Fronius Auto Argon-Arc Welding

5/21/2018 Fronius Auto Argon-Arc Welding

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R. BRUNMAIER 99TIG-HOTWIRE WELDING PROCESS

Fronius Schweimaschinen

Vertrieb GmbH & Co KG

GF II - Automation

Buxbaumstrae 2

A-4600 Wels

INFORMATION ON TIG-HOTWIRE

WELDING PROCESS


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SCHEMATIC SKETCH

-

+ -

+TIG-power source

Hotwire-

power sourceControl unit

PA8000 /FPA 9000

Wirefeederunit

Shielding gas

TIG-

torch

Hotwire-

torch

+

-


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ECONOMY

Overlay welding 100% duty cycle (kg/h)

Filler metal: Alloy 625-IG, 1.2

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

3.24

Tungsten0

1

2

3

4

5

6kg/h

Electrode

Hand

4mm

TIG

COLD-WIRE

1.2mm

390A

TIG

HOT-

WIRE

1.2mm

390A

GMAW

1.2mm

Corgon 18

SUB.ARC

4mm

400A


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ADVANTAGES


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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


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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


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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


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Welding is possible

in all positions

WELDING POSITIONS


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Power-station construction

Project: Lippendorf / GermanyFlue-gas desulphurisation plant:

Welding of 4 absorbers, D = 16 m

Internal overlay welding with Alloy 59

USAGE EXAMPLES


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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


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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


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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

S G S


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Automatic overlay welders - 2 double stations:

Valve body material: Alloy 625

Offshore - engineering

USAGE EXAMPLES

USAGE EXAMPLES


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Valve bodies:

Repair overlay welding with Alloy 625

Internal overlay welding of

valve blocks:

Cladding material:

Nickel-based Alloy 625,=1,2mm

USAGE EXAMPLES

USAGE EXAMPLES


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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


USAGE EXAMPLES


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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


USAGE EXAMPLES


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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

USAGE EXAMPLES


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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

USAGE EXAMPLES


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Overlay welding:

Ship components

USAGE EXAMPLES

Ship - building

USAGE EXAMPLES


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Pressure-pipeline construction:Assembly seams

Material thickness: 10-50mm

USAGE EXAMPLES

Pipeline construction

USAGE EXAMPLES


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Circular seam - ,Longitudinal seam - and

overlay welding

Material: Cr-Ni / Duplex

USAGE EXAMPLES


USAGE EXAMPLES


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Tube to tube welding:Orbital vehicle POLYCAR 130

with Systemcontroller FPA 2003

USAGE EXAMPLES


USAGE EXAMPLES TIG HW PLASMA


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TIG-HW-PLASMA

Cicular seam welding:

Joint welding

Thickness:4 - 40mm

Pipe length: 2x15mMaterial:C-Steel /

CrNi - for chemical plants

Features:

automatic in- and out-transport of the pipes

USAGE EXAMPLES TIG-HW-PLASMA


TIG HOTWIRE PLASMA EQUIPMENT


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TIG-HOTWIRE-PLASMA-EQUIPMENT

TIG-PLASMA

Power Source PT450:

- switchover between

TIG and PlasmaMains 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/minPLASMA-HW-Torch:

- with wire-guide-unit FWH4

REFERENCE LIST


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REFERENCE LISTABB ATOM AB Vsteras - S 2 KHS Bad Kreuznach - D 1

ABB KENT LTD. West Yorkshire - GB 1 KVAERNER NATIONAL Aberdeen - GB 1ABB 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. So Paulo - Brazil 1 NUOVO PIGNONE Massa - I 1

ALLIED TEK Bangkok - Thailand 1 PREUSSAG ARMATUREN GMBH Peine - D 1AMAG 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. Jury - 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


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Fronius Auto Argon-Arc Welding