MOVE YOUR SUBMERGED ARC WELDING TO THE NEXT LEVEL
We are the submerged arc process specialist. Together we will develop the best solution while maximizing your savings through highest deposition rates, highest quality and optimized parameters with your actual equipment and potential investments.
Lincoln Electric offers the total solution for submereged arc welding:
• Outstanding process expertise
• Maximizng your welding time
• The best flux/wire portfolio
• High-end equipment and accessories
• Local procedure development
• Customized automation
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THE SUBMERGED ARC WELDING PROCESS
The arc being shielded and hidden under the flux, high current density can be considered with the following benefit:
• Operator protection from arc ray and heat radiation
• High deposition rate and high quality welds
• Versatile welding process with combination of wire diameter, flux type, single or multiple electrodes, welding current wave shape and welding mode.
The submerged arc wire standard portfolio includes different wire sizes, mainly between 2.0 and 4.0 mm wire diameter. The choice of wire size is made in accordance with the welding procedure parameters in order to maximize the current density and increase the melt off rate, without exceeding the wire current carrying capacity.
LONG STICK OUT PROCESS
The combination of the Power Wave® AC/DC 1000® SD Inverter technology with the addition of an extension to the welding torch enables the long stick out process (LSO). The LSO relates to a physical principle which, by pre-heating the wire, improves the fusion of the filler metal and increases the deposit rate without changing the welding current or the travel speed.
Long stick out process can also be used with multiple arc procedure in order to get the optimum output from your Power Wave® AC/DC 1000® SD investment.
WIND POWER CHALLENGES AND SOLUTIONS
As the world population approaches 8 billion, global energy consumption is growing exponentially. To fight global warming, clean energies are increasingly popular. Hence the number of Wind farms is rising sharply across the globe.
At the same time, governments are reducing or eliminating clean energy subsidies and the Wind industry is challenged with producing at lower costs. To remain profitable, the only way forward is to increase productivity whilst maintaining quality.
Regarding welding productivity, Lincoln Electric has the products, knowledge, experience and support teams to help wind tower manufacturers achieve their targets. In particular, the Tandem Long Stick Out (TLSO) submerged arc welding process can deliver substantial savings. In Tandem, 1 or 2 LSO torches can be used. In the 2 LSO configuration, deposition reates can easily exceed 40kg/h using 4 mm wires.
SUBMERGED ARC EQUIPMENT
Although the long stick out process may not be new, its effects were limited by the welding generator technology. The Power Wave® AC/DC 1000® SD Inverter and its Waveform Control Technology™ wave-shape control eliminate the arc ignition uncertainties thanks to its special management of the welding current, thus making it possible to make the most of this process’s unprecedented effectiveness.
Power Wave® AC/DC 1000® SD Inverter is the first power source equipped with wave-shape control technology. By working with an alternating polarity, the current’s wave shape can be changed.
By modifying the balance, the Offset and the frequency, it is now possible to increase the deposit rate and deepen the penetration using the same amount of welding energy, easily adjust the shape of the seam and reduce the interactions between the arcs.
Combining AC current and LSO will improve the deposition rates, shorten the welding time, and lead to decreasing the cost of each weld.
OPTIMIZED FLUX AND WIRE COMBINATION
Highest repeatability at lowest defect rate is essential to pipe production. Matching the material properties requires optimized flux and wire combinations.
Lincoln Electric offers a variety of welding fluxes and wires designed to work together and deliver excellent weld characteristics and properties. Over 150 combinations are available for single and multiple pass welding, for both automatic and semi-automatic applications.