Solutions for submerged arc welding

1 THE FULL SOLUTION FOR. submerged ARC welding . GLOBAL LEADER FOR submerged ARC welding . KNOWN WORLDWIDE FOR QUALITY, PERFORMANCE. AND PRODUCTIVITY. NETHERLANDS. UNITED KINGDOM. POLAND. CANADA FRANCE RUSSIA. GERMANY. UNITED STATES SPAIN. JAPAN. ITALY. CHINA. UAE. MEXICO. INDIA. LOCATIONS. COLOMBIA SINGAPORE. Global Headquarters PERU. Solution Centers BRAZIL. SOUTH AFRICA. CHILE AUSTRALIA. ARGENTINA. 11 000 Employees worldwide 325+ Global R&D Team 125 Years of experience 38 Solution Centers Billion USD revenue submerged ARC welding . FOR EVERY INDUSTRY. TECHNICAL EXPERTISE PRODUCTIVITY Solutions . GLOBAL APPLICATION SUPPORT. GO TO WEB PAGE. 2 submerged ARC welding TABLE OF CONTENTS. MOVING YOUR submerged ARC SOLUTION TO THE NEXT LEVEL 4. THE submerged ARC welding PROCESS 8. WELD COST STUDIES 11.

2 submerged ARC EQUIPMENT 14. submerged ARC CONSUMABLES / PACKAGING 16. POWER WAVE SOFTWARE Solutions : CHECKPOINT 17. Solutions FROM ONE HAND 18. submerged ARC welding 3. MOVING YOUR submerged ARC SOLUTION TO THE NEXT LEVEL. MOVING YOUR submerged ARC SOLUTION. TO THE NEXT LEVEL. High quality welding results Lincoln Electric is the submerged arc process specialist. Together we will Excellent bead appearance develop the best solution while maximizing your savings through highest Highest deposition rates deposition rates, highest quality and optimized parameters with your actual Deep penetration equipment and potential investments. Rate yourself on the next graph and I ncreased productivity let's move together to the next step. Tandem Twin Triple Arc POWER SOURCES. MULTIPLE. Tandem Arc Investment Tiny Twin Arc POWER SOURCE.

3 SINGLE. Long Stick Out Single Wire 150 200 250 300 350 400. 100 Deposition Rate (%) vs Single electrode 50. 40. Deposition Rate (kg/h). Tandem Long Stick Out ( ). 30. Tiny Twin Arc ( ). Long Stick Out ( ) Triple Arc ( ). 20. Tandem Arc ( ). 10. Single Arc ( ). 300 600 900 1200 1500 1800 2100 2400. Total welding Amperage (A). 4 submerged ARC welding MILD STEEL WIRE DEPOSITION RATES IN submerged ARC welding . Average Deposition Rate in (kg/h). Improvement versus standard Single Arc in [ %]. DC+ AC. Standard Long Standard Long Stick Out Stick Out Stick Out Stick Out Single Wire kg/h kg/h kg/h kg/h mm +54% +23% +130%. Single Arc Tiny Twin Arc kg/h kg/h . 2 x mm +48% +112%. DC+/AC AC/AC. Standard Long Standard Long Stick Out Stick Out Stick Out Stick Out Tandem Arc kg/h kg/h kg/h kg/h 2 x mm +188% +262% +218% +346%.

4 Tandem Twin kg/h kg/h . + 2 x mm +256% +300%. Multiple Arcs AC/AC/AC. Standard Stick Out Triple Arc kg/h 3 x mm +392%. High quality Lincoln welding Electric results supports you to select: Excellent Optimum bead appearance process Highest deposition rates Ideal parameters Deep penetrationthat guarantee the required Consumables I ncreased productivity mechanical properties customized to your application GO FOR. NEXT. STEP. submerged ARC welding 5. MOVING YOUR submerged ARC SOLUTION TO THE NEXT LEVEL. DEPOS. DEPOSITION RATES SINGLE POWER SOURCE. The single power source configuration panel I T I ON. Single Wire Long Stick Out Tiny Twin Arc Standard platform Low additional investment Very low additional investment Easy to upgrade To be used over 700 A High deposition rate Deposition rate up to 10 kg/h High deposition rate and high speed weld Low heat input (less distortion).

5 _____ To be used on fillet or filling weld Flux / wire ratio reduction 1 Power source Reduced penetration Deposition rate up to 30 kg/h 1 Wire feeder Deposition rate up to 20 kg/h Recommended with Power Wave . 1 Wire _____ AC/DC 1000 SD. 1 Power source _____. 1 Wire feeder 1 Power source 2 Wire 1 Wire feeder 1 Drive roll kit 1 Wire 1 Long Stick Out kit TYPICAL STANDARD DEPOSITION RATES FOR SINGLE POWER SOURCE. DC+ AC. Single Wire mm Tiny Twin Arc x mm Single Wire mm Tiny Twin Arc x mm Standard Stick Out Long Stick Out Standard Stick Out Standard Stick Out Long Stick Out Standard Stick Out Typical Deposition Rate kg/h kg/h kg/h kg/h kg/h kg/h Improvement vs. Single Wire mm 100% 154% 148% 123% 230% 212%. 250. +130%. 200. +112%. Productivity Improvement Percentage %. 150. + 54% + 48%. DC+.

6 +23%. 100. AC. 50 Hz 50. 25% balance -25% offset 0. Single Wire Single Wire, Tiny Twin Arc Single Wire Single Wire, Tiny Twin Arc DC+ Long Stick Out DC+ AC Long Stick Out AC. DC+ AC. 6 submerged ARC welding DEPOSITION RATES MULTIPLE POWER SOURCES. The tandem and triple arc configuration panel AT E S. R Tandem Tiny Twin Triple Arc High productivity High welding speed High deposition rate up to 35 kg/h Versatile process with Power Wave . AC/DC 1000 SD. _____. High productivity and high speed weld 3 Power source High deposition rate up to 30 kg/h Tandem _____ 3 Wire feeder 3 Wire 2 Power source Favourable weld geometry pass/cap pass 2 Wire feeder 3 Wire High deposition rate up to 25 kg/h 1 Drive roll kit Long stick out option with all benefits on demand _____. 2 Power source 2 Wire feeder 2 Wire TYPICAL STANDARD DEPOSITION RATES FOR MULTIPLE POWER SOURCES.

7 DC+/AC AC/AC AC/AC/AC. Single wire Tandem Tiny Tandem Arc + Tandem Tiny Tandem Arc Triple Arc Tandem Arc Tandem Arc mm Twin Long Stick Out Twin + Long Stick Out 3 x mm Typical Deposition Rate kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h Improvement vs. Single Wire mm 100% 288% 356% 362% 318% 400% 446% 492%. 500. + 392%. 450. + 346% + 287%. 400. + 300% DC+. Productivity Improvement Percentage %. 350 +262%. + 256%. AC/AC. 300 + 218% 50 Hz 25% balance + 188% -25% offset 250. AC/AC/AC. 200 50 Hz 25% balance -25% offset 150. 100. 50. 0. Single Wire Tandem Arc Tandem Tiny Tandem Arc Tandem Arc Tandem Tiny Tandem Arc, Triple arc DC+ DC+/AC Twin Long Stick Out AC/AC Twin Long Stick Out AC/AC/AC. DC+/AC DC+/AC AC/AC AC/AC. submerged ARC welding 7. THE submerged ARC welding PROCESS. THE submerged ARC welding PROCESS.

8 The arc being shielded and hidden under the flux, high current density can be considered with the following benefit: Operator protection from arc ray and heat radiation High deposition rate and high quality welds Versatile welding process with combination of wire diameter, flux type, single or multiple electrodes, welding current wave shape and welding mode welding PARAMETERS (VARIABLES). WIRE DIAMETER/AMPERAGE. The submerged arc wire standard portfolio includes different wire sizes, mainly between and mm wire diameter. The choice of wire size is made in accordance with the welding procedure parameters in order to maximize the current density and increase the melt off rate, without exceeding the wire current carrying capacity as shown in the following table. Amperage Used Wire Diameter 200 300 400 500 600 700 800.

9 Mm kg/h mm kg/h mm kg/h mm kg/h 10. 12. 8. 10. (kg/h). Rate(kg/h). 6. 8. DepositionRate 64. Deposition mmkg/h kg/h mm kg/h 4. mm kg/h 2. mm kg/h mm kg/h 2. mm kg/h 0. mm kg/h 0 200 300 400 500 600 700 800. 200 300 400 500 600 700 800 900. Amperage Used Amperage Used 8 submerged ARC welding POLARITY. In most of the submerged arc applications it is possible to work in DC current with the electrode being either positive or negative. Thanks to Lincoln Electric Waveform Control Technology embedded in the new Power Wave . AC/DC 1000 SD power source and the new MAXsa Controllers and Feeders, we can now take over the full area between DC+ and DC-. DC + DC- AC. Most common mode Improves deposition A compromise between Deep penetration and rate (25%) the two DC modes stable arc Limits penetration The optimum choice with Limited arc stability Power Wave AC/DC 1000 SD.

10 Waveform Control Technology capability provides precise control over: Frequency Balance Offset (Number of switch per (Percentage of time in (Positive/Negative second from positive to the positive polarity Amplitude). negative polarity) portion of one cycle). Offset : Positive Current Level = Penetration AC Frequency Current, Voltage, or Power Cycle Balance = Penetration/Deposition Offset : Negative Current Level = Deposition Stick-out: 32mm 15. DC- 13. Deposition Rate (kg/h). AC Square wave 25% balance, -20 offset 11. AC Square wave 25% balance 9. AC Square wave 50% balance 7. DC+. 5. 3. 200 400 600 800 Current (A) 1000. submerged ARC welding 9. THE submerged ARC welding PROCESS. ELECTRICAL STICK OUT. Electrical Stick Out setting: The electrical stick out or CTWD (contact tip to work distance) is the distance set between the contact tip end and the work piece.