plates. that this would have been essentially manifested in the
tensile test results.
This research, leads to the conclusion that, when dealing
with multi-run welding of thick plates, surprisingly high Summary
heat inputs can be used in submerged arc welding appli- As a means of reducing labour costs and of improving
cations without impact toughness properties being exces- productivity, maximum heat input must be applied
sively impaired. when welding. However, in order that sufficient impact
toughness properties might be obtained in the welded
Strength not a problem joint, it is at times necessary to restrict the maximum
When transverse tensile tests were performed on heat input. The need for restriction is so much the
welded joints, the majority of the test specimens broke greater, the lower the temperatures at which good
on the parent material side - all the results fulfilled the impact toughness properties are required, the greater
20 45-1/2-V 31 35 6 Wm - 95 61
Fl - 112 79
Fl+1 - 178 125
Fl+5 - 43 19
37 45 5 Wm - 103 58
Fl - 120 60
Fl+1 - 132 52
Fl+5 - 51 20
43 60 5 Wm - 113 52
Fl - 80 44
Fl+1 - 90 58
Fl+5 - 74 45
55 98 4 Wm - 73 31
Fl - 57 32
Fl+1 - 112 56
Fl+5 - 50 29
60-V 50 81 2+1 Wm 48 21 13
Fl 47 31 20
Fl+1 55 35 25
Fl+5 76 71 23
Parent material: - 43 28
Requirement: - min 27 -
40 60/90-X 70 40 3+3 Wm 70 56 27
Fl 94 62 34
Fl+1 73 45 27
Fl+5 104 46 33
Parent material: - 83 -
Requirement: - min 27 -
In a light-hearted sense, one could say that the results OLLI VHKAINU
for the heat-affected zones and weld metals were such Is Product Manager at Rautaruukki Steel, Raahe,
that the traditional impact toughness competition Finland
between steel manufacturer Rautaruukki and filler
manufacturer ESAB ended in a draw!
The BrasFELS shipyard, in Angra dos Reis, Brazil is involved in the conversion of
petroleum tankers to FPSO (Flotation-Production-Storage-Operation) vessels.
OK Tubrod 75 all-position basic cored wire, a Brazilian development with European,
US and Korean equivalents, passed the yards extensive qualification tests to provide
extra FCAW productivity.
OK Tubrod 75
The Caratinga FPSO was completed earlier this year.
Two consumables were widely applied, OK Tubrod 71
Ultra (E71T-1) for FCAW of components for a service
temperature down to 30C and the basic OK 55.00
(E7018-1) stick electrode for the welding of EH36 with
a CVN impact requirement down to 40C.
For the construction of the Baracuda FPSO, a higher
welding productivity was required and the yard evaluated Figure 2. Conversion to FPSO vessel.
Note: OK Tubrod 75 is a local product for the Brazilian WELDING PROCEDURE, 3G POSITION
market. Basic ESAB types for offshore fabrication
Welding Process: FCAW Position: 3G
with a comparable performance are: Base Material: EH 36 Thickness: 25.4 mm
Filler Metal: OK Tubrod 75 1.2 mm
OK Tubrod 15.24 and FILARC PZ6125 for Europe. Classification: AWS A 5.20 E71T-5 (M)
Dual Shield T5 for the US and Asia Pacific. Shielding Gas: CO2 / 18 L/min
Preheat: 21C min. Interpass: 250C max.
Technique: Maximum weave 25.0 mm
OK TUBROD 75
Electrode extension: 10 - 15 mm
Typical chemical composition of the weld metal (%) Current / Polarity: DC
C Si Mn
CO2 0.040 0.50 1.50 Weld Current Voltage Travel Heat
Ar+CO2 0.055 0.53 1.68 Layer Speed Input
(A) (V) (mm/s) (kJ/mm)
Typical mechanical properties of the weld metal
Strength Yield Elong. Impact
Root 150 23 0.6 5.8
(MPa) (MPa) (%) (J) at -40C
2nd Pass 130 22 1.3 2.2
CO2
Fill 130 22 3.0 1.0
(DC-) 480 400 22 90
Cap 130 22 3.3 0.9
The downhill welding of fillet welds by the MAG process is regarded as an insecure
method by many in the welding industry, and is, therefore, rarely used. Some German
shipyards, however, have successfully developed and applied downhill welding proce-
dures for thin-walled applications using OK Tubrod 14.12 metal-cored wire.
Root Root with 1st final run Root with final run on either side
Figures 4 to 6. building-up of runs, square butt weld, t = 7 mm; vertical down welding.
Additional benefits
Additional benefits of the downhill MAG welding of
fillet welds with OK Tubrod 14.12 are:
Metallurgically perfect
The welded joints are easily tested by X-Ray. Fusion
faults introduced by lack of skill give clear indications.
The excellent mechanical properties have been con-
firmed by various tensile, bend and CVN impact tests.
Weld metal and HAZ hardness increase has not been
observed.
At first glance, the bevelling of plate edges may look When welding, the accuracy of the angle and the cut
easy, but it requires considerable knowledge and expert- quality are very important, but the straightness of the
ise to build an installation that cuts accurately and fast cut is critical. If it is not perfectly straight, the root gap
and that is, at the same time, user-friendly. Over more will vary and unacceptable weld defects are more like-
than 70 years, ESAB Cutting Systems has used its glob- ly to occur; this apart from the fact that the joint vol-
al experience in cutting installations to further improve ume increases and more filler material is needed.
each generation of control units. The result is continu-
ing improvements and simpification in programming
and the use of cutting installations. This constant inno-
vation, results in lower bevelling costs, higher produc-
tivity, and increased customer competitiveness.
Bevel shapes
The welding of medium and large thickness plates
requires a weld joint preparation which can be either a
V-,Y-,K- or X- bevel, depending on the welding H2 L2
process, application and plate thickness. If Angel = 45
H2=L2
H1
H1 H2
Figure 2. Cutting angle.
Figure 1a, 1b, 1c. V-,Y-, X- and K- bevels Figure 3. Cutting length.
Oxy-fuel cutting.
The earliest technology to be incorporated in gantry cut-
ting machines, and still one of the most cost-effective cut-
ting processes. Oxy-fuel cutting is, however, limited to
the use of carbon steel and is not suited for aluminium,
stainless steel, brass or copper. When used for bevelling,
it is limited to a plate thickness of 75mm and a 45 angle.
Main features:
Endless rotating (CNC) which allows any kind of
bevel shape.
CNC controlled lateral torches and angle setting.
Figure 8. Up to 45 manual Figure 9. The endless rotat- Linear potentiometer height control with air cooled
angle setting of the lateral ing head allows any kind of sensor foot, for bevel cutting of V-, Y-, K- and X-
torches. bevel shape. joints, offering:
absolute high accurate bevel height control of +/-
As previously stated, height control is one of the most Bevel height control accuracy less than 0.3 mm.
important factors to be considered. With the plasma The bevel angle can be continuously (interpolated)
process, the cutting arc length changes with the bevel changed within one linear contour block or within
angle and is, therefore, not accurate enough to be used numerous following blocks.
The programmed cutting speed will be continuously
adjusted for the change of bevel angle.
Bevel angle setting accuracy: 0.2
Straightness of the cutting edge: 0.5
within 1000mm.
The organisation programme module.
Can compensate the angle variation up to 1.
Can consider the upper melting radius.
Can reduce the repeatable dimension tolerances to
2mm & bevel 30 at 15mm thickness.
Installation on NUMOREX and TELEREX type
Figure 14. Bevel degree accuraty of 1. machines.
Main features :
Endless rotating head (CNC) which allows any kind
of bevelling shape. To be installed only on the
ALPHAREX range of machines.
Bevelling capacity up to 45 on 10mm carbon steel
and 30 on 12 mm carbon steel.
CNC controlled lateral torches and angle setting.
High accurate bevel height control via the capacitive
nozzle.
Less heat distortion.
Y-, K- and X -bevels possible under certain circum-
stances.
Marking and cutting possibilities.
ESAB and PERMANOVA tools and high power fiber optics. It The main focus of the new combina-
of Mlndal, Sweden, have announ- holds a strong position in the auto- tion will be on laser-aided
ced an agreement under which the motive industry with robotised MIG/MAG welding, a very produc-
two companies will co-operate laser solutions for welding, cutting, tive and high quality welding
closely in the development of laser- brazing, hybrid welding, hardening process with a wide range of applica-
hybrid welding systems. and marking. tions in welded fabrication.
PERMANOVA, as a producer of
laser systems, is renowned world-
wide for its expertise in laser process
Svetsaren no. 1 2003 35
Two new wire feeders, the
ESABFeed 30-4 and ESABFeed 48-
4 complement the ESABMig weld-
ing machines. Both feeders benefit
from four-wheel drive and opti-
mised feed roller profiles to ensure
excellent feeding qualities; electron-
ic control of the drive wheels helps
to achieve an accurate and stable
arc. The two feeders are available
either with an enclosed spool holder
or equipped to use ESABs
Marathon Pac bulk wire spools.
NEW ORBITAL TIG HEADS FOR HIGH QUALITY TUBE WELDING a key determinant of the quality of
the product. It is well suited to
ESABs new PRH orbital TIG PRH tools are available in three chemical, food and pharmaceutical
tube-welding tools are easy to oper- sizes, enabling welding of tubes industry applications in which
ate and capable of connecting thin- between 3mm and 76.2mm diameter. smooth, even internal and external
walled tubes with butt welds of the Each PRH tool is water-cooled and weld seams are mandatory to satisfy
highest quality, regardless of mate- forms a complete unit incorporating hygiene considerations.
rial; titanium can be welded as eas- the return conductor.
ily as stainless steel. The welding heads are driven by
encoder motors for the precise posi-
For efficient, quality assured welding tioning of each sector when welding
comprehensive gas shielding around with different sets of parameters.
the tube is provided using a system
based on the chamber principle. All PRH thus provides a highly effi-
rotating components including the cient means of producing high qual-
tungsten electrodes are enclosed in a ity welds on metal tubing used in
sealed chamber formed by the outer the most demanding applications.
casing, which also incorporates
clamping elements to locate and The equipment is designed for
align the tubes being welded. industries where weld seam finish is
UNIQUE MODULAR LEGIO FRICTION STIR WELDING EQUIPMENT The relatively modest cost of
LEGIO machines will allow fabri-
A major development in the field of service worldwide. The LEGIO
cators to consider FSW for small
Friction Stir Welding, the LEGIO FSW machine concept retains the
batches of products. Industries like-
modular FSW machines. same level of functionality but modu-
ly to benefit from the equipment
lar construction allows faster delivery
include automotive, aerospace,
With the launch of the LEGIO at significantly lower cost. In essence,
marine, architectural, construction
modular friction stir welding the customer determines the working
and general engineering.
(FSW) machine concept ESAB is area, the bed configuration, the
making the FSW process applicable clamping arrangement, and the num-
to a much wider industrial base. ber of heads. Several options are
then available to satisfy the applica-
Use of FSW has hitherto demanded tion requirements, whilst the control
substantial investment in a custom- system has been developed specifi-
engineered machine. By contrast, a cally to handle the FSW process.
LEGIO machine is built from
standard modules capable of satis- The potential market is very large
fying most applications. The system as the process is extremely versatile
is capable of welding materials from and requires no special surface
1.2mm thickness to 65mm thickness preparation. As well as welding two
from one side. components of the same grade of
aluminium, the FSW process can
ESAB has been the world's leading join dissimilar alloys or even join
developer of FSW equipment since two completely different metals. In
the process was first commercialised many cases FSW can be used to join
in 1992. A large number of materials that cannot be welded by
SuperStir machines are now in any other means.
Svetsaren no. 1 2003 37
WELDING WIRE FEEDERS GIVE back time and creep start. Certain
CUSTOMERS AMPLE CHOICE combinations of control panel and
An exceptionally broad range of power source also deliver the fol-
rugged welding wire feeders and lowing additional functions: a digi-
controllers is being launched by tal voltage/current meter; crater
ESAB for use with a variety of dif- filling; 14 pre-programmed synergic
ferent types of welding machine. lines; and a facility to create two
There is a choice of three alterna- customised synergic lines.
tive feeding mechanisms and nine
controllers for use with step-con- To keep the set-up time as short as
trolled or thyristor-controlled possible, all of the connection
power sources. cables are of the quick-connect
For wire diameters up to 1.2mm, type, and standard connection
the ESABFeed 30-2 feeder is a two- cables are available to enable the er is to be used as part of a semi-
wheel-drive unit with 30mm diame- working zone to be extended as far automated welding system, a
ter feed rollers. While the 30-4 feed- as 35m from the power source. remote control output provides a
er has the same size rollers, it bene- Irrespective of the length of the 42V AC power supply, start/stop
fits from a four-wheel-drive arrange- connection and return cables, control and remote monitoring and
ment that enables wire diameters up ESABs TrueArcVoltage system control of the welding current and
to 1.6mm to be fed. If wire up to ensures that the welding current voltage, depending on the power
2.4mm is to be fed, ESAB offers the and voltage are always measured source employed.
48-4 four-wheel-drive feeder that correctly, thereby helping to ensure
has 48mm rollers and a pair of drive a consistent weld quality. To assist with portability, the feed-
motors. ers can be equipped with an option-
If a water-cooled welding gun is al counterbalance, lifting eye or
Regardless of which of the nine being used, ESABs LogicPump wheel kit.
control panels is selected, all feed- (ELP) starts the water pump auto-
ers include features such as matically as soon as welding com- More information is available in a
two/four stroke, adjustable burn- mences. Moreover, if the wire feed- new brochure.
CADDYTIG AND CADDYARC WELDING EQUIPMENT IS RUGGED, dles electrodes from 1.6 to 3.2mm
PORTABLE, AND IDEAL FOR THE MOBILE PROFESSIONAL WANTING diameter and has adjustable hot
HIGH QUALITY WELDS start, thereby ensuring easy, reliable
starts. Furthermore, the adjustable
ESABs latest CaddyTig 150 and trol of the pre and post gas flow and arc force and the ArcPlus helps
CaddyArc 150 welding machines the ramp up/down also helps to to maintain an excellent weld quali-
are designed for use by professional ensure the weld quality is excellent ty, and the high power reserve
welders who are out and about, at the start and finish as well as dur- allows a long mains lead to be used.
working both indoors and outdoors. ing weld passes. When used for
Moreover, the portability and flexi- MMA welding, there is a further ESABs CaddyTig and CaddyArc
bility does not come at the expense facility for adjusting the hot start, machines all operate from a stan-
of weld quality, which remains high arc force and ArcPlus parameters. dard 230V power supply and are
thanks to the incorporation of Up to four sets of welding parame- equipped with a sturdy carrying
proven ESAB inverter technology ters can be stored in the user- handle. If a unit is to be frequently
and several sophisticated features. friendly controllers memory of the moved, an optional shoulder strap
CaddyTig, two for TIG and two for and trolley are available.
Both the CaddyTig and CaddyArc MMA. These parameter sets can
machines benefit from an integral either be selected from the control
voltage and current meter so that the panel or via the TIG torch switch.
user can closely monitor the welding Users have the choice of pulse pro-
process, and a remote control facility gramming and/or manual pulse
enables the welding parameters to be switching when switching between
adjusted from the torch, in addition the two TIG parameter sets.
to a remote on/off switch.
For those who do not need TIG
Suitable for both TIG and MMA capability, the CaddyArc 150 can be
welding, the CaddyTig 150 has high- used for MMA welding of most fer-
frequency ignition and Lift Arc, rous metals, including alloyed and
allowing the user to select the opti- unalloyed steels, stainless steel and
mum setting for the ideal start; con- cast iron. The CaddyArc 150 han-
38 Svetsaren no. 1 2003
the applicable flux and wire combi-
nation is made.
The matte appearance results from a for most commonly used grades of
new surface treatment that is part of stainless steel. The wires are sup-
an improved manufacturing process. plied in 15kg basket spools for semi-
In addition to the surface being automatic welding and 250 or 475kg
matte, rather than shiny, the diame- MarathonPac bulk drums for mech-
ter has a tighter tolerance and the anised and robotic welding.
stiffness is higher. Furthermore, strict
control of the cast and helix both of As one of the worlds leading sup-
which are important properties for pliers of welding equipment and
spooled wires leads to additional consumables, ESAB manufactures
benefits. its own solid wires for stainless
steel, un-alloyed and low-alloyed
Taken together, these product char- steel, and aluminium. The new
acteristics give the new wires greatly matte stainless steel MIG wires
ESAB has developed a new genera- improved feedability and a very sta- have been developed as a direct
tion of solid stainless steel MIG ble welding arc, resulting in depend- response to demand from the mar-
welding wires that feature a matt able performance for the MIG ketplace for improved welding per-
surface appearance. These wires process, consistently high weld qual- formance, drawing upon ESABs
provide improved welding proper- ity, and minimal post-weld cleaning. extensive experience and specialist
ties and lead directly to enhanced ESAB matt stainless steel MIG wires knowledge of the production tech-
MIG welding performance. are available in a range of diameters nologies involved.
The new wire produces an excep- The new AristoRod range current-
tionally stable and spatter-free weld- ly comprises OK AristoRod 12.50
ing arc. In addition to enabling high- (EN G3Si/ER70S-6), OK
er duty work cycles, resulting in AristoRod 12.57 (EN G2Si/ER70S-
increased productivity, this spatter- 3) and OK AristoRod 12.63 (EN
free welding arc also reduces the G4Si/ER70S-6). The range is avail-
necessity and cost of post weld grind- able on 18kg adapter-free basket
ing. spools and in environmentally recy-
ESAB has introduced OK AristoRod, clable, octagonal cardboard drums,
a new family of solid copper-free Contact tip wear, a traditional prob- 250 or 475kg MarathonPac. These
MAG welding wires that enables lem with copper-free wires, has been are specifically suited for mecha-
fabricators to get the best out of improved to a level superior to cop- nised and robotised stations,
their welding stations, whether they per-coated wire, so arc stability is because downtime for spool chang-
are semi-automatic, mechanised or guaranteed over a longer period and ing is considerably reduced.
robotised. downtime for tip changing is limited.
ESAB AB, Box 8004, SE-402 77 Gteborg, Sweden. Phone: +46 31 50 90 00, Fax: +46 31 50 93 90, Web: www.esab.com, E-mail: info@esab.se
Svetsaren, Esab AB, Marketing Communication
c/o P.O. Box 8086, 3503 RB Utrecht, The Netherlands
Tel. +31 30 248 5223. Fax. +31 30 241 1535
Internet: http://www.esab.com
E-mail: info @ esab.se