Air Liquide Welding, Le - Vítejte > Air Liquide Welding Czech

Wind Energy
www.oerlikon-welding.com
OERLIKON solutions for Wind Energy
Introduction
.............................................................
2
OERLIKON and the Wind Energy Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manufacturing Process for wind turbine towers
.................
4 to 5
Automation
Flame & Plasma cutting machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 to 7
Flame & Plasma cutting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AZURMATIC cutting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SAW equipment, 3A system, power sources . . . . . . . . . . . . 10 to 11
Column & Booms & Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 to 14
Rotators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Characteristics of Wind Towers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Consumables
OERLIKON consumables for the Wind Energy Industry
Key products and designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Selection Guide & Classification Society Approvals . . . . . 18 to 19
Productivity Focus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25
Normalised Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Packaging of Welding Consumables . . . . . . . . . . . . . . . . . . . . . . 26 to 27
Arc Equipment
MMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Plasma cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
MIG/MAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 to 31
MIG/MAG Torches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Personal Protection Equipment, PPE
and Workplace Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1
Introduction
Air Liquide SA, with its headquarters in Paris, France,
is one of Europe’s larger multinational companies.
It had a consolidated turnover of € 11.9 billion in 2009,
with 43.000 employees all over the world.
Air Liquide Welding is represented throughout the world by
individual ALW companies with a brand portfolio optimised
locally to the needs of all types of customers. OERLIKON brand
is an important part of this portfolio and has a long and
distinguished history of innovation in welding products. These
ALW companies are involved in many different areas of
OERLIKON product design, development and application.
The research and development centre, AL CTAS, is located in
Paris and is the largest privately owned centre for welding R&D.
This facilitates the rapid transfer and implementation of
important innovations and advances in welding technology
throughout the whole of the OERLIKON global network. The
utilisation of the strengths and experience of this network
enables OERLIKON to maintain its position and international
reputation for innovative leadership at the forefront of advanced
welding technology in both welding consumables and
increasingly equipment and processes.
2
With this background, OERLIKON has generated a proven
history of supplying welding consumables on an ongoing basis
for the most demanding and critical applications, particularly in
the energy sector to industries such as offshore oil and gas and
nuclear power generation. OERLIKON has continued to work
closely with owners, construction contractors and fabricators to
supply customised solutions through performance and
innovation by developing and supplying welding products and
processes capable of meeting the stringent mechanical property
specifications and increasingly the demands for enhanced
welding productivity.
The results of this process of ongoing innovation and product
development are demonstrated by the range of automated
installations, welding consumables and equipment specifically
tailored for the high productivity requirements of wind turbine
tower and foundation fabrication.
OERLIKON and wind turbine tower fabrication
The value of international expertise:
Quality
Flexibility
OERLIKON has a total commitment to quality. The extensive
product ranges of automated installations, welding consumables
and equipment are manufactured in group production facilities
which are ISO certified. Detailed certification is supplied as a
matter of routine and customers’ special quality requirements,
such as increased frequency of batch testing or specialised
certification, are also readily accommodated. Large single
batches of welding consumables, with specialised testing, are
regularly supplied in accordance with customer requirements.
The OERLIKON product range is continuously developing in
response to changing technological requirements. As new steel
types are developed and used, as new more demanding
applications are developed, so OERLIKON reacts to provide the
right products, regularly meeting engineering departments and
major manufacturers at the design stage to ensure optimum
welding solutions.
A team of highly qualified engineers is ready to respond, with
the objective of providing technologically relevant and practical
solutions, specifically tailored for the wind energy industry. This
applies not only to welding products and equipment but also
advanced proven process solutions, to identify the most
applicable methods of enhancing deposition rates and
productivity. A large information base is at the service of every
customer to ensure the most cost effective selection of process
and welding procedure to meet the needs of any application.
Please consult OERLIKON Technical service.
Track Record
OERLIKON is a technological innovator and major supplier of
welding products and equipment to large industries. A track
record of highly successful products combining quality and
technology with technical service has been firmly established.
For details of the complete product range,
consult www.oerlikon-welding.com
Continually adapting to our customers’ needs
3534-53
CTAS plays a key role in collaborations and
partnerships with various universities and customers
and is committed to bring innovation and
added-value to the welding & cutting markets.
1529-54
The adaptation of welding and cutting solutions
to technical changes in materials and manufacturing
conditions is carried out continually by the 140
engineers and technicians of CTAS, the largest
private research centre in the welding industry.
Market oriented, our metallurgists and engineers
work in direct collaboration with steelmakers,
specifiers as well as manufacturers of wind-towers
and components in the wind energy sector in order
to improve the productivity and quality of our
products and solutions.
3534-52
OERLIKON’s involvement with its products does not stop at
manufacture. OERLIKON provides a close and detailed
participation with the application of products, right from the
initial selection to welding performance on site.
All OERLIKON products are backed by a full technical
information package, which is available in printed or electronic
format on the OERLIKON web sites. Product information is
written to enable the professional welding engineer to select the
correct OERLIKON product for the application.
In order to elaborate the technology of the product range in
more detail, technical articles are available in the journal of
OERLIKON’s welding and cutting expertise, “Competence”.
3534-57
Technical Service
Information
3
Wind Tower Manufacturing Process
Sand
Blasting
1
Plate
Cutting
Shell Rolling
4
and
Tack Welding
Plate Butt
3
Welding
2
Longitudinal
5
Shell Welding
3
2
4
1
10
4
Fla
Wel
nge
ding
6
Shell
7
Pre-assembly
Tower
8
Growing Line
Wind Tower
door cutting 9
and welding
Sand Blasting
10
& Painting
DELIVERY
6
5
7
9
8
5
Flame and Plasma Cutting Machines
2
OXYTOME / PLASMATOME RS & TWIN RS
- CYBERTOME open the way to all oxycutting
and plasma arc cutting operations that require the
use of machines capable of cutting very wide plates and
implementing more complex options.
General cutting introduction
2004-062
This essential phase of plate preparation contributes to the final
quality of the assembly. It is carried out by an automatic cutting
machine designed according to a machine tool concept that is
fully compliant with prevailing standards in terms of accuracy
and reproductibility.
Given the large size of the plates, a heavy duty machine is
recommended for wind tower fabrication.
This equipment is fitted with 1 or 2 programmable bevelling
units and, if required, an on-board operator platform. It will
provide accurate and fast preparation for all types of weld
preparations (butt weld, V, X or K) in its standard configuration
for thicknesses up to 70 mm with 3 oxy torches with 45° set up.
2004-061
(Non-standard configurations are available for other thicknesses).
Pieces to be cut
Specific program for each side
6
Flame and Plasma Cutting Machines
2
2006-298
Reinforced structure
for OXYTOME / PLASMATOME (RS)
For plates wider than 4 m or for certain equipment, a reinforced
structure is used to ensure a smooth accurate and stable
movement.
HPC DIGITAL
PROCESS
This new control concept
for cutting machines has
been specially created for
easier workshop integration
of modern, state-of-the-art
machines implementing
the latest features
in flame cutting and/or
plasma cutting and/or
plasma marking processes.
2003-211
OXYTOME RS
HPC DIGITAL PROCESS operates under WINDOWS 2000
installed on an industrial computer. The system features:
numeric control, process control, a Human Machine Interface,
a touch screen, a control console for all start-up and
emergency stop operations.
TWIN RS structure for OXYTOME / PLASMATOME
The TWIN RS structure is designed as a double transversal
beam equipped with liner guides and bearing,
located in a safe position away from heat
radiation. This machine is specially suitable
for bevelling head applications requiring a
transversal cutting stroke over 4 m or tool
holder of 800 mm. Finally, the accuracy
of this machine is particulary suitable
for HP plasma applications.
2007-361
PLASMATOME TWIN RS
Designed as a “machine tool” concept in terms
of accuracy and repeatability according to current standards.
This design can be modified to accomodate special requirements,
and allows sheet metal cutting of 8 m width and more.
2003-342
CYBERTOME
7
Flame and Plasma Cutting Tools
0823-003
2
Tool holder PO 150 HPC
Plasma bevelling head
Capacitive sensor.
Automatic ignition
Proportional 3 way gas
regulation unit
System rotation and tilting are entirely servo-controlled by the
HPC digital process controller which makes it possible to
program a bevel angle change during a run. This light but rugged
system guarantees excellent cutting results.
Tool Holder PO 150/250
HPC, Arc Voltage regulation,
Straight cut for thin
plate cutting.
Anti torch collision device.
CNC process control
interface
Angular protected slide
Programmable dual tech sensing device (arc voltage control or
tactile probe)
2007-487
2005-785
Plasma straight head
Can be fitted on CYBERTOME, OXYTOME RS and twin.
Numerical control programs the blowtorch bevel positions.
Can be fitted on CYBERTOME, numerical control programs
the blowtorch positions.
V, X or K type bevels from 0 to 45° for plates up to 70 mm
thick.
V, X, or K type bevels from 0 to 45° for plates up to 60 mm thick
(other options
on request).
8
1065-001
VXK
endless rotation bevelling unit
2004-062
VXK
endless rotation bevelling programmable unit
AZURMATIC Cutting Tables
2
Extraction table for dry cutting
The AZURMATIC table with air extraction offers very high
efficiency in terms of fume extraction due to the unique system
of transverse extraction ducts.
Robustly designed in one-piece or modular form, the table is
divided over its length into 1 metre sections, extraction taking place
across the full width of the table on the module in operation only.
Mechanical grills actuated by the displacement of the machine
provide suction under the plate at the place of cutting only.
This principle of operation guarantees optimum extraction,
irrespective of the size of the plate being cut, while maintaining a
modest extraction air-flow rate.
2002-506
Technical characteristics:
• transverse duct extraction system,
• table of 1 meter standard section or smaller to improve
extraction efficiency,
• removable slag boxes,
• removable workpiece supporting frame with flat irons
(section 100 x 6 mm) and wire mesh grid (50 x 50 x 5 mm),
• maximum capacity: plate up to 300 mm thick.
Special table variants available on request
With conveyor supporting the plate, moving from loading
area to cutting area.
With automatic vibration conveyor for the extraction of the
slag and dust.
With automatic tilting of the frame to remove the skeleton.
Special customer request to fit manufacturing workshop
layout and organisation.
High flow filters to fit table configuration
Filtering installation designed to work on a modular table and
contains fume extractor, cleaning filters and dust containers
or bags.
Polyester cartridges
with H13 PTFE membrane
Air admission
Prefilter
Network suction
control allowing:
• air flow rate auto
regulation depending
on the air volume to
be extracted
• a constant air
flow rate whatever
the saturation level
of the cartridges
Noise reducer
in air exhaust
Hopper with dust
drum or BIGBAG
Frequency
control
9
3
5
6
Equipment for Submerged Arc Welding
7
8
3A Machine and process controller
With the 3A welding system, Air Liquide
Welding brings its customers all the benefits
of its expertise in submerged arc welding on column
and boom configurations, seamer installations, mechanised
machines and autonomous tractors.
3A WELDING SYSTEM
a new generation of mobile console control device
The 3A Welding System plug & play Mobile Console gives the operator complete mobility
and permits the management of both machine and process. This new generation interface
is easy to use and operators are rapidly able to program the machine efficiently.
The multipurpose 3A welding system concept is designed for all arc welding processes,
and the equipment remains upgradable with the open architecture.
Mobile console: browsing on the screens
with a graphic representation of the machine.
dvanced
utomatic
rchitecture
Advanced mobile console
Centralised console
Mobile plug & play system
User friendly-interface
Automatic machine management
Process management
Machine cycle control
Integrated peripherals
Architecture based on new concept
Modular and flexible solutions
Full digital control
Ready for networking and communication
SAW head configurations for 3A welding system
Single wire
Twin arc
Tandem arcs
Tandem hybrid
Tandem twin
Tandem powder
1 300 A* 100% DC+
1 300 A* 100% DC+
1 300 A* 100% DC+
1 000 A 100% AC
1 300 A* 100% DC+
1 000 A 100% AC
1 300 A* 100% DC+
1 000 A 100% AC
1 300 A* 100% DC+
1 000 A 100% AC
* Maximum current with single power source, possibility to connect power sources in parallel
10
5
3
6
7
8
Submerged arc welding head
Push Flux delivery and recovery.
Joint tracking solution with motorised positional adjustment.
Wire feeding assistance for drum packaging.
500 W brushless motor wire feeder with digital regulation.
Gouging switch-off for quick repair.
Video camera.
2006-781
STARMATIC power sources
2000-357
2008-312
Rugged, reliable, suitable for difficult industrial environments.
Full bridge technology (with 6 thyristors):
- more stable arc characteristics
- easier to control
Fan-cooled, fitted with thermal cut-out.
Easy to move using crane or forklift.
Quick connection to the core
STARMATIC 1003 AC/DC
STARMATIC 1303 DC
of the machine by simple
and accessible connectors.
1 300 A - 44 V
1 000 A - 44 V
Duty cycle at 100%
Remote control system.
2 DC
1 AC - 1 DC
Welding range
Function type CC/CV:
Primary power supply
400-440 V 50/60 Hz* three-phase 380/400/415 V 50/60 Hz* three-phase
1 - SAW direct current (DC)
Thyristors
Thyristors
Technology
2 - SAW alternative current (AC)
99 kVA
64.6 kVA
Power at 100% duty cycle
3 - SAW gouging arc.
External-static characteristics
- flat
- drooping
Net weight
AC
483 kg
DC
540 kg
* For other primary power supply three-phase, consult Air Liquide Welding.
11
Column and Boom Solutions
5
6
Column & Boom for longitudinal
or circumferential welding
Fixed or Mobile Based Column & Boom depending
on the number and arrangement of the workstations.
Height depending on maximum shell diameter.
Wire spools located on the other end of the boom.
Cable chain on arm and column.
Boom movement range up to 4.3 m.
Column travel adapted for internal and external welding.
Programmable welding length.
Optional rotator block for circumferential welding.
Combined with LP or LP-2R rotator set.
2008-454
12
Flange welding
6
Pieces to be welded: for flanges
(circular welding)
Welding the internal and external seams
2662-29
Manual tack welding operation
Heavy duty manual MIG welding power source.
CITOWAVE 500 (optimum solution).
CITOMIG 400W XP (minimum requirement).
Shell and flange welding
Flange welding
Fixed or Mobile Based C&B depending on the number
and arrangement of the workstations.
Height depending on maximum shell diameter.
Wire Spools located on the other end of the boom.
Internal and external welding of the base and wind tower
flanges is carried out using a HEADMATIC heavy duty head
stock and standard CBMATIC XLM or LM column and boom.
An alternative solution is to use a standard LP rotator.
Cable chain on arm and column.
+/- 45° swivel head.
Rotation block.
When Air Liquide Welding engineers install the production
process, they will help to determine the best manufacturing
sequences and preparations required to obtain accurate final
part dimensions.
13
Growing line / Tower assembly
Final stages
7
2010-306
Growing line by adding shells one by one or two by two
with pre-assembly station.
Pre-assembly station for 2 shells to maximise productivity.
Boom movement range up to 7.3 m for 2 shells module
assembly.
Weight depending on maximum diameter.
Boom movement range up to 4.3 m for pre-assembly station.
Mobile column and boom configuration accessing several
growing lines for simultaneous fit-up operations.
Mobile rotator set depending on maximum weight of tower
section.
Combination of one set of standard rotator with on lorry plus
one set of fit up rotators.
Anti drift system (mechanical stop).
Wind tower door cutting and welding
Currently a manual process.
For automatic door cutting and welding please contact
OERLIKON service.
Accessories support integration
Manual welding of tower accessories
Integration of support for the cable chain and ladder.
Integration of floor levels.
Blasting and painting
14
9
10
Growing line / Tower assembly
8
Special rotators for paint cabin environment.
U grooved rollers on request.
5
7
8
Rotators
9
10
2008-356
Special frame conception with built-in roll supports reduces welding height from the ground.
Machined bed on the idler and drive roll for perfect alignment.
Remote pendant kit auto and display is standard on all versions.
LP Rotators
Thick polyurethane layer on the roller
Screw adjusting working diameter
Manual remote / 3 A system compliant
Possible options:
- Lorry and railway
- Self aligning version
LP XX - 2R
2008-447
2041-004
LP series of heavy-duty rotators for wind tower applications:
42 t to 200 t and more
LP-2R Rotators
TR series of fit-up rotators TR associated with LP range
Tower growing line and the can pre-assembly line are generally equipped with a set of fit up rotators
associated with a standard set of LP rotators. The four wheels of the rotator set supporting the new
section are adjustable in height individually by an
hydraulic cylinder. This gives complete flexibility
of positioning on the new section. The operator is
able to adjust rapidly and accurately via the
independent remote control. This is a low cost
solution for handling the assembly of conical sections.
It also does not require other equipment such as
a crane to extend the growing section.
TR Rotators
ASSOCIATED
ROTATORS
LMC/LFC 30 LMC/LFC 55 LMC/LFC 100 LMC/LFC 200
TR 42/ LP 42 TR70/ TR 100 TR 160/ TR 200
TR 30/ ST 30
TR 55/ LP 55 LP70/ LP100 LP160/ LP 200
This anti drift system allows the section to turn without twisting.
The system is commonly fixed on the idle rotator and is very
useful for multi-turn
applications often
found on wind tower
heavy thickness
welding sections.
ASSOCIATED
ROTATORS
MAD 30
MAD 55
TR 30/ ST 30
TR 42/ LP 42
TR 55/ LP 55
MAD 100
2356-065
This option allows moving the can or tower
section for fit up assembly and growing line.
One motorised unit per movable section.
Anti drift device
2008-448
Motorised lorry, railways,
used for fit up stations
and growing lines
The operator adjusts the position
of the can for tack welding via the
remote control of the fit up rotators
MAD 200
TR70/ TR 100 TR 160/ TR 200
LP70/ LP100 LP160/ LP 200
15
2010-311
Wind Turbine Towers
General features
Typical Weld Preparations
Can longitudinal seams
Can to Can
Circumferential seams
3m
34° Min.
1
08 - 15 mm
Longs & Circs
Can
to Flange
seams
0 - 2 mm
Gap.
2
16 - 17 mm
Longs & Circs
6 mm ±1
8 mm
1
30°
16 mm
18 mm
2
34° Min.
3
4
10-80 m
SECTION THICKNESS INCREASING
37 mm
6 mm ±1
18 - 44 mm
Longs & Circs
60 mm
20 mm
30°
0 - 2 mm Gap.
0 - 2 mm Gap.
3
40 mm
5
45°
5°
30°
6
5
6
Flange
Circs.
5 mm ±1
6 mm ±1
4.2 m
60 mm
4
Flange
Circs.
6 mm ±1
0 - 2 mm Gap.
0 - 2 mm Gap.
Typical parameters are as follows:
LAND tower (1,65 MW to 3 MW)
Min dia: 2500 mm
Max dia: 5000 mm
Thickness shell welding:
• 8 to 15 mm (butt joint) 2 passes
• 12 to 30 mm (bevel 45) 15 passes
• 25 to 55-70 mm max
Cutting range: 5 mm to 200 mm
Tower height: 80 m, 90 m, 100 m
Number of sections per tower: 5 or 6 + foundation section
Conicity: 3°
Material: S 355
Tower construction: in sections from 12 m up to 22 m
Width of the shell: from 2500 mm up to 5000 mm
• Maximum format of supply of steel plate 16 m x 4 m
16
OFFSHORE tower (up to 7 MW)
Requires tailored solutions
Min dia: 3000 mm
Max dia: 8000 mm
Thickness shell welding:
• 125 mm max
Cutting range: 5 mm to 200 mm
Tower height: 120 m
Number of sections per tower: 6 or more + foundation
section
Conicity: 3° - bottom section can be parallel
Material: structural steel and possibly high strength steel
Tower construction: in sections up to 40 m (600 tons)
Width of the shell: from 3000 mm up to 8000 mm
• Maximum format of supply of steel plate 16 m x 4 m
Guide to OERLIKON consumable designations
for Wind Turbine Tower Applications
A selection of key OERLIKON welding consumables
for Wind Turbine Tower Applications.
For further details of the complete range consult
www.oerlikon-welding.com.
Product/Range
Key Features
Main Applications
OP 121TT
Industry benchmark product, world wide recognition.
Agglomerated fluoride fully basic flux, B.I. 3.1. Low hydrogen controlled. Multi-wire, AC/DC.
Highly tolerant to welding parameter variations during welding and to higher heat input
welding.
Used for all high productivity welding applications, multi-wire, multi-twin wire, metal
powder additions with OE-PD3.
SAW wires: OE-SD3 and OE-SD3 1Ni ¼Mo for higher heat input welding.
Thick section welding, 20-150 mm+.
Tough weld metal, ISO-V at -60 ºC,
CTOD at -10 ºC.
High productivity joint filling.
OP 121TTW
Agglomerated fluoride fully basic flux, B.I. 3.1. Multi-wire, AC/DC.
Very low hydrogen controlled, very low impurity/residual elements.
SAW wires: OE-SD3 and OE-SD3 1Ni ¼Mo for higher heat input welding.
Thick section welding, 20-150 mm+.
High productivity joint filling, narrow gap
welding.
ISO-V at -60 ºC, CTOD at -10 ºC.
OP 120TT
Agglomerated fluoride fully basic flux, B.I. 3.1. Low hydrogen controlled. Multi-wire, AC/DC.
Manganese and silicon donation during welding, heat input control to maximise weld metal
toughness.
SAW wires: OE-S2 and OE-S2 Mo.
Thick section welding, 20-63 mm.
ISO-V at -40 ºC to -60 ºC.
Cost effective wire combinations
OP 139
Agglomerated fluoride basic flux, B.I. 2.2. Low hydrogen controlled. Multi-wire, AC/DC.
Excellent slag detachability, very stable arc characteristic and suitable for higher heat
input welding.
Manganese and silicon donation during welding.
SAW wires: OE-S2 and OE-S2 Mo.
Thick section welding, 20-63 mm.
High productivity joint filling, reduced joint
angles.
Cost effective wire combinations.
ISO-V at -40 ºC to -50 ºC.
OP 132
Agglomerated aluminate-basic flux, B.I. 1.5. Low hydrogen controlled. Multi-wire, AC/DC.
Excellent slag detachability, very stable arc characteristic, used with flux cored wire for
wind tower applications.
SAW wire: OE-S2 and FLUXOCORD 31HD.
Thick section welding, 20-63 mm.
High productivity joint filling, reduced joint
angles.
ISO-V to -40 ºC.
DRYBAG
Vacuum packaging system for OERLIKON SAW fluxes.
Variety of formats, 25, 500, 800 kg.
Eliminates flux re-conditioning prior to use.
e.g. following extended transport or use in
high humidity regions.
C-Mn alloy metal powder with matching composition to OE-SD3.
SAW wire/flux/powder combination: OP 121TT/OE-SD3/PD3.
High productivity joint filling.
ISO-V at -60 ºC, CTOD at -10 ºC.
C-Mn and low alloy ferritic steel wires , copper coated, all formats
CARBOFIL 1, 1A and GOLD.
Wide range of structural steels.
Tacking before SAW welding.
FLUXOFIL M10S
Metal cored wire used with mixed gases, virtually no slag.
Seamless, coppered, very low hydrogen characterisitc.
Precision layer wound.
Door frame applications.
Highly resistant to weld cracking,
ISO-V to -60 ºC.
CITOFLUX M00
Metal cored wire used with mixed gases, virtually no slag, used in both short and spray
arc modes.
Door frame applications, ISO-V to -40 ºC.
FLUXOCORD 31HD
Flux cored wire for SAW welding with OP 132 and OP 121TT W, seamless, coppered.
High productivity, ISO-V to -40 ºC.
FLUXOCORD 43.1
Flux cored wire alloyed with Ni,Mo,V for SAW welding with OP 121TT W, seamless,
coppered.
When a normalising heat treatment is
required.
SPEZIAL
Industry benchmark product, world wide recognition.
Low hydrogen (-16) double coated C-Mn deposit, smooth operation, easy slag release.
Versatile, repairs, gap bridging,
ISO-V to -20 ºC.
SUPERCITO 7018S
Low hydrogen (-18) basic coated C-Mn deposit, stable arc, good slag release.
Thicker section structural steels,
ISO-V to -40 ºC.
Submerged Arc Fluxes
Metal Powder
OE-PD3
MAG
CARBOFIL
Cored Wires
MMA
Note: For full details of the OERLIKON range of welding consumables, consult www.oerlikon-welding.com or the Product Data handbook.
17
Selection Guide
Selected OERLIKON Consumables for Wind Turbine Tower Applications.
All-Weld-Metal Mechanical Properties, as welded condition.
Structural steels
SUBMERGED ARC
OP 121TT/OE SD3
OP 121TT/OE SD3/PD3
OP 121TT/OE SD3 1Ni ¼Mo
OP 121TTW/OE SD3
OP 120TT/OE-S2
OP 120TT/OE-S2 Mo
OP 139/OE-S2
OP 139/OE-S2 Mo
OP 132/FLUXOCORD 31HD
METAL CORED WIRES
FLUXOFIL M10S
CITOFLUX M00
MIG/MAG
CARBOFIL 1
CARBOFIL 1A
CARBOFIL 1A GOLD
MMA
SPEZIAL
SUPERCITO 7018S
SPECIAL APPLICATIONS
OP 121TTW/FLUXOCORD 43.1*
Shielding
Gas
C
Mn
Si
S
760: SA FB 1 55 AC H5
760: SA FB 1 55 AC H5
760: SA FB 1 55 AC H5
760: SA FB 1 55 AC H5
760: SA FB1 66 AC H5
760: SA FB1 66 AC H5
760: SA AB 168 AC H5
760: SA AB 168 AC H5
760: SA AB 167 AC H5
-
0.07
0.07
0.07
0.05
0.06
0.06
0.06
0.06
0.06
1.6
1.6
1.3
1.3
1.2
1.2
1.8
1.8
1.9
0.3
0.3
0.3
0.25
0.4
0.4
0.3
0.3
0.4
<0.020
<0.020
<0.020
<0.015
<0.020
<0.020
<0.020
<0.020
<0.020
A5.18: E70C 6M H4
A5.18: E70C 6M H4
17632-A: T 42 6 M M 1 H5
17632-A: T 46 4 M M 1 H5
M21
M21
0.07
0.04
1.6
1.7
0.4
0.5
<0.010
<0.020
A5.18: ER 70S - 6
A5.18: ER 70S - 6
A5.18: ER 70S - 6
14341-A: G 42 4 M G3Si1
14341-A: G 46 4 M G4Si1
14341-A: G 46 4 M G4Si1
M21
M21
M21
0.08
0.08
0.08
1.1
1.3
1.3
0.6
0.7
0.7
<0.025
<0.025
<0.025
A5.1: E7016-H8
A5.1: E7018-1-H4
2560-A: E38 2 B 12 H10
2560-A: E42 6 B 32 H5
-
0.06
0.08
0.9
1.2
0.7
0.4
<0.015
<0.015
-
760: SA FB 1 55 AC H5
-
0.05
1.4
0.1
<0.020
AWS
EN ISO
Combination
Flux
A5.17: F7 A8 EH12K
A5.17: F7 A8 EH12K
A5.23: F8 A8 ENi5-Ni5
A5.17: F7 A8 EH12K
A5.17: F7 A6 EM12K
A5.17: F8 A4 EA2-A2
A5.17: F7 A6 EM12K
A5.23: F8 A6 EA2-A2
A5.17: F7 A8 EC-G
* N+(A=550-650ºC)
OERLIKON SAW Flux Selection Guide for Wind Turbine Tower Applications
OERLIKON SAW FLUX
OP
OP
OP
OP
OP
121TT
121TTW
120TT
139
132 (FC 31HD)
KEY:
Multi-Wire
Twin- Wire
Polarity
AC/DC operation
OE-PD3 Metal
Powder Additions
Closed Bevel
e.g.14º
Narrow Gap
***
***
**
***
***
***
***
***
***
***
***
***
***
***
***
***
**
**
***
***
***
***
***
**
*
*
-
**
**
***
***
**
*
-
Preferred Choice
Excellent
Good
Satisfactory
Not recommended
Classification Society Approvals.
AWS
DESCRIPTION
Structural steels
SUBMERGED ARC
OP 121TT/OE SD3
OP 121TT/OE SD3/PD3
OP 121TT/OE SD3 1Ni ¼Mo
OP 120TT/OE-S2
OP 120TT/OE-S2 Mo
OP 139/OE-S2
OP 139/OE-S2 Mo
OP 132/FLUXOCORD 31HD
METAL CORED WIRES
FLUXOFIL M10S
CITOFLUX M00
MIG/MAG
CARBOFIL 1
CARBOFIL 1A
CARBOFIL 1A GOLD
MMA
SPEZIAL
SUPERCITO 7018S
SPECIAL APPLICATIONS
OP 121TTW/FLUXOCORD 43.1*
EN ISO
Shielding Gas
CE
TUV
-
-
Technischer
Uberwachungs
Verein
American Welding
Society
European
Normalization
Combination
Flux
A5.17: F7 A8 EH12K
A5.17: F7 A8 EH12K
A5.23: F8 A8 ENi5-Ni5
A5.17: F7 A6 EM12K
A5.17: F8 A4 EA2-A2
A5.17: F7 A6 EM12K
A5.23: F8 A6 EA2-A2
A5.17: F7 A8 EC-G
760: SA FB 1 55 AC H5
760: SA FB 1 55 AC H5
760: SA FB 1 55 AC H5
760: SA FB1 66 AC H5
760: SA FB1 66 AC H5
760: SA AB 168 AC H5
760: SA AB 168 AC H5
760: SA AB 167 AC H5
-
0035-CPD-C308
0035-CPD-C308
0035-CPD-C308
0035-CPD-C308
0035-CPD-C308
0035-CPD-C308
0035-CPD-C308
0035-CPD-C308
03768
09895
04066
04067
09858
09859
10378
51.098.09
51.098.02
51.098.02
51.098.21
51.098.21
51.098.22
A5.18: E70C 6M H4
A5.18: E70C 6M H4
17632-A: T 42 6 M M 1 H5
17632-A: T 46 4 M M 1 H5
M21
M21
0035-CPD-C305
-
-
A5.18: ER 70S - 6
A5.18: ER 70S - 6
A5.18: ER 70S - 6
14341-A: G 42 4 M G3Si1
14341-A: G 46 4 M G4Si1
14341-A: G 46 4 M G4Si1
M21
M21
M21
0035-CPD-301
0035-CPD-301
0035-CPD-C312
00265
00266
11041.00
42.098.02
42.098.01
42.098.17
A5.1: E7016-H8
A5.1: E7018-1-H4
2560-A: E38 2 B 12 H10
2560-A: E42 6 B 32 H5
-
0035-CPD-C306
0035-CPD-C307
00061.12
TUV
10.116.07 / 10.098.07 (P)
DB
-
760: SA FB 1 55 AC H5
-
0035-CPD-C308
2141.09
-
* N+(A=550-650ºC)
Note: For full details of the OERLIKON range of welding consumables, consult www.oerlikon-welding.com or the Product Data handbook.
18
DB
Die
Bahn
Ni
Mo
Tensile Strength
MPa
V
Yield Strength
MPa
A5
%
ISO-V
ºC
J
<0.020
<0.020
<0.020
<0.015
<0.020
<0.020
<0.020
<0.020
<0.020
0.8
-
0.2
0.5
0.4
-
-
530-630
530-630
600-650
560-640
500-600
600-700
500-570
570-630
530-630
>450
>450
>530
>450
>420
>450
>430
>480
>400
>25
>25
>24
>25
>24
>24
>27
>21
>24
-60
-60
-60
-60
-40
-40
-50
-50
-60
>50
>40
>40
>70
>50
>50
>70
>50
>50
<0.010
<0.020
-
-
-
500-640
530-680
>420
>460
>26
>24
-60
-40
>60
>75
<0.025
<0.025
<0.025
-
-
-
500-640
550-680
550-680
>420
>460
>460
>24
>24
>24
-30
-30
-30
>70
>80
>80
<0.025
<0.020
-
-
-
470-600
510-610
>380
>420
>26
>24
-20
-50
>80
>90
<0.020
1.8
0.35
0.12
570-670
>460
>22
-40
80
FLUXOCORD
Flux Cored Wires
10-40
***
***
*
**
**
**
***
***
-
***
ABS
American
Bureau
of Shipping
Plate Thickness, mm
40-60
60-150+
BV
Bureau
Veritas
***
***
***
***
***
DNV
Det Norske
Veritas
***
***
***
**
**
-20C
ISO-V Toughness, J
-40C
***
***
***
***
***
***
***
***
**
**
GL
LRS
Germanischer
Lloyd
Lloyd's
Register
of Shipping
PRS
-60C
Structural steels
SUBMERGED ARC
OP 121TT/OE SD3
OP 121TT/OE SD3/PD3
OP 121TT/OE SD3 1Ni ¼Mo
OP 121TTW/OE SD3
OP 120TT/OE-S2
OP 120TT/OE-S2 Mo
OP 139/OE-S2
OP 139/OE-S2 Mo
OP 132/FLUXOCORD 31HD
METAL CORED WIRES
FLUXOFIL M10S
CITOFLUX M00
MIG/MAG
CARBOFIL 1
CARBOFIL 1A
CARBOFIL 1A GOLD
MMA
SPEZIAL
SUPERCITO 7018S
SPECIAL APPLICATIONS
OP 121TTW/FLUXOCORD 43.1*
CTOD
-10C
***
***
***
**
***
***
-
-
RMRS
OERLIKON SAW FLUX
OP 121TT
OP 121TTW
OP 120TT
OP 139
OP 132 (FC 31HD)
RINA
Polski Russian Maritime Registro
Rejestr
Register of
Italiano
Statkow
Shipping
Navale
3YM (-40 °C)
4YQ 460M
3YM
-
A3YM
A3YM
-
IVY42M H5
IIIYM
IIIYM
IVY40M, IIIY40T H5
-
5Y40M
3YM
4YM, 3Y40T H5
-
4Y40M H5
3M, 3YM
3YM
4Y40M, 3Y40T H5
-
-
5Y40M HHH
-
-
3YSA H5 (P)
SA3YM H5 (P)
IVY42MS H5 (P)
-
4Y40S H5 (P)
-
-
-
3YSA
3YSA
3YSA
SA3YM
SA3YM
SA3YM
IIIYMS
IIIYMS
-
3YS
3YS
3YS
3S,3YS H15
3S,3YS H15
-
-
-
(P)
-
3H10-3Y (P)
3H5-3Y
3-3YHH
33YHHH
3Y40 H10
4Y40 H5
3Y H10
-
3m 3Ym H10
33Y H5
-
3YHH
-
-
-
-
-
-
-
-
-
-
Structural steels
SUBMERGED ARC
OP 121TT/OE SD3
OP 121TT/OE SD3/PD3
OP 121TT/OE SD3 1Ni ¼Mo
OP 120TT/OE-S2
OP 120TT/OE-S2 Mo
OP 139/OE-S2
OP 139/OE-S2 Mo
OP 132/FLUXOCORD 31HD
METAL CORED WIRES
FLUXOFIL M10S
CITOFLUX M00
MIG/MAG
CARBOFIL 1
CARBOFIL 1A
CARBOFIL 1A GOLD
MMA
SPEZIAL
SUPERCITO 7018S
SPECIAL APPLICATIONS
OP 121TTW/FLUXOCORD 43.1*
2662-37
P
19
2010-305
Productivity Focus
There are a number of routes to enhance the deposition rate
of the submerged arc welding (SAW) process and increase overall
fabrication productivity. These range from methods requiring modest
investment, such as a reduction in wire diameter, the use of flux
cored wires or metal powder additions up to process modifications
involving capital investment in multi-wire and narrow gap welding.
This overview of methods for enhancing the deposition rate
of the submerged arc process when welding structural steel
sections is intended to act as a guide to the main choices
available in different fabrication scenarios.
The number of combinations of process and welding
consumables, polarity of welding current and weld preparation
is extensive and the examples chosen are illustrative of proven
techniques. Contact OERLIKON for further details.
Air Liquide Welding has a detailed knowledge of the product
and process variants and there are OERLIKON submerged arc
wires, fluxes, powders and equipment with proven track records
in gaining full benefit from high deposition process routes.
1 - Submerged arc welding with Solid Wire
The Effect of Single Solid Wire Diameter
Single Head: Single Wire & Twin Wire Welding
By decreasing the wire diameter used, at constant current,
the current density is increased and hence the deposition rate
is increased. At 450 A, current densities for SAW wires in the
size range 2.0 - 4.0 mm are as follows:
The effects of welding current on deposition rate are shown
below. When SAW welding with a single solid 4 mm SAW wire
at 700 A the deposition rate is 8 kg/hr of weld metal.
SAW Wire Diameter
mm
Current Density at 450 A
A/mm²
2.0
143
2.4
99
3.0
64
3.2
56
4.0
36
Twin wire welding uses two smaller diameter submerged arc
welding wires, generally 2.0 mm or 2.4 mm diameters, which
are fed through the same contact tube using a single control
panel and a single power source. Using twin 2.4 mm wires at
the same current increases the deposition rate to 9 kg/hr of
weld metal and using 2.0 mm wires at the same current further
increases the deposition rate to 10 kg/hr of weld metal.
20
15
2 x 2.0 mm DC+
15
2 x 2.4 mm DC+
4 mm DC+
4 mm DC+
Deposition rate (kg/hr)
Deposition rate (kg/hr)
3.2 mm DC+
10
5
0
5
0
250
500
750
1 000
Current Intensity (A)
By decreasing the SAW solid wire diameter from 4.0 mm to
3.2 mm and welding at 700 A, the deposition rate is increased
from 8 kg/hr to 9 kg/hr with very low capital expenditure and
operator training.
20
10
250
500
750
Current Intensity (A)
1 000
1 250
2010-310
Two heads (Tandem): Tandem Single Wire,
Tandem with a Twin Wire Trail and Tandem
Twin Wire Welding
The process variants most utilised using two welding
heads are as follows:
Higher currents of ~900 A can
be used combined with increased
welding speeds.
Mechanical properties are retained,
no overall change in arc energy.
Excellent weld bead shape and appearance.
Very low capital investment.
Wide range of applications, joint filling and fillet welding.
Can be used in hybrid-twin and twin-tandem configurations
(see later).
Against the reference of a single solid 4 mm SAW wire,
deposition rate improvements can be achieved by using twin
2.4 mm or twin 2.0 mm SAW wires. At 900 A, the deposition
rate of the 2.4 mm twin arrangement is 12 kg/hr and for the
2.0 mm twin arrangement is 13 kg/hr.
Tandem welding with 2 solid 4 mm wires welding at 1400 A,
the lead wire with DC+ polarity and an AC trail, this gives a
deposition rate of 18 kg/hour.
Tandem with a Twin Wire Trail (hybrid tandem twin) welding at
1500 A with a lead single 4 mm wire using DC+ current and
the trail head with twin 2.4 mm wires using AC current, gives
a deposition rate of 21 kg/hour. This arrangement has the
advantage of using only the lead wire for the rooting passes,
followed by hybrid tandem-twin welding for joint filling.
Tandem Twin welding with two twin 2.4 mm wires in each
head welding at 1600 A, this gives a deposition rate of
24 kg/hr.
Increasing the number of wires from single DC+ to tandem wire
welding will result in more than twice the deposition rate in an
AC/DC+ configuration.
35
Deposition rate (kg/hr)
The process advantages of
twin wire welding are as follows:
30
2 x TWIN 2.4 mm
4 mm DC + TWIN 2.4 mm AC
4 mm DC + 4 mm AC
25
20
15
10
1 000
1 250
1 500
1 750
2 000
Current Intensity (A)
21
Productivity Focus
2 - FLUXOCORD flux cored welding
wires for SAW
3 - Metal Powder Additions
OERLIKON FLUXOCORD is a range of flux cored wires
specifically designed for use with the SAW process. These
seamless wires are manufactured using the OERLIKON
FLUXOFIL process and are supplied copper coated in either
standard reel or bulk packaging formats. The deposition
rate of the SAW process can be improved considerably
using these flux cored wires with no capital expenditure
required for new equipment.
Increased deposition rate by ~25% when used with
OERLIKON OP SAW fluxes.
Excellent mechanical properties, at least as good as the
equivalent solid wire.
Flexibility of alloying regime, wide range of compositions
available.
Very limited operator training required, uses standard SAW
equipment.
Flexible: used single, tandem and twin wire and with metal
powder addition.
Seamless, with reduced sensitivity to atmospheric conditions.
This process increases the deposition rate when
submerged arc welding through the addition of a controlled
amount of steel alloy metal powder to the welding system.
This process was developed by OERLIKON for producing
high toughness joints, ISO-V and CTOD tested, in thick
structural steel sections for the offshore oil and gas industry,
where it has been widely used.
Increase in deposition rate at constant heat input.
Proven track record for high toughness butt welding
applications.
No deterioration in weld metal strength or toughness.
Robust equipment which is low cost, reliable and easy to
install and operate.
Used with single, tandem, twin, tandem with a twin wire trail
and tandem twin wire systems.
There are two main process variants:
Forward feed system for butt welding.
Wire feed system for fillet welding and special applications.
Forward Feed system:
The metal powder is delivered in a metered pre-set amount
ahead of the SAW flux burden.
The metal powder is fused into the weld pool as the submerged
arc wire is consumed, resulting in an increased deposition rate.
20
15
12
Deposition rate (kg/hr)
FLUXOCORD 31HD
1
Solid 4 mm DC+
10
2
3
5
10
11
0
250
500
750
4
1 000
Current Intensity (A)
5
8
When SAW welding single wire welding with 4 mm
diameter wire at 700 A, replacing a solid OE-SD3 wire
with FLUXOCORD 31HD will increase the deposition rate
from 8 kg/hr to 10 kg/hr.
22
9
6
7
1. SAW Wire - 2. Wire feed adaptor - 3. Feed rolls - 4. Busbar
5. Unmelted SAW flux - 6. Melted SAW flux - 7. Weld deposit
8. Base plate - 9. Metal powder addition - 10. SAW flux feed
11. Powder feed unit - 12. Powder feed unit control
30°
The use of the powder addition process is illustrated by:
37 mm
a) Tandem wire Welding
60 mm
The joint is welded with an arc energy of 3.6 kJ/mm at a deposition
rate of 18 kg/hr with OE-SD3, lead wire DC+ and trail wire AC, with
OP 121TTW SAW flux and a 5 kg/hr addition of OE-PD3 metal powder.
Run
Wire
1 Root
SD3
SD3
SD3
SD3
SD3
SD3
SD3
SD3
SD3
SD3
SD3
SD3
SD3
2
3
4-5
6 - 11
12 - 14
15 - 18
4
4
4
4
4
4
4
4
4
4
4
4
4
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
Flux
Powder
PD3
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
20 mm
30°
Angle
Polarity
Amperage
A
Voltage
V
Speed
mm/min
HI kJ/mm
Interpass
0
0
20
0
20
0
20
0
20
0
20
0
20
DC+
DC+
AC
DC+
AC
DC+
AC
DC+
AC
DC+
AC
DC+
AC
550
600
620
600
620
600
620
600
620
600
620
600
620
29
32
36
33
36
33
36
33
36
33
36
33
33
550
1.74
-
650
3.83
-
700
3.61
-
700
3.61
150 °C
700
3.61
-
700
3.61
220 °C
700
3.61
-
30°
b) Hybrid Tandem Welding
The joint is welded with an arc energy of 2.8 kJ/mm at a deposition rate
of 30 kg/hr with the lead wire OE-SD3 4 mm DC+ and the trail head with
twin wires FLUXOCORD 31HD 2.4 mm AC with OP 121TTW SAW flux
and a 5 kg/hr addition of OE-PD3 metal powder.
Run
Wire
Flux
Powder
PD3
1 Root
SD3 4 mm
SD3 4 mm
2.4 mm FC31
SD3 4 mm
2.4 mm FC31
SD3 4 mm
2.4 mm FC31
SD3 4 mm
2.4 mm FC31
SD3 4 mm
2.4 mm FC31
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
2
3
4-8
9
10 - 13
Twin
Twin
Twin
Twin
Twin
HD
HD
HD
HD
HD
Run
Wire
Flux
Powder
PD3
1 Root
2
SD3 4 mm
SD3 4 mm
SD3 4 mm
Twin 2.4 mm FC31 HD
SD3 4 mm
Twin 2.4 mm FC31 HD
OP 121 TTW
OP 121 TTW
5 kg/h
5 kg/h
OP 121 TTW
5 kg/h
OP 121 TTW
5 kg/h
3
4-5
37 mm
60 mm
20 mm
30°
Angle
Polarity
Amperage
A
Voltage
V
Speed
mm/min
HI kJ/mm
Interpass
0
0
20
0
20
0
20
0
20
0
20
DC+
DC+
AC
DC+
AC
DC+
AC
DC+
AC
DC+
AC
550
600
700
600
800
600
800
600
800
600
800
29
32
35
32
35
32
35
32
35
32
35
500
1.91
-
800
3.28
-
800
3.54
150 °C
1000
2.83
-
1000
2.83
225 °C
1000
2.83
-
Angle
Polarity
Amperage
A
Voltage
V
Speed
mm/min
HI kJ/mm
Interpass
0
0
0
20
0
20
DC+
DC+
DC+
AC
DC+
AC
650
650
630
760
660
760
31
31
31
36
31
36
500
500
2.42
2.42
-
900
3.13
120 °C
900
3.19
-
23
2010-309
Productivity Focus
4 - The Effects of Polarity
Tandem wire SAW welding with a DC+ lead wire, AC trail
wire configuration with a deposition rate of ~15 kg/hr of
weld metal more than doubles the 7 kg/hr deposition rate
of single wire DC+ SAW welding.
15
4 mm DC+
Deposition rate (kg/hr)
An increase in deposition rate of nominally 25% is obtained
by using AC polarity rather than DC+ polarity, regardless of
wire diameter.
4 mm AC
10
5
0
250
500
750
1 000
Current Intensity (A)
5 - Weld Preparation, Narrower Joints
& Narrow Gap Welding
Weld Length 15 m
50
45
U - Tulip, filled with Tandem 4 mm + 4 mm
40
V, filled with Tandem 4 mm + 2 x 2.4 mm
Time to complete (h)
A small adjustment to the weld preparation can have a
significant effect on the volume of weld metal to be
deposited and hence is capable of improving joint completion
times. The limitations of narrowing the joint preparation are
process control, slag detachability and the final aspect ratio
of the weld bead. Weld beads with an aspect ratio which is
too deep and narrow become increasingly susceptible to
solidification, “hot”, cracking and other effects related to plate
centre line segregation.
35
X, filled with Tandem 4 mm + 2 x 2.4 mm
30
25
20
15
10
5
0
An asymmetric double-V weld preparation is an alternative
high productivity solution, welded from both sides using hybrid
tandem SAW using a 4 mm lead and a twin 2.4 mm trail for
joint filling. The joint completion time is reduced by narrow gap
welding only at section thicknesses of >80 mm in the standard
configuration using tandem 4mm wires with a tulip joint
preparation. This is because this type of tulip preparation can
only be welded narrow gap from a single side.
Submerged arc narrow gap is a welding process requiring
high levels of capital expenditure and specialised plate
preparation equipment, which delivers progressive
productivity advantages as joint thickness increases above
~80 mm.
24
30
50
70
90
110
130
Total Plate Thickness (mm)
OERLIKON welding consumables, such as OP 121 TT &
OP 121 TT W welding fluxes, in combination with OE low
alloy ferritic welding wires, have been extensively used with
the narrow gap process, producing high toughness joints
in very thick section thicknesses, 80-200 mm. Further
deposition rate enhancement can be obtained by using
OP 121 TT W in combination with OERLIKON FLUXOCORD
wires when narrow gap welding.
2010-308
2010-304
Deposition Rates, Welding Speeds
and Normalised Applications
Deposition Rates - Summary
Normalised application
This figure illustrates the deposition rates of the SAW
process variants most used by fabricators. The SAW flux is
OP 121 TT, with OE-SD3, FLUXOCORD 31HD and PD3
metal powder. Using a single SAW head, deposition rates
can be increased from 7 kg/hr using 4 mm solid wire SAW
towards 20 kg/hr using twin 2.0 mm solid wires. Deposition
rates of 20 kg/hr are readily attained using two SAW heads,
with limited capital expenditure and operator training.
When welding large turbine blade assemblies, fatigue
cracking is a potential problem and a normalising treatment
is generally specified. The submerged arc welding solution
is OP 121 TTW flux with FLUXOCORD 43.1, a seamless flux
cored wire depositing nominally 1.8%Ni, 0.4%Mo, 0.12%V
weld metal. Following a full normalising heat treatment
at 940 ºC the weld metal has good ISO-V toughness down
to -60 ºC.
OERLIKON FLUXOCORD 43.1 is a special cored wire
developed for single wire submerged arc welding with
OP 121 TTW flux for fully heat treated applications and is
not suitable for as welded or stress relieved applications.
Tandem wire Twin + OE PD3
Tandem wire Twin
Tandem wire hybrid
Tandem wire + OE PD3
SAW heads configurations
Tandem FLUXOCORD 31 HD
Tandem wire
Single head Twin wire
Single wire + OE PD3
Single FLUXOCORD 31 HD
Single wire
0
10
20
30
40
Deposition rate (kg/hr)
Single wire
Twin arc
1 300 A* 100% DC
1 300 A* 100% DC
Additionally, by using tandem, or twin configurations,
welding speeds are increased, from typically 75 cm/min. to
>100 cm/min.
Tandem wire Twin + OE PD3
Tandem wire Twin
Tandem wire hybrid
Tandem arcs
Tandem hybrid
1 300 A* 100% DC
1 000 A 100% AC
1 300 A* 100% DC
1 000 A 100% AC
Tandem wire + OE PD3
Tandem FLUXOCORD 31 HD
Tandem wire
Single head Twin wire
Single wire + OE PD3
Single FLUXOCORD 31 HD
Single wire
0
50
100
150
200
Tandem twin
Tandem powder
1 300 A* 100% DC
1 000 A 100% AC
1 300 A* 100% DC
1 000 A 100% AC
Welding Speed cm/min
* Maximum current with single power source, possibility to connect power sources in parallel
25
MMA
Drums (ROUNDPACK)
Standard Packaging
Heavy duty cardboard drums
320 kg & 600 kg formats,
100% recyclable,
Reliable rapid pay off at high
wire feed speeds,
Fitted sling points for handling safety,
Vacuum Packaging
2010-269
B 300
100% recyclable
2009-012
2006-200
2006-939
Spools
Reliable protective packaging for most
applications
3 packets per outer carton
Packet weight ~5 kg
2006-937
MIG/MAG wires (solid and FCW)
2662-31
2662-05
2008-677
Product Packaging
Welding Consumables
No re-conditioning required before use
No quivers or holding ovens are required
Ideal for on site applications
Simplified QA procedures
DRY
Pack contents ~1 kg
Supplied in outer cartons ~15 kg
VPMD
Pack contents ~3 kg
Supplied in outer cartons ~15 kg
SAW Fluxes
BIGBAG
500, 800 and 1000 kg formats
Mounted on an integral pallet
Ready slung for crane lifting safety
Very fast flux discharge
2006-936
SAW Wires
Spools
B 450 (25 kg)
B 570 (90 kg)
100% recyclable
Drums
300 kg
700 kg
Variants of packing solutions are available on request to suit specific requirements.
26
2010-269
2007-474
DRYBAG
This new packaging solution has been developed by the
Air Liquide Welding research teams for OERLIKON submerged
arc welding fluxes. DRYBAG packaging system features:
Triple layer composite
technology system
Fully moisture proof
Low vacuum
Protection from atmospheric humidity
Designed for the most hostile
ambient conditions
No re-conditioning required before use
Protection during extended
transport and storage
Supply: 1 tonne (40 sacks
x 25 kg DRYBAG) per pallet
2004-112-r
A specially designed packaging
system for high consumption
environments. Combining the
BIGBAG bulk flux packaging system
with the composite technology
DRYBAG system, delivering these
additional benefits:
2006-943
Sacks
Weld sealed
100% recyclable (“4”)
Easy to handle
Effective flux protection
from the environment
Supply: 1 tonne (40 sacks
x 25 kg) per pallet
DRYBAG
2007-386
Absolute watertight control for submerged arc fluxes.
DRYBAG an innovative packaging system from
OERLIKON reduces costs, time and energy.
The needs of industry
2007-474
The fabrication specifications for large structures usually
require a guaranteed very low level of SAW flux moisture in order
to attain a diffusible hydrogen level of less than 5 ml/100 g in
the deposited weld metal. These specifications clearly stipulate
the conditions required to guarantee compliance with this
requirement.
DRYBAG:
a packaging solution from our R&D teams
The research and development and the production departments
of the Air Liquide Welding group, have developed an innovative
new packaging system for OERLIKON submerged arc welding
fluxes: DRYBAG a fully moisture proof packaging system making
any requirement for flux conditioning unecessary, resulting in
high-quality welds even in the most hostile ambient conditions.
DRYBAG is made of an advanced composite foil, specially
developed for vacuum packaging applications. For enhanced
security, a partial vacuum is produced in the DRYBAG during the
packaging of the welding flux. The low-pressure serves as an
indicator for the security of the packaging. OERLIKON DRYBAG
offers similar levels of security as packaging in metal drums, but
is more cost effective. DRYBAG is available in 25 kg or larger,
500, 800 or 1000 kg formats. The 25 kg-DRYBAG can be
stored, transported and palletised in the same way as regular
25 kg bags and the larger formats have an integral pallet.
Advantages
No risk of moisture ingress, even during transcontinental or
maritime transport and following long-term storage in adverse
conditions.
No risk from ambient humidity, even in extreme climatic
conditions.
No need to re-condition the flux before use.
This new packaging solution enables fabricators to reduce the
risk of hydrogen induced cracking.
No requirement for detailed control of temperature or humidity
during storage, thereby saving time and energy costs.
Improved, simplified handling and storage compared to existing
solutions using metal drums, again reducing costs.
27
MMA electrode power sources
2570-07
OERLIKON propose a wide range of equipment
for MMA welding. This is a selection of units
for on site applications in all conditions.
Very light and portable unit for maintenance,
Ultra flexible for light
duty and flexible
finishing applications.
Multi-process (MMA, Gouging, TIG DC, MIG)
inverter unit,
Welding MMA electrodes
up to Ø 6.3 mm,
MIG welding with the
DV 4004 wire feeder
option,
CC/CV 3phase unit,
Weighing only 29 kg.
2006-762
CITOARC 3500i
2009-092
CITOARC 1800HPF
CITOROD 6500 XT
More performance 160 @ 50%
at 40 °C.
With 16 A shuko plug.
Suitable for welding with
cellulosic electrodes.
VRD (Voltage Reduction
Device) for increased
safety when welding
on site.
Inverter technology.
2010-066
Technical specifications:
For the heaviest duty applications
including gouging,
Thyristor technology,
Multiprocess
(MMA, Gouging,
TIG DC, MIG)
- 3 phase unit,
Possibility of
MIG/MAG
welding using
DEVIDARC an
autonomous
wire-feeder.
2008-800
CITOARC 1900 EXPERT
CITOARC 1800 HPF
CITOARC 1900 EXPERT
CITOARC 3500i
CITOROD 6500 XT
230 V single-phase
230 V single-phase
400 V three phase
230 - 400 V +/- 15%
50/60 Hz three phase
15 A
16 A
28.5 A
61.5 - 35.4 A
44 V
67 V (14 V rest voltage)
91 V
68 - 75 V
10 - 180 A
5 -160 A
5 - 350 A
10 - 630 A
Primary
Power supply
Effective consumption
Secondary
Open circuit voltage
Welding current
Duty cycle 10 min. cycle (at 40 °C)
Diam. Electrode
MMA
Gouging
Dimensions (L x W x H)
Net weight
28
180 A at 20%
160 A at 40%
350 A at 35%
630 A at 35%
1.6 to 4.0 mm
1.6 to 4.0 mm
1.6 to 6.0 mm
1.6 to 6.0 mm
-
-
Up to 6.3 mm
Up to 10 mm
170 x 320 x 395 mm
205 x 345 x 450 mm
525 x 300 x 390 mm
1000 x 600 x 600 mm
6.6 kg
9 kg
29 kg
176 kg
Plasma cutting
Plasma cutting installations
1909-01
OERLIKON has a complete Manual Plasma
cutting range for all applications.
From the CITOCUT 10KT, a single phase portable unit with integrated compressor, a
highly portable unit that cuts up to 10 mm, to the NERTAJET 50, a high
performance chopper, multi gas machine that cuts up to 50 mm of steel.
2007-117
CITOCUT 40C
High cutting capcity: 40 mm with 120 A,
4 steps for setting the current
according to the thickness
to cut,
IP 23 for indoor
and outdoor
applications,
High quality cut
with drag cutting
nozzles,
Delivered ready to use with 6 m
torch, air hose, primary cable,
earth cable, start set of wear
parts.
Technical
specifications:
Technology
2010-260
CITOCUT 40i CITOCUT 40C NERTAJET 50
Inverter
Transformer
Chopper
Maximum
thickness
40 mm
40 mm
50 mm
Primary power
supply (3 phase)
400 V
220/230/
380/400 V
230/400/
415/440 V
Maximum
consumption
40 A
40 A (400 V)
60 A (415 V)
Up to 120 A
Up to 120 A
Up to 150 A
720 x 310
x 430 mm
500 x 855
x 705 mm
1170 x 710
x 1200 mm
35 kg
125 kg
260 kg
Cutting intensity
Dimensions
(L x W x H)
Weight
1909-12
Work of high quality
and precision with
contact cutting.
Multi-voltage
three-phase,
Intensive work
(100% duty cycle),
Well suited for
stainless steels
and light alloys
with Ar/H2 up
to 50 mm,
Plasma gouging,
Manual or automatic applications,
Assistance gas use possible to improve quality cutting
in large thickness,
Water cooled torches,
Chopper (secondary power transitions) technology.
Heavy duty portable cutting
unit inverter technology.
Quality cut, up to 40 mm,
Contact cut, distance cut,
plasma gouging,
Blow back start, no HF
interference,
Grid cutting capability.
2007-280
NERTAJET 50
CITOCUT 40i
29
2221-06
2191-01
MIG/MAG manual installations
CITOMIG 500 XP
Product features and advantages:
Three-phase, dual-voltage power
supply allowing connection to any type
of three-phase power supply,
Digital parameter display (plate
thickness / current / wire speed),
4-rollers feed with speed regulation
system providing constant wire feed,
“Assisted adjustment” mode taking into
account the thickness to be welded,
“Spatter reduction” system based on
coil saturation after the striking phase,
2T/4T/spot/intermittent welding modes
for an optimised operating procedure,
Ventilation automatically operates when required,
2 coil positions,
Plug-in harnesses on generator side,
Fully sheathed and shielded harness for greater
robustness,
Ultra-compact wire-feed unit designed for restricted
access,
Wire-feed unit delivered with the possibility of wire
speed adjustment and equipped with gas purge.
2006-788
Optimised performance and advanced functionality:
With its CITOMIG range OERLIKON offers welding sets employing highly developed and
carefully applied technology. This robust and reliable range will always meet the challenge,
even under heavy duty conditions. CITOMIG sets available in air or water, compact or separate
versions, meet every need and offer the following advantages.
CITOPULS AND CITOWAVE, (INVERTER TECHNOLOGY)
With pulsed current and spray modal, special for aluminum. The state of the art in inverter
technology. Highly reliable power sources representing leading edge process development.
2008-662
CITOPULS MXW
30
Product features and advantages:
Regulation and numerical controls: total control
of power supply wave forms for an improvement
of the processes, and of the thicknesses, and exact
parameter reproduction,
Increased power (Voltage/Current): increases
the arc rigidity with pulsed mode, which improves
penetration and allows a good fusion of
“hard-to-weld” wires,
More processes: Soft current, Speed Short ArcTM
(SSATM), pulsed and MMA,
More memory: 121 welding programs on
CITOPULS MXW for all welding applications;
The remote control box also allows memorisation
of 10 programs,
More cycles: 2T / 4T/ Spot weld / Cold Double Pulse
current (CDP),
More options: large options offer in order to make
the welding process easier and safer,
Potentiometer torch.
Process
advantages for a
perfect assembly:
This new generation
of power sources
provides new welding
methods able to
meet quality and
productivity levels
to answer the needs
of the wind energy
industry.
2006-026
2221-05
CITOWAVE MXW
Product features and advantages:
Same as the CITOPULS range with in addition:
Advanced torch “DIGITAL”: a range of ergonomic torches with
the possibility on the handle to - select the program number
- adjust the wire feed speed - adjust the arc length,
More processes: Soft current, Pulsed, SSA, SSP, SM,CDP,
MIG brazing, MMA, and PR Spray,
More memory: 153 welding programs on CITOWAVE MXW for all
welding applications. The power sources also allow memorisation
of 100 programs, selectable from the wire feeder, remote control
and CITORCH M E family,
Control of aluminium welding (Spray ModalTM): special welding
transfer which provides reduced porosity and increases the
penetration,
Technical specifications:
Technology
Primary power supply (3 phase)
CITOMIG 500 XP
More controls: parameters monitoring, indication of defects,
parameter blocking on several levels, printing, 99 programs,
calibration…
More cycles: 2T / 4T/ Spot weld / Cold Double Pulse current (CDP)
CITOPULS 420
CITOPULS 520
CITOWAVE 400
Thyristor
Inverter
230/240/380/400 V
400 V
CITOWAVE 500
Primary consumption @ I max
50 A (400 V)
35 A
45 A
35 A
45 A
Welding current
16 A - 480 A
20 A - 420 A
20 A - 500 A
20 A - 400 A
20 A - 500 A
Duty cycle 10 min. cycle (at 40°C)
480 A @ 50%
400 A @ 60%
500 A @ 60%
400 A @ 60%
500 A @ 60%
Suitable wire diameter
Dimensions (L x W x H)
Net weight
Process
0.8 to 1.6 mm
925 x 580 x 1060 mm
845 x 380 x 855 mm
200 kg
107 kg
Definition
Customer advantages
Power
source
Speed
Short
ArcTM
(SSA)
The Speed Short ArcTM allows a high travel speed due to a rigid arc and a
cold regime. It is very effective for welding thin steel plates, working in
position and in closed angle and filling bevels. The SSATM is used for short
circuit welding though the normal globular regime travel speed domain.
Increase in travel speed
Reduced distortion
(thin steel sheets)
Suited to welding in position
Tolerance and usability
CITOWAVE
CITOPULS
Soft
Silence
PulseTM
(SSP)
The Soft Silence PulseTM is a quieter pulsed mode mainly intended for
stainless steel welding applications. The SSPTM produces a softer but very
stable arc with good wetting of the weld bead. This waveform significantly
reduces spatter and gives a very fine appearance to the weld bead.
Reduction of noise
Good wetting of the weld
bead
Reduction of spatter
Good weld bead appearance
CITOWAVE
Cold
Double
PulseTM
(CDP)
The Cold Double PulseTM produces very high quality welds on thin material
while avoiding distortion. CDPTM gives a TIG appearance to the weld and is
very effective on very thin aluminium or stainless steel sheet (< 2 mm). The
operating technique is made easier due to good control of the weld pool
even on badly-prepared sheets. This sequencer mode automatically chains
hot arc and cold arc regimes together.
CITOPULS
CITOWAVE
Effective on thin sheets
Reduces distortion
Easy operating technique
TIG appearance weld bead
31
2009-469
MIG/MAG Torches
OERLIKON offers a modern and complete range of solutions for
the extraction of welding fumes and air ventilation in order to
ensure the workforce an improved working environment in full
conformance with current legislation and directives.
MIG/MAG welding suction torches:
WST RANGE
Indirect fume collection for extraordinary efficiency
A complete range of torches:
From that distance, with an extraction air volume of 80 - 130 m /h, depending
on the type of torch, the collection zone is larger than with direct
collection, and the percentage of collected fumes is close to 90 - 95%.
• Air cooled
3
2008-522
The fume collector is fixed and placed 7 cm above the molten pool.
The collection process has no direct effect on the shielding gas and the
quality of the welds is protected in all welding positions. Also, the collector
is fixed (not adjustable), to guarantee optimal conditions at all times.
Technical feature:
WST 258
Air cooled or water cooled from 150 A @ 68% to 500 A @ 100%.
• Water cooled
2008-547
2003-084
2003-084
A step toward improved working conditions
WST 508 W
With WST torch
Without WST torch
Standard high efficiency
water cooled welding torches:
CITORCH M 450W NG
2009-278
This water cooled MIG/MAG welding torch is the best solution
for heavy duty work required in wind turbine tower applications.
Available in length 3, 4 and 5 m with a 450 A @ 100% duty cycle and
can be used with solid or cored wired wires up to 1.6 mm diameter.
32
Personal Protection Equipment,
PPE and Workplace Products
2009-471
Air Liquide Welding through WELDLINE brand offers a wide range
of tools and accessories dedicated for welding applications (cables,
earth clamps, torches, brushes and hammers, sprays…) as well as
personal protective equipment for the welder (gloves, clothing,
goggles, mask…) and for the workshop (strips, curtains etc.).
Cables and connectors
2008-574
2000-174
Primary and secondary cables, solid copper meeting
the requirements of international standards.
20
07
-81
4
Ovens
This process requires a MMA power source, a gouging torch
and a source of compressed air.
Electrode diameter range is
4.0 mm to 19 mm.
2008-579
A full range of portable
quivers, holding and
re-baking ovens for MMA
electrodes and hopper
ovens for SAW flux.
2004-989
Electrodes for gouging CARBONAIR
Welder Protection
Torches for air gouging
FLAIR 600 for gouging
work up to 600 A (10 mm
diameter electrodes).
FLAIR 1000 for gouging work
up to 1000 A (13 mm diameter
electrodes).
2007-805
FLAIR gouging torches with air flow rate controlled
on the torch handle.
2007-804
2008-247
A complete range of helmets, leather and cotton clothing,
glasses, gloves and shoes. The ZEPHYR helmet ensures
comfort and protection with a new high performance liquid
crystal cell, extra-wide vision and extreme reliability. The
ZEPHYR is equipped with a forced air flow system preventing
welding fume from infiltrating into the welder’s helmet. The filter
and protection screen are easy to extract, with pressure on the
push button. Adjustable head gear (4 positions) with an
optimised design to ensure good protection of the head, and
light weight for comfort.
33
Temperature Conversion Table
°C
°C
°F
°F
°C
°F
25.5
25.0
24.4
23.8
23.3
-
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
-
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
- 29
- 28
- 27
- 26
- 25
- 20.2
- 18.4
- 16.6
- 14.8
- 13.0
-
22.7
22.2
21.6
21.1
20.5
-
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
-
11.7
11.1
10.6
10.0
9.44
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
31.1
30.5
30.0
29.4
28.8
-
24
23
22
21
20
- 11.2
- 9.4
- 7.6
- 5.8
- 4.0
-
20.0
19.4
18.8
18.3
17.8
-
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
-
8.89
8.33
7.78
7.22
6.67
16
17
18
19
20
61.8
63.6
65.4
67.2
68.0
28.3
27.7
27.2
26.6
26.1
-
19
18
17
16
15
- 2.2
- 0.4
1.4
3.2
5.0
-
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
- 6.11
- 5.56
- 5.0
- 4.44
- 3.89
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
°F
°C
18.9
19.4
20.2
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
123.8
125.6
127.4
129.2
131.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
35.6
36.1
36.7
37.2
38
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
43
49
54
60
66
110
120
130
140
150
230
248
266
284
302
°F
°C
°F
°C
- 418
- 328
- 238
- 148
- 58
-
36.6
36.1
35.5
35.0
34.4
-
-
45.0
44.4
43.8
43.3
42.7
- 49
- 48
- 47
- 46
- 45
-
56.2
54.4
52.6
50.8
- 49
-
33.8
33.3
32.7
32.2
31.6
-
42.2
41.6
41.1
40.5
40.0
-
44
43
42
41
40
-
47.2
45.4
43.6
41.8
40.0
-
-
39.4
38.8
38.3
37.7
37.2
-
39
38
37
36
35
-
38.2
36.4
34.6
32.8
- 31
-
°F
°C
°F
°C
-
33.3
2.78
2.22
1.67
1.11
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
7.78
8.33
8.89
9.44
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
- 0.56
0.00
0.56
1.11
1.67
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
2.22
2.78
3.33
3.89
4.44
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
13.3
13.9
14.4
15.0
15.6
5.00
5.56
6.11
6.67
7.22
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
16.1
16.7
17.2
17.8
18.3
°F
°C
°C
°C
-
- 250
- 200
- 150
- 100
- 50
°C
°F
29.2
27.4
25.6
23.8
22.0
- 156.6
- 128.8
- 101.1
- 73.3
- 45.5
34
33
32
31
30
-
°F
°F
71
77
82
88
93
160
170
180
190
200
320
338
356
374
392
177
182
188
193
199
350
360
370
380
390
662
680
698
716
734
621
649
677
704
732
1150
1200
1250
1300
1350
2102
2192
2282
2372
2462
1177
1204
1232
1260
1288
2150
2200
2250
2300
2350
3902
3992
4082
4172
4262
99
100
104
110
116
210
212
220
230
240
410
413
428
446
464
204
232
260
288
316
400
450
500
550
600
752
842
932
1022
1112
760
788
816
843
871
1400
1450
1500
1550
1600
2552
2642
2732
2822
2912
1316
1343
1371
1399
1427
2400
2450
2500
2550
2600
4352
4442
4532
4622
4712
121
127
132
138
143
250
260
270
280
290
482
500
518
536
554
343
371
399
427
454
650
700
750
800
850
1202
1292
1382
1472
1562
899
927
954
982
1010
1650
1700
1750
1800
1850
3002
3092
3182
3272
3362
1454
1482
1510
1538
1566
2650
2700
2750
2800
2850
4802
4892
4982
5072
5162
149
154
160
166
171
300
310
320
330
340
572
590
608
626
644
482
510
538
566
593
900
950
1000
1050
1100
1652
1742
1832
1922
2012
1038
1066
1093
1121
1149
1900
1950
2000
2050
2100
3452
3542
3632
3722
3812
1593
1621
1649
2900
2950
3000
5252
5342
5432
Note: the numbers in bold type refer to the temperature, either in Celsius or Fahrenheit, which is desired to convert into the other scale. If converting from
Fahrenheit degrees to Celsius degrees, the equivalent temperature will be found in the left column, while converting from Ceslsius degrees to Fahrenheit
degrees the answer will be found in the column on the right.
34
Impact Toughness Conversion Table
J
ft.lb.
J
ft.lb.
J
ft.lb.
J
ft.lb.
20
22
24
26
28
30
32
34
36
38
40
42
44
46
14.7
16.2
17.7
19.1
20.6
22.1
23.6
25.0
26.5
28.0
29.5
30.9
32.4
33.9
48
50
52
54
56
58
60
62
64
66
68
70
72
74
35.4
36.8
38.3
39.8
41.3
42.7
44.2
45.7
47.2
48.6
50.1
51.6
53.1
54.5
76
78
80
82
84
86
88
90
92
94
96
98
100
102
56.0
57.5
59.0
60.4
61.9
63.4
64.9
66.3
67.8
69.3
70.8
72.2
73.7
75.2
104
106
108
110
112
114
116
118
120
122
124
126
128
130
76.7
78.1
79.6
81.1
82.6
84.0
85.5
87.0
88.5
89.9
91.4
92.9
94.4
95.8
J
ft.lb.
J
ft.lb.
J
ft.lb.
132
134
136
138
140
142
144
146
148
150
152
154
156
158
97.3
98.8
100.3
101.7
103.2
104.7
106.2
107.6
109.1
110.6
112.1
113.5
115.0
116.5
160
162
164
166
168
170
172
174
176
178
180
182
184
186
118.9
119.4
120.8
122.3
123.8
125.3
126.7
128.2
129.7
131.2
132.6
134.1
135.6
137.1
188
190
192
194
196
198
200
138.5
140.0
141.5
142.9
144.4
145.9
147.4
Conversion factors:
1 Joule = 0.73756 ft.lb.
1 ft.lb. = 1.35582 J
Welding Units Comparison Tables
Deposition rates
Wire feed speed
Consumable weight
lbs/hr
kg/hr
ins/min
m/min
lbs
kgs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
0.45
0.9
1.36
1.81
2.26
2.72
3.17
3.68
4.08
4.53
4.98
5.44
5.89
6.35
6.80
7.25
7.71
8.16
8.61
9.07
9.52
9.97
10.43
10.88
11.33
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
450
475
500
525
550
575
600
625
650
675
700
0.6
1.3
1.9
2.5
3.1
3.8
4.4
5.1
5.7
6.3
6.9
7.6
8.2
8.9
9.5
10.2
10.8
11.4
12.0
12.7
13.3
14.0
14.6
15.2
15.8
16.5
17.1
17.8
2.2
4.4
6.6
8.8
11.0
13.2
15.4
17.6
19.8
22.0
33.0
44.0
55.0
66.0
77.0
88.0
99.0
110.0
1
2
3
4
5
6
7
8
9
10
15
20
25
30
35
40
45
50
Electrode
and wire diameter
inches
mm
0.024
0.030
0.035
0.045
0.052
1/
16
5/
64
3/
32
7/
64
1/
8
5/
32
3/
16
1/
4
0.6
0.8
0.9
1.0
1.2
1.6
2.0
2.4
3.0
3.2
4.0
5.0
6.0
Electrode length
inches
mm
10
12
13
14
18
250
300
330
350
450
35
Stress Conversion Table
N/mm2
ksi
psi
MPa
N/mm2
ksi
psi
MPa
N/mm2
ksi
psi
MPa
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
21.8
23.2
24.7
26.1
27.6
29.0
30.5
31.9
33.4
34.8
36.3
37.7
39.2
40.6
42.1
43.5
45.0
46.4
47.9
49.3
21800
23200
24700
26100
27600
29000
30500
31900
33400
34800
36300
37700
39200
40600
42100
43500
45000
46400
47900
49300
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
370
380
390
400
410
420
430
440
450
460
470
480
490
500
510
520
530
540
50.8
52.2
53.7
55.1
56.6
58.0
59.5
60.9
62.4
63.8
65.3
66.7
68.2
69.6
71.1
72.5
74.0
75.4
76.9
78.3
50800
52200
53700
55100
56600
58000
59500
60900
62400
63800
65300
66700
68200
69600
71100
72500
74000
75400
76900
78300
350
360
370
380
390
400
410
420
430
440
450
460
470
480
490
500
510
520
530
540
550
560
570
580
590
600
610
620
630
640
650
660
670
680
690
700
710
720
730
740
79.8
81.2
82.7
84.1
85.6
87.0
88.5
89.9
91.4
92.8
94.3
95.7
97.2
98.6
100.1
101.5
103.0
104.4
105.9
107.3
79800
81200
82700
84100
85600
87000
88500
89900
91400
92800
94300
95700
97200
98600
100100
101500
103000
104400
105900
107300
550
560
570
580
590
600
610
620
630
640
650
660
670
680
690
700
710
720
730
740
N/mm2
ksi
psi
MPa
N/mm2
ksi
psi
MPa
N/mm2
ksi
psi
MPa
750
760
770
780
790
800
810
820
830
840
850
860
870
880
890
900
910
920
930
940
108.8
110.2
111.7
113.1
114.6
116.0
117.5
118.9
120.4
121.8
123.3
124.7
126.2
127.8
129.1
130.5
132.0
133.4
134.9
136.3
108800
110200
111700
113100
114600
116000
117500
118900
120400
121800
123300
124700
126200
127800
129100
130500
132000
133400
134900
136300
750
760
770
780
790
800
810
820
830
840
850
860
870
880
890
900
910
920
930
940
950
960
970
980
990
1000
1010
1020
1030
1040
1050
1060
1070
1080
1090
1100
1110
1120
1130
1140
137.8
139.2
140.7
142.1
143.6
145.0
146.5
147.9
149.4
150.8
152.3
153.7
155.2
156.6
158.1
159.5
161.0
162.4
163.9
165.3
137800
139200
140700
142100
143600
145000
146500
147900
149400
150800
152300
153700
155200
156600
158100
159500
161000
162400
163900
165300
950
960
970
980
990
1000
1010
1020
1030
1040
1050
1060
1070
1080
1090
1100
1110
1120
1130
1140
1150
1160
1170
1180
1190
1200
166.8
168.2
169.7
171.1
172.6
174.0
166800
168200
169700
171100
172600
174000
1150
1160
1170
1180
1190
1200
Conversion factors: 1
1
1
1
N/mm2 = 145.038 psi
N/mm2 = 0.145038 ksi
MPa = 145.038 psi
MPa = 0.145038 ksi
Note: psi values have been rounded off to the nearest fourth digit.
36
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