STRENGTH THROUGH COOPERATION

Welder Guide Book

non copper-coated solid MaG wires with advanced surface characteristics

OK AristoRod™

2

Contents

Introduction 3

Before you start welding - checklist 4

• Contact tip and gas nozzle 4

• Contact tip size, liner size and wire diameter 4

• Liner 5

• Gas and water 5

• Wire feed unit 5

• ESAB Marathon Pac™ installation 6

• Drive rolls and wire feeding 8

• Shielding gas 9

Contact tip and gas nozzle 10

Welding parameter setting 12

OK AristoRodTM product range 14

SATTM process 15

Don't miss out the interesting OK AristoRod microsite. It explains why OK AristoRod™ wires bring trouble-free, high productivity welding in robotised, mechanised or manual operation supported by unique video animation in 24 languages, scientific data and high speed arc recording. It discusses quality and productivity benefits in detail and reviews the full range of wire types for non- and low-alloyed steels.

www.esab.com/aristorod

3

In order to benefit the most from using AristoRod™ MAG 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 of AristoRod™ non copper-coated solid wires.

Feature BenefitConsistent welding performance

Consistent weld results

Stable arc with low feeding force

High weld quality. 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

Introduction

OK AristoRod™ is a family of non copper-coated MAG wires with superior welding performance. OK AristoRod™ unique Advanced Surface Characteristics (ASC) gives the user higher performance and efficiency no matter if it is manual, mechanised or robotic MAG welding. OK AristoRod™ therefore has a positive impact on reducing overall welding costs. ESAB's unique ASC has enabled the creation of a family of non-copper-coated wires which do not contaminate wire feeders, liners, torches and contact tips with copper particles. This results in trouble free feeding, a high process stability, reduced consumption of wear parts and superior welding properties.

ESAB OK AristoRod™ has a number of unique features. These translate into clear end user benefits which, together, add up to increased productivity and lower welding costs.

4

Wire diameter (mm)

Description ESAB item nr. Pieces/box

1.0 AristoTip 1.0M8/10/30mm 0700300301 200

1.2 AristoTip 1.2M8/10/30mm 0700300303 200

1.4 AristoTip 1.4M8/10/30mm 0700300305 200

For additional sizes, contact ESAB.

Before you start welding

To fully benefit from the excellent weldability of OK AristoRod™ MAG 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 AristoTip contact tips are recommended for use with AristoRod™ wires.

✓ Grind the end of the liner conical for optimal fitting of the contact tip (ESAB M8).

✓ Ensure that the contact tip is the correct size and fits tightly.✓ Ensure the gas nozzle is free from spatter.

CHECKLIST

correct incorrect

5

Liner✓ Spiral steel liners are recommended.✓ Never use liners which have

been used for copper-coated wires. Copper residuals may stick onto the AristoRod™ wire and deteriorate it is 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. Firstly remove contact tip.

Correct

Incorrect

Gas and water ✓ Check gas and water

connections for leaks.✓ Check if water cooler is filled and pump operates

satisfactorily.

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.

6

Special cone for Jumbo Marathon Pac™ with 475kg non- or low-alloyed wire.

ESAB Marathon Pac™ installationESAB 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

Original lifting yoke to handle the drum safely and to not damage the drum or wire.

ESAB MarathonPac™ is completed by a full range of accessories for efficient internal transport and handling and for 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.

7

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™).

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.

8

✓ Use drive rolls with smooth, double V-grooves. U-shaped grooves or knurled rolls may damage the AristoRod™ 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 feedings 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 such that it is possible to stop a bend wire at the gas nozzle by applying a 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.

Smooth Knurled

Before you start welding

Check drive rolls and wire feeding

9

Shielding gas✓ Check that the appropriate gas

is used. Adjust gas flow rate to between 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 too.

10

2 mm

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 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 lengthThe stick-out is the distance between the contact tip and workpiece and must be kept between 12 and 20 mm (ø1.0 and 1.2 mm). Excessive stick-out results in a too short arc length, larger droplets, an unstable arc and spatter, so poor weldability. Additionally, it may reduce the gas protection which can lead to porosity. When welding in spray arc with too short 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.

Correct positioning of contact tip.

12-20 mm

Ideal stick-out for wire diameters1.0 and 1.2 mm.

11

20 mm

12-20 mm

When welding in short arc transfer, the arc stability and start properties will improve when reducing the stick-out.

Gas nozzle diameterVarious nozzle diameters must be available to allow satisfactory 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 this, 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.

12

Use positive polarity for OK AristoRodTM solid 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 vitally important to keep the stick-out constant within the correct range for each welding position.

• Select a welding current (I) which suits your application from the figure on page 13.

• 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 a stick-out.

Incorrect. Arc length too long. Arc becomes too wide, giving 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.

13

NOTE: As mentioned, stick-out control is very important. If the recommended stick-out length is not maintained constant, 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 AristoRod’s advanced surface characteristics 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

3

3

2

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4

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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. Difficult to control.

Welding in globular area. Unstable arc and excessive spatter.Try to avoid.

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ESAB Swift Arc Transfer™

ESAB Swift Arc Transfer™ is a high productivity MAG process that utilises AristoRod™ non-copper coated wires at very high wire feed speeds . The SAT™ process produces flat welds with good penetration and without undercut.

The ultimate high productivity process.

ESAB’s AristoTM U82 robot package enables SATTM welding. it is a complete set of welding equipment and consumables, based on ESAB’s latest digital power source technology. The package consists of:• The Aristo™ Mig 5000iw

inverter or ESABMig 4002, 5002 or 6502 choppers.

• The AristoTM U82 control unit

with SATTM synergic lines or The Aristo W82 interface for different robot brands.

• The Robofeed 3004w ELP encapsulated wire feeder with up to 30 m/min. wire feed speed.

• Cable packages.• The Marathon Pac bulk drum

with robot quality welding wire and optional bobbin holder.

SATTM

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Forced short arc

Wire feed speed (m/min)

Arc

vol

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Rotating arc

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ESAB ABBox 8004, SE-402 77 Gothenburg, Sweden.Phone: +46 31 50 90 00. Fax: +46 31 50 93 90.E-mail: info@esab.sewww.esab.com

Reg

. No:

XA

0016

1520

06

2012

. P

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Net

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ESAB operates at the forefront of welding and cutting technology. Over one hundred years of continuous improvement in products and processes enables us to meet the challenges of technological advance in every sector in which ESAB operates.

Quality and environment standardsQuality, the environment and safety are three key areas of focus. ESAB is one of few international companies to have achieved the ISO 14001 and OHSAS 18001 standards in Environmental, Health & Safety Management Systems across all our global manufacturing facilities.

At ESAB, quality is an ongoing process that is at the heart of all our production processes and facilities worldwide. Multinational manufacturing, local representation and an international network of independent distributors brings the benefits of ESAB quality and unrivalled expertise in materials and processes within reach of all our customers, wherever they are located.

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