Svetsaren 2 2003 9.5 (Page 1) - ESAB Asia
THE ESAB WELDING AND CUTTING JOURNAL VOL. 58 NO.2 2003MIG/MAG WELDINGANDAND RELATEDRELATEDPROCESSESROCESSES
THE ESAB WELDING AND CUTTING JOURNAL VOL. 58 NO. 2 2003Articles in Svetsaren may be reproduced without permission but withan acknowledgement to ESAB.PublisherBertil PekkariEditorBen AltemühlEditorial committeeBjörn Torstensson, Johnny Sundin, Johan Elvander, Lars-Erik Stridh, Lars-Göran Eriksson,Dave Meyer, Tony Anderson, Peter Budai, Arnaud Paque, Klaus BlomeAddressSVETSAREN, ESAB AB, Marketing Communicationc/o P.O. Box 8086, 3503 RB Utrecht, The NetherlandsInternet addresshttp://www.esab.comE-mail: info@esab.seCover photo courtesy Nista BV. Amsterdam,The Netherlands. MAG repair welding ofcutter heads.Lay-out: Duco Messie. Printed in The Netherlands by True ColoursContents Vol. 58 No. 2 2003You'll never walk alone.37ESAB provides Martifer Portugal withwelding and cutting technology for the roofconstruction of Euro 2004 soccer stadium.OK AristoRod and MarathonPac takeMAG welding productivity to new levels.New copper-free welding wire and variousbulk packaging options make a team that ishard to beat when it comes to productivity.2527Welding of austenitic vessels for newCERN cyclotronThe Slovakian fabricator, SES, producesvacuum proof vessels for particle generator.ESAB high-alloyed welding consumablesfor ferritic stainless steel exhaust systemsA complete range of consumables to meet anew trend in the automotive industry.Tandem MIG/MAG welding with ESABSaipem's Blue Stream Project.912A double pipeline, laid through the BlackSea at a record depth of more than 2 kilometers, by Saipem. ESAB consumablesand WPS’es played an important role.Essential Variables for MIG WeldingAluminiumThe MIG welding of aluminium needs particular attention to detail, explained byAlcoTec Wire Corporation.28Power sources in arc welding3018ESAB gives crucial support to reopenedPolish shipyard for the crack-free weldingof thick walled tanks in the world's largestduplex stainless steel chemical tankers.Welders' love affair with new self-shieldedflux-cored wires.Successful applications in civil constructionthroughout the USA.One one is more than two22Laser hybrid welding combines the advantages of laser- and MAG welding.The developments in power sources arereviewed, providing useful selection guidance.Status report on NOMAD33Szczecin Yard making comeback14ESAB's Tandem station is a productiveoption that soon pays back the investment.3538ESAB is involved in European Commissionproject that develops an unmanned weldingrobot for low-volume production.The mechanised FCAW of high strength steelfender piles for the new Rio Paraná bridgeAn interesting piece of welding engineeringby ESAB-CONARCO in Argentina.ESAB welding solutions and support aidrevived shipbuilding on the River Tyne inEngland.The re-opened Wallsend, Newcastle yardhas returned to naval shipbuilding.Stubends & Spatter.
You’ll never walk alone!ESAB provides Martifer with welding and cutting technology for the construction of Euro 2004soccer stadium.By: Ben Altemühl, editor of Svetsaren.Martifer, Portugal’s largest metal construction company, and third in size on the Iberian Peninsula,is involved in the construction and renovation of stadiums for the Euro 2004 soccer tournament,of which the new Benfica stadium, Luz, in Lisbon, is undoubtedly the most impressive. ESABPortugal provided Martifer with a complete, highly efficient solution for the robotic cutting andmechanised welding of 2m diameter and 40mm thick pipes.AcknowledgementWe compliment our ESAB Portugal colleagues JorgeLima, Sérgio Silva, João Henrique and Mário Cordeiroon their creative technical solution, designed and implemented under considerable time pressure. Their efficientteamwork symbolises the ESAB way of doing business,"your partner in welding and cutting".Football and welding – not that far apartFrom June 4th to July 12th 2004, it will be Portugal’s turn tohost the finals of the European soccer cup, that takes placeevery four years. As many as 50 countries have competedin the qualification rounds and, eventually, 15 made it tothe finals to join Portugal in the tournament. Already, thissoccer crazy nation is buzzing with excitement at thethought that they will be hosting the crème de la crème ofEurope’s players and that Portugal will be in the focus ofthe international sports media for almost a month.The tournament – the world’s biggest sporting event afterthe Olympics and the World Cup finals – will see 7 new sta-diums being built and three others being extensively renovated. The project will cost around 550 million Euro, ofwhich 20% is being paid by the Portuguese government andthe rest by clubs and local governments.Martifer is involved in four stadiums, two in Porto and twoin Lisbon. ESAB welding products are a common sight atthese construction sites but, technically, the most interesting is a tailor-made solution created for the construction ofthe new ‘Èstadio da Luz’, the Stadium of the Light, thehome of one of Portugal’s most famous clubs, Benfica. Thenew Stadium of the Light is being erected next to Benfica’sprevious, now demolished stadium in the north-west of thecity. Already, four giant red arcs supporting the suspendedroof, mark the skyline of that part of Lisbon.These arcs required an intelligent cutting and welding solution, both for pre-fabrication and on-site assembly. After afierce battle with the competition, ESAB Portugal won thewelding and cutting contract for this prestigious project.ESAB’s solution not only satisfied the high quality andSvetsaren no. 2 2003 3
ing 2 tonnes per meter) were joined to form a 24m longsegment (Figure 2). In total, 41 of these segments had tobe constructed within three months. A challenging pieceof work!CuttingThe 40mm thick pipes received a symmetrical X-bevelwith a land of 3mm and a 30 degrees bevel angle, requiring three cuts, as shown in Figure 3. Two cutting processes were considered, oxyfuel and plasma cutting.Cutting speed was obviously the predominant requirement, because of the very tight production time allowedby the stadiums’ building schedule. In addition, a consistently high bevel quality was needed to enable efficientand defect-free welding with the planned mechanisedwelding processes for prefabrication and on-site assembly.Figure 1. Two ESAB designed welding cabins at a breathtaking height.Plasma cutting is obviously the fastest process. For thinmaterial, it can be up to 10 times faster than the oxyfuelprocess and the cutting quality is at least as good. There isa price tag attached to plasma cutting, however.Depending on the material thickness, it can be moreexpensive than oxyfuel cutting, and a return on investment depends on the price and complexity of the installation, and of course on the type of application.In this project, the initial straight cut was in 40mm thickSt 52-3, followed by two cuts through a smaller thicknessunder the bevel angle. Plasma cutting was calculated to be2 times faster than oxyfuel cutting for the initial cut(Table 1), and three times faster for the complete bevel.A similar cutting economy was valid for the edge preparation for the on-site assembly welds. These could only bewelded from the outside and therefore each prefabricatedsection received a 35 degrees V-bevel with a land of 2mmon both ends, for which two cuts were needed.Figure 2. 24m long prefabricated arc sections waiting to belifted in place.safety demands placed on this public facility, but was crucial in providing Martifer with the speed of production thatenabled them to meet the very tight project schedule.Like a rainbow in the skySpectators lucky enough to witness the final or any othermatch in the Stadium of the Light, will be able to see theperfectly ‘round’ arcs like red rainbows in the sky.Television spectators will, no doubt, be offered an equally exciting zoom-in view at the start of the match. The eyeis misleading, however. The arcs are not round but multilateral, consisting of many small pipe segments that arecut under a slight angle, and welded together – usingESAB technology.To imagine that Martifer welders have been doing their highprecision work in a cabin sliding over the arc as its construction proceeded (figure 1), sends shivers down my spine.The majority of the welds were not made at high altitude,however. In prefabrication, six 4 meter long pipes (weigh-4 Svetsaren no. 2 2003The bevel quality of a plasma cut is at least as good as anoxyfuel cut and has a smoother surface texture. It has theadditional advantage that there is less dross (molten andsolidified oxydes) on the edges. (figure 4).A third advantage of plasma cutting is that there is no needfor preheating, as with oxyfuel cutting, saving time and thecost of gas. With this solution, the tight production schedule could be met, justifying the higher investment needed.The robotic cutting solution agreed by both ESAB andMartifer consisted of a PT 600 XLS plasma head and anESP 400C plasma power source with programming box,supplied by ESAB Cutting Systems in the USA, mounted30º1240mm33mmFigure 3. Symmetrical X-joint and cutting sequence.
2 ESAB LAW 520 W water-cooled, heavy duty powersources. 2 MEK 4S wire feeders. 2 water-cooled PSF 410W torches.Figure 4. Plasma cut Xbevel. Smooth surface andlittle dross.on an industrial 6 axis robot. Special positioners for theinstallation were supplied by PEMA.The installation acts on two different intelligence levels: The robot provides the 3-dimensional movement ofthe torch. Before the first cut, it reads the geometry ofthe actual pipe end and re-calculates the settings. The power source is pre-programmed with individualparameter settings for all three cuts.The shielding gas was compressed air, the starting gas wasN2 and the cutting gas was O2.ESAB Portugal, assisted by ESAB Cutting Systems,installed and implemented the complete cutting solutionwithin 60 days, including training of the operators. Thecutting time per joint was about 30 minutes. Figure 5shows a bevel being cut.Prefabrication weldingFor joining the pipes to 24m long sections in prefabrication,Martifer’s existing column and boom station with singlewire SAW head -applied for both the inside and outsidewelds – proved sufficiently productive to satisfy the production schedule. The flux/wire combination was ESABOK Flux 10.71/OK Autrod 12.22, the most commonlyapplied consumables for this type of pipe application(Figure 6). Another industry that benefits greatly from theexcellent welding characteristics of OK 10.71/12.21 is thefabrication of windmill towers. All welds were in thedownhand position while the pipes were rotated on selfaligning 70 TAW Pema positioners. Figure 7 shows thejoint design and bead sequence of the prefabrication welds.It took around 15 hours to complete each weld.The LAW 520 is a thyristor-controlled machine with verygood characteristics for FCAW. Welding parameters arestepless adjustable allowing excellent fine-tuning of thewelding parameters.FILARC PZ6113 all-position rutile-cored wire, diameter1.2mm was chosen as the welding consumable for themechanised welding, together with the basic stick electrodeOK 48.00 for the manual welding of the root run.PZ6113 has excellent welding characteristics in all positions when welding upwards from 6 to 12 o’clock. The fastfreezing slag supports the weld pool well and the soft andstable spray arc is very tolerant for irregularities in the pathof the welding arc. The slag is always easily removed; wellwithin the time that the tractors need to travel back to the6 o’clock position. This allows the duty cycle to be as highas possible. The wire is welded in Ar/20% CO2 mixed gas.One parameter setting (190A/24V) was choosen for allbeads throughout the joint, being the optimal setting forthe most critical position between 4 and 5 ‘o clock. Thetravel speed varied as the filling of the joint proceeded,from 31cm/min. for the hot pass to 17cm/min. for the caplayers. The weaving width gradually increased to a maximum of 20-25mm. This is easy for the welders. They donot have to re-adjust parameters during welding, so thereis no inherent risk of welding defects. Figure 9 shows thejoint design and the positioning of layers and beads.The equipment and the welding procedure was tested andaccepted on a mock-up installation in the factory beforebeing applied on-site. Still, the conditions 90m high abovethe stadium are not the same as in a comfortable workshop. ESAB specialists dedicated considerable time toAssembly on siteMechanised FCAW was chosen as the most dependableand productive solution for the assembly of the prefabricated sections at the Benfica stadium. ESAB supplied thewelding equipment and assisted Martifer in the design oftwo welding cabins. Each cabin contained the followingmechanised welding equipment: ESAB Railtrac FW 1000. Two tractors walking the circumference of the pipe from 6 to 12, clockwise andcounter clockwise, over a rail attached to the )Cost differenceoxy/plasmaper meter40404209403.87 Figure 5. Cutting ofa bevel edge.Cost/kg0.56 0.53 Table 1. Cost comparison between oxyfueland plasma cutting for the initial cut in 40mmwall thickness pipe. Plasma cutting is fasterand cheaper. Triple torch oxyfuel cutting wasconsidered, but was not easy to achieve forround profiles.Svetsaren no. 2 2003 5
the fine-tuning of the welding parameters when depositing the first production welds. The changing angle of thegirth welds along the circumference of the arc presenteda particular problem, because of the changing action ofthe gravity on the weld pool. The solution was to apply adifferent weaving pattern for the most extreme locations.70ºFigure 7. Jointdesign and beadsequence for subarc welds in prefabrication.119732141084.040mm5 613 14 1215160.8mm max.In total 40 welds were produced to complete all four arcs.One weld took 1.5-2 days, including 6 hours of preheatingto 150 C. The work in the two cabins proceeded 24 hoursa day. All welds were 100% non-destructive tested. Inprefabrication, the welds were X-ray tested and, in assembly, US testing was applied.Martifer Group, a solid allianceMartifer holds a strong position in the civil construction sector. It was founded in 1990 and has since expanded tobecome Portugal’s largest metal constructor, specialising inshopping malls, sport stadiums, bridges, public housing andfactory halls. The Martifer group incorporates five companies; Martifer, Martinox, specialised in stainless steel structures, Martifer Aluminios (glass facades) and the international initiatives Martifer Spain and Martifer Polska.Figure 8. FCAW withFILARC PZ6113 andRailtrac FW 1000.60ºFigure 6. Single wireSAW with OK Flux10.71/OK Autrod12.22. Inside weld.StubendsSpatter&Fireman in heart and soulThe types of industry to which ESABsupplies its welding and cutting products vary from the smallest workshopto vast industrial enterprises like shipyards and automobile production centers. The company Luis Figueiredo SAin Cacia, Portugal could be typified as"small but beautiful".Today it builds a range of trailers andspecial vehicles, but the company wasfounded when the owner turned hishobby, fire fighting, into profession.6 Svetsaren no. 2 2003Figure 9. Jointdesign and beadsequence ofassembly weld.Luis Figueiredo has had a fascinationfor fire fighting since his youth and hewas predestined to become a fireman.During his many years of service as afire fighter, he developed an opinionof his own on how fire engines shouldbest be built and equipped. It was 21years ago, when Luis decided to bringhis ideas into practice and startedbuilding the trucks that are nowadaysin service at fire stations all over thecountry.The fabrication principle hasremained the same over the years.The chassis and cabin are bought in,but from there the fire engine is buildup completely according to the ideasof Luis Figueiredo. A lot of welding isinvolved to fabricate the many components in steel, stainless steel andaluminium.ESAB has been with the companyever since the beginning, representedby its distributor Unisolda. Over theyears, sales engineer Alvaro Silva of30-4032123.25Unisolda has earned a reputationthroughout the company for his valuable support and advice.Luis Figueiredo remains a fireman inheart and soul. 53 of age now, he isstill member of the voluntary firebrigade.
AristoRod and MarathonPac take MAG welding productivity to new levelsBy Per Sundberg, ESAB AB, Gothenburg Sweden.OK AristoRod copper-free MAG wire is a recent ESAB innovation. Together with variousMarathonPac bulk packaging options it makes a team that is hard to beat.New OK AristoRod wires are given the unique copperfree ASC (Advanced Surface Characteristics) surfacetreatment, an important ESAB development. With thistechnology, ESAB is the first to produce bare wires withwelding characteristics that are at least as good as those ofthe best copper-coated wires in the market – but withsuperior feeding properties.Traditionally, the copper coating on MAG welding wiresperforms important functions. It lubricates the feedingprocess, improves the current transfer and protects againstcorrosion during storage. But the use of copper also has itsdownsides. The gradual build-up of copper dust and flakescan cause clogging in the feed system and lead to increasedspatter and poor weld finish and, eventually, to a completebreakdown of the welding process. Regular maintenanceand cleaning of the feed system is absolutely necessary toavoid feeding problems. However, this is time consumingand particularly costly when it concerns downtime ofmechanised or robotic welding systems.By removing the dust and flaking associated with copper,ESAB has removed the biggest contributor to the clogging of guns and liners and, with it, a major cause of production stoppages and increased cleaning schedules. Inaddition, greater arc stability results in less spatter,improved weld quality and finish and, consequently, inreduced weld cleaning.The good feeding properties brought about by ASC areexemplified by the feed force diagram, figure 1, resultingfrom feeding force tests with OK AristoRodand high quality copper-coated wire. Thesteel liner had a length of 4.5m andcontained a loop of 300mm diameter.The suppressed areas show themargins observed during the30 min. test. In feeding, a constant and preferably low feedforce is beneficial. The diagram shows that feed forcevariations are much higherfor copper-coated wire thanfor OK AristoRod.Contact tip wear is also afeature of the past. Thischaracteristic,alwaysassociated with earliergenerations of copper-free welding wire, does not applyto new AristoRod wires. ASC results in the lowest possible tip wear, comparable with the best copper-coatedwires available.ASC also minimises the risk of corrosion during extendedperiods of storage.The absence of copper on the wire brings yet another advantage. The amount of copper in the welding fume is reducedto an absolute minimum (figure 2), helping to satisfy concentration limits in the work environment – even better thancopper-coated wire. This contributes to improved workingconditions for the welder, along with other necessary precautions such as adequate fume extraction.(N) 1009080706050403020100OK AristoRod – Ø1.0Copper-coated wire – Ø1.0Feed force varianceFeeding forceAristoRod A new generation of copperfree MAG Welding wire.04 69Wire feed speedFigure 1: Feed forcediagrammes for 1.0mmdiameter size AristoRodwires vs copper-coatedwires.12 15(m/min)%0.45mg/h1000.40Copper-coated wire0.35Copper-coated wire800.30600.250.20400.15OK AristoRod 0.10OK AristoRod 200.0500150A/ 200A/ 250A/ 300A/19V 22V 27V 31V150A/ 200A/ 250A/ 300A/19V 22V 27V 31VFigure 2: Quantity of copper in welding fume.AWS and EN classifications.ProductClassifications WireAWS A5.18OK AristoRod 12.50 ER70S-6OK AristoRod 12.57 ER70S-3OK AristoRod 12.63 ER70S-6EN 440G3Si1G2SiG4Si1Classific
teamwork symbolises the ESAB way of doing business, "your partner in welding and cutting". Football and welding – not that far apart From June 4th to July 12th 2004, it will be Portugal’s turn to host the finals of the European soccer cup, that takes plac
svetsaren qsettm - a breakthrough in short arc welding focus on cutting new aristo wire feeders for shipyards marathon pactm - total mig/mag efficiency the esab welding and cutting journal vol. 60 no. 2 2005the esab welding and cutting journal vol. 61 no. 1 2006
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