Ok AristoRod Non-Copper-Coated Wire Welder … · 12.50 ER70S-6 G3Si1 G 42 4 G 38 2 ... 12.57...
Transcript of Ok AristoRod Non-Copper-Coated Wire Welder … · 12.50 ER70S-6 G3Si1 G 42 4 G 38 2 ... 12.57...
NoN copper-coated solid gmaw wires with advaNced surface characteristics
Ok AristoRod™ Non-Copper-Coated Wire Welder Guidebook
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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
contents
introduction 2
Before You start welding 3
• ContactTipsandGasNozzle 3
• Liners 4
• GasandWater 4
• WireFeedUnit 4
• MarathonPac™Installation 5
• CheckDriveRollsandWireFeeding 7
• ShieldingGas 8
contact tip and gas Nozzle 9
• CorrectStick-OutLength 9
• GasNozzleDiameter 10
welding parameter setting 11
• HowtoGetanOptimumSetting 11
oK aristorod™ - the complete range 13
esaB swift arc transfer™ 14
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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.
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.
feature Benefit
Consistent welding performance Consistent weld results
Stable arc with low feeding forceHigh 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
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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
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.
correct incorrect
For contact tip sizes and packages, please contact ESAB or your local Distributor.
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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
•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.
Correct
Incorrect
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Special cone for Jumbo Marathon Pac with 1050 lbs (475 kg) non- or low-alloyed wire.
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
Before You start welding
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.
marathon pac installation
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Step 6. Attach the wire conduit to the wire feeder. Avoid liner bends or point pressure on the liner.
Step 1. Remove the rubber strap and VCI paper.
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 2. Place the wire conduit attachment or “spider” on top of the Marathon Pac.
Step 5. Attach the wire conduit to the lid or cone with the quick connector.
Step 3. Feed the welding wire through the centre of the spider.
Before You start welding
marathon pac installation
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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.
Before You start welding
Smooth Knurled
9
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.
Before You start welding
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contact tip and gas Nozzle
It is essential to fit the gas nozzle and
contact tip at the right distance relative
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
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
20 mm ) ø 0.040 in. and 0.047 in. (ø 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
long. The weldpool will get hotter and more
difficult to control.
Incorrect. Contact tip too recessed.
Incorrect. Contact tip protruding beyond gas nozzle.
2 mm
Correct positioning of contact tip.
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.).
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contact tip and gas Nozzle
gas Nozzle diameter
Various nozzle diameters must be available
to allow adequate access to the joint, to
maintain the above recommended stick-
out, 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
gas protection can be assured.
Incorrect. Use of standard gas nozzle restricts access to narrow joints, resulting in too long a stick-out.
Correct. Use a smaller diameter nozzle or a conical nozzle for the 1st layers in the root area.
Correct. Use of standard gas nozzle for completing the joint ensures good gas protection and correct stick-out.
When welding in short arc transfer, the arc stability and start properties will improve
when reducing the stick-out.
1/2 - 3/4 in. (12-20 mm)
> 3/4 in. (> 20 mm)
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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.
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
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.
•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.
welding parameter setting
Correct. Correct arc length. Stable and concentrated arc with a quiet spray droplet transfer.
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.
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welding parameter setting
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.
•Due to OK AristoRod’s 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.
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100 150 200 250 300 350 400
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1 Welding in short arc area. Use for thin plate, tack welding or positional welding.
When arc length is tooshort increase voltage.
When arc length is toolong decrease voltage.
Welding in spray arc transfer. High productivity, thick plate, downhand welding, low spatter.
Excessive weld metal. Di�cult to control.
Welding in globular area. Unstable arc and excessive spatter.Try to avoid.
Amperage
Volta
ge
OK AristorodTM
0.040 in.(1.0 mm)
0.047 in.1.2 mm
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oK aristorod - the complete range
aws and eN classifications
oK aristorod
classification wire
classification wire and weld metal shielding gassteel type
aws eN-iso eN-iso 14175
a5.18 a5.28 14341-a 16834-a 21952-a /-B m21 c1
12.50 ER70S-6 G3Si1 G 42 4 G 38 2Normal strength
12.57 ER70S-3 G2Si G 38 3 G 35 2Normal strength
12.62 ER70S-2 G2Ti G 46 4 G 42 3Normal
strength
12.63 ER70S-6 G4Si1 G 46 4 G 42 2Normal strength
12.65 ER70S-6 G4Si1 G 46 4 G 42 2Normal strength
13.08 ER80S-D2 G4Mo G 50 4 G 46 0Creep
resistant
13.09 ER80S-G G2Mo G MoSi /G 1M3
G 46 2 G 38 0Creep
resistant
13.12 ER80S-GG CrMo1Si / G 55M 1CM3
Creep resistant
13.16 ER80S-B2Z CrMo1Si / G 55A 1CM
Creep resistant
13.22 ER90S-GG CrMo2Si /
G 62M 2C1M3Creep
resistant
13.26 ER80S-G G Z 3Ni1Cu G 46 4 G 42 0 Weather resistant
55 (13.13) ER100S-G G Mn3NiCrMo G 55 4High
strength
69 (13.29) ER110S-G G Mn3Ni1CrMo G 69 4High
strength
79 (13.31) ER120S-G G Mn4Ni2CrMo G 79 4High
strength
89 (1B96) ER120S-G G Mn4Ni2CrMo G 89 4High
strength
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oK aristorod - the complete range swift arc transfer™
Swift Arc Transfer is a high productivity
GMAW process using OK AristoRod
non-copper coated welding wires at
very high wire feed speeds. The SAT
process produces flat welds with good
penetration and no undercut.
the ultimate high productivity process.
ESAB’s Aristo™ U82 robotic package
enables SAT welding. It is a complete
set of welding consumables and
equipment, based on ESAB’s latest
digital power source technology.
The package consists of:
•The Aristo MIG 5000i inverter power
source or ESAB's MIG 4002c, 5002c
and 6502c chopper power sources.
•The Aristo U82 control unit with SAT
synergic lines or The Aristo U82
interface for different robot brands.
•The Robofeed 3004w ELP
encapsulated wire feeder with up to
98.4 ipm (30 m/min) wire feed speed.
•Cable packages.
•The Marathon Pac bulk wire drum
with robot quality welding wire and
optional bobbin holder.
SATTM
Sho
rt a
rcM
ixed
arc
Sp
ray
arc
Forced short arc
Wire feed speed (m/min)A
rc v
olta
ge
Rotating arc
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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.
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