Lincoln Electric Making Fillet Welds User's Manual
Contents
1. 75 In some respects when offset is 50 Negative adjusted to maximum values the arc action almost becomes analogous to that of a pulsed arc Negative values contribute to increasing deposition to levels Square Wave Normal Curve Square Wave Negative Offset 50 Positive 7 Total Amps Total Amps lt 1CYCLE closely approaching the values obtainable with DC 1 60 SECOND negative welding See Figure 5 Square Wave Current Offset l o Figure 5 Figure 6 shows two welds the same 3 8 10mm flat Comparison of offset vs normal balanced wave position fillet as Figure 3 but this time made using a setting of 25 balance 10 offset Note that this results in an additional gain of 12 in travel speed This is a net gain of 29 over DC The increased deposits possible using a combination of wave balance and wave offset may raise the question about root penetration While at present the major welding codes do not allow sizing a fillet weld based on root penetration some producers of proprietary products do Figure 7 shows the depth of penetration as compared to DC for a number of settings This shows a variation of only 05 1 3mm in DC SW AC with Offset penetration a variation of nine to ten percent All of AC P Balance the welds were made when the plate was at room 10 Offset temperature and at 54 25Kj heat input Figure 6 SW AC SW AC Square Wave SW AC 25 Balanced 25 Ba2. Figure 3 shows two 3 8 10mm flat positioned fillet welds Both were made at 814 amperes but the square wave AC 25 balance wave is made 17 faster Figure 4 graphically shows the significance that square wave balance can and does play Note that only 25 of the time is the arc positive while 75 of the time it is negative This flexibility can be used to tailor the arc to achieve best results by increasing deposition decreasing penetration or decreasing deposition and increasing penetration SINE WAVE SQUARE WAVE E TRANSITION REGIO VOLTS VOLTS 1 CYCLE i 1 60 SECOND 60 Hz SINE WAVE vs 60 Hz SQUARE WAVE Figure 2 DC AC 25 Balanced Figure 3 Groyed arca is portion of posibwo hall side dded to the negative half side UNBALANCED SQUARE WAVE RED BALANCED SOWUARE WAVE VOLTS VOLTS i CYCLE 1160 SECOND UNBALANCED SOUARE WAVE Figure 4 2 Rms root mean square value of current or voltage For example when someone refers to 110 volts this is actually an rms value as is 30 volts AC etc APPLICATION Making Fillet Welds with Power Wave AC DC 1000 System Welding Guide Square Wave Offset Effect Offset is expressed as a percentage between 25 and 25 of the rms value that is kept positive or negative In other words 25 means the normal positive component of each cycle is held to 25 of the normal rms value and the negative component becomes
3. almost always been the preferred choice for producing submerged arc welds Some of these reasons are Lowest capital cost for equipment Greater arc stability than with AC Virtual elimination of arc striking problems A OO N Power issues single phase vs three phase balanced power While DC negative may offer the highest deposit rate per ampere it is seldom used for automatic welding that must meet stringent code requirements This is because DC negative is more prone to magnetic arc interference arc blow porosity resulting from contaminants organic and or inorganic contaminants in or on the steel and greater potential for slag entrapment because of the larger and colder weld puddle DC negative has always been the method of choice for welding off analysis steel or dirty steel where it is desirable to have minimum dilution But with Power Wave AC DC 1000 technology this is no longer the best option The Power Wave AC DC 1000 provides the capability of easily using the best welding mode for the job at hand Understanding Power Wave AC DC 1000 To fully understand the potential for possible productivity gains using the Power Wave AC DC 1000 system understanding the major AC components and what they contribute is helpful The major components consist of 1 Square wave vs a conventional sine wave 2 Square wave balance 3 Square wave offset 4 Square wave frequency Figure 1 shows photogr
4. LINCOLN amp THE WELDING EXPERTS WAVEFORM CONTROL TECHNOLOGY Making Fillet Welds with Power Wave AC DC 1000 System Welding Guide 40 Increase in Travel Speed 5 16 8mm Horizontal Fillet Weld 5 32 4mm Dia Electrode 525 Amperes Both Welds e Constant current sometimes referred to as variable voltage e Constant voltage e Square Wave AC Choice of AC frequency from 10 Hz to 100 Hz e Wave balance control to allow more or less DC positive component Offsetting the AC wave to change the magnitude of the negative or positive component e Virtual elimination of arc striking problems LINCOLN e Virtual elimination of arc blow ELECTRIC e Documented productivity increases over conventional submerged arc welding Patented This product is protected by one or more of the following United States patents 6 809 292 6 795 778 6 700 097 6 697 701 6 683 278 6 660 966 6 600 134 6 683 278 6 596 570 6 570 130 HEXTWELD 6 536 660 6 489 952 6 472 634 6 636 776 6 486 439 6 441 342 6 365 874 6 291 798 6 207 929 6 111 216 4 927 041 4 861 965 and other pending U S patents Similar patents are maintained in other countries T h e PYT ASUTE Copyright 2005 The Lincoln Electric Company All rights reserved NX 3 50 5 05 T o S i we l dion ge 7 ss h e r e APPLICATION Making Fillet Welds with Power Wave AC DC 1000 System Welding Guide DC welding has
5. Less than 11 months to recapture the cost of the Power Wave AC DC 1000 and returns a 36 5 percent increase in production capacity Producing 5 16 8mm horizontal fillet welds Present weld DC 525 amps 15 0 in Min 0 0 0 cc es 1 33 Ft Power Wave Weld 525 amps 25 bal 10 off 30Hz 21 0 in min 0 95 Ft Dollar Saving per Foot of WIG x 6 2 nnana anaana 0 38 Ft Annual Saving based upon a 2000 hour year 31 920 Less than 10 months to recapture the cost of the Power Wave AC DC 1000 and with a 40 percent increase in production capacity To maintain or improve your competitive edge contact the nearest Lincoln Electric Technical Sales Representative to discuss and start the process toward lower welding costs and increased productivity Based upon present cost of an equipment setup that includes Power Wave AC DC 1000 Power Feed 10A Controller Travel Carriage and essential accessory items including vertical and horizontal adjusters contact nozzle and wire reel Prices for other packages will vary The cost of other equipment packages may alter the time to recapture the purchase cost Customer Assistance Policy The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equipment Our challenge is to meet the needs of our customer and to exceed their expectations On occasion purchasers may ask Lincoln Electric for adv
6. ak values and less time transitioning As the frequency is increased the opposite occurs This can be of considerable help when making fillet welds between thick and thin members in reducing burn through and undercut resulting from overheating the thinner member as might be the case when welding stiffeners to girder web plates This is further illustrated in Figure 10 Penetration vs Frequency i Te Gr a H O d ya ama Seconds e pmm 4 Heig Seting r X re a uii jH ali DI Mertz Setting k i BD Herz Setting 2 F FREQUENCY EFFECT Figure 8 Conventional sine waves in red are superimposed schematically with Power Wave square waves to illustrate the frequency effect The voltage and current values are identical for all three curves APPLICATION Making Fillet Welds with Power Wave AC DC 1000 System Welding Guide Penetration vs Frequency Deposition Rates vs Frequency Figure 9 compares three 31 7 9mm horizontal fillet Frequency also plays a role in total deposition rate welds made at 10 70 and 90 Hz All were made at the Deposition rates may increase about 6 as the same heat input and travel speed Penetration ranges frequency is lowered Deposition rate decreases from 2 1mm to 3 2mm in depth slightly as frequency is increased This could be significant when producing large single pass fillet welds Frequency Hz 10 70 90 Penetration mm 2 5 3 2 2 1 Figure 9 5 32 4 0mm Diameter El
7. aphs of two 5 16 8mm horizontal fillet welds One is made using a good DC procedure and one using a square wave 25 balanced 10 offset and 30 Hz Both are excellent fillets but the square wave procedure is forty percent faster Note that the amperage used is virtually the same 520 vs 527 amperes DC 527 Amps Figure 1 40 faster travel speeds by using Power Wave AC DC 1000 Square Wave procedures over DC procedures 1 These welds comply with the geometry requirements for leg and throat dimensions of all AWS codes APPLICATION Making Fillet Welds with Power Wave AC DC 1000 System Welding Guide Square Wave vs Sine Wave Figure 2 shows one cycle of a true 60 Hz sine wave with a square wave superimposed upon it Note that while the rms value and the peak values are the same for both waves the transition time for peak to peak is much shorter for the square wave The transition period is what has always caused instability with conventional AC welding but with the rapid transition associated with the Power Wave AC DC 1000 arc Stability is increased Square Wave Balance Square wave balance can allow the arc to act more as a DC negative or DC positive arc thus increasing deposition rate or increasing penetration This is always expressed as a percentage of the DC component i e 25 Balance means that only 25 of the cycle will be positive while 75 of the cycle will be negative etc
8. d on the left is with DC The weld on the right is with AC 25 Balanced 10 Offset 60Hz APPLICATION Making Fillet Welds with Power Wave AC DC 1000 System Welding Guide CONVERTING TO A POWER WAVE PROCEDURE An easy approach to making a conversion to a Power Wave AC DC 1000 procedure is to use this table as a general guide and follow these steps 1 Start with the existing variable voltage DC positive procedure as the reference procedure the reference travel speed and voltage 3 Adjust frequency from 30 to 90 HZ stop if the current value begins to drop 4 Shift the AC balance to 25 a Increase voltage 2 3 volts b Increase travel speed 1 2 times reference value 5 Add 5 to 10 negative minus offset a Increase voltage an additional 1 2 volts b Raise travel speed to 1 3 times reference speed This will yield a good starting point for converting a DC fillet welding procedure Fine tuning these steps will yield the maximum increase with equal or improved weld appearance Easy Welding Procedure Setup The Power Wave AC DC 1000 system is the easiest system ever produced when it comes to changing from one welding procedure to another e No need to move change welding cables even when changing polarity or changing from constant current to constant voltage No need to internally reconnect power carrying taps or bus bars hence in many instances no need for a maintenance electricia
9. ectrode AC 25 Balanced 10 Offset Hz shown above 525 Amperes 1 0 25mm 21 ipm 827mm min Travel Speed SW AC 25 BAL 10 OFFSET SW AC 25 BAL 10 OFFSET SW AC 25 BAL 10 OFFSET SW AC 25 BAL 10 OFFSET D D D D Welding Mode A a Q R 9 Penetration mm 5 40 3 83 3 91 3 87 4 10 4 02 ii er u e _ rir z a i p I ii n Ei Li F i T k ii gmi DHL i l eee eee eet E E i A Hm i r ri i EU r ELT n i os w ot aay a p ns v 1 ToN Figure 10 Penetration vs Frequency 5 32 4 0mm Electrode 1 25 31 8mm ESO 526 Amperes 31 Volts 18 ipm 457mm min Travel 54 4 Kj Heat Input APPLICATION Making Fillet Welds with Power Wave AC DC 1000 System Welding Guide Power Wave AC DC 1000 Deposition Rate Illustrating the ability of Power Wave AC DC 1000 technology to significantly increase fillet welding productivity Figure 11 shows the deposition rate vs amperes for 5 32 4mm diameter electrode This figure can be used to predict the increased deposit rate while maintaining a constant current 35 15 9 A l DEPOSIT RATE vs AMPERES F 5 32 4 0mm Diameter Electrode fa 1 25 31 8 mm ESO co Aa 30 A 13 6 m E Di 11 4 ae F k m E Wi gt 9 1 Aa E F ra z A 645 6 8 KA 40mm Diameter Electrode Fo welght per foot 085 pounts amp weight per meter 1399 kilog
10. ice or information about their use of our products We respond to our customers based on the best information in our possession at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such information or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirement Subject to change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information WHAT IS NEXTWELD The challenges facing industrial fabricators today are increasingly difficult Rising labor material and energy costs intense domestic and global competition a dwindling pool
11. lanced Mode DC Balanced 25 Balanced 10 Offset 20 Offset Penetration mm 5 53 4 06 4 06 4 02 4 r ay i Sad ye iui n y ay ip ig i TT T l 100 i70 T40 ioga Figure 7 Penetration vs Various Modes All welds made using 5 32 4mm Diameter Electrode 525 Amperes 31 Volts 1 25 81 8mm ESO 18 ipm 457 2mm min Travel Speed 54 25 Kj Heat Input APPLICATION Making Fillet Welds with Power Wave AC DC 1000 System Welding Guide Square Wave Frequency While frequency is historically accepted to be fifty or sixty hertz the Power Wave AC DC 1000 can function at any chosen frequency between zero DC and 100 hertz Frequency can play an important role in a specific welding procedure Relative to a normal sixty hertz deposition rates can be slightly increased or decreased as can penetration Frequency alters the total time for the arc to be at peak values As the frequency decreases more time is available at peak value and more importantly less time is spent in the transition region The converse occurs as frequency is increased Figure 8 frequency effect illustrates this by showing what occurs during one complete cycle As the frequency of the AC wave is altered the amount of time spent at peak current and voltage values and the amount of time spent transitioning from positive to negative values also changes In general as the frequency is lowered more time is spent at pe
12. n Control all output functions on the control panel Fully supported by Lincoln s Power Wave Submerged Arc Utilities software where demanding applications require activity reporting or even remote procedure verification see Nextweld NX3 20 brochure The heart of the system is the Power Wave AC DC 1000 featuring e Balanced input line draw even when welding with AC High 86 electrical efficiency contributes to keeping energy charges low 95 power factor assures minimizing excess ampere draw from the supply lines Continuous output rating 1000 amperes assures the system is ready to go full time Pa Til rida e H PII NITTI nity i HTI E H P N ETAT AAN Ty TITTY H Hit ry I 1 ii mT il I i WAVEFORM CONTROL TECHNOLOGYT Making Fillet Welds with Power Wave AC DC 1000 System Welding Guide APPLICATION Power Wave AC DC 1000 System Cost Recapture Analysis Example Using a burden charge of 40 00 Hr an operating factor of 40 and the need to produce either of the following welds Producing 1 2 13mm flat positioned fillet welds Present weld DC 885 amps 10 40 iN MIN 0 0 ees 1 92 Ft Power Wave Weld 885 amps 25 bal 20 off 30Hz 14 2 in min 1 41 Ft Dollar Saving per Foot of Weld nnan an wane cake ee ae ee ea Oo wwe 0 50 Ft Annual Saving based upon a 2000 hour year 28 400
13. of skilled workers more stringent and specific quality demands LINCOLN ELECTRIC Through our commitment to extensive research and investments in product development Lincoln Electric has established an industry benchmark for applying technology to improve the quality lower the cost and enhance the performance of arc welding processes Advancements in power electronics digital communications and Waveform Control Technology are the foundation for many of the improvements Thi HEXTWELD NEXTWELD brings you a series of Process Technology Application and Success Story documents like this one NEXTWELD explains how technologies products processes and applications are linked together to answer the important questions that all businesses face e How can we work faster smarter more efficiently e How can we get equipment and people to perform in ways they ve never had to before e How do we stay competitive NEXTWELD is the future of welding but its benefits are available to you today Ask your Lincoln Electric representative how to improve the flexibility efficiency and quality of your welding operations to reduce your cost of fabrication LINCOLN amp ELECTRIC THE WELDING EXPERTS THE LINCOLN ELECTRIC COMPANY www lincolnelectric com 1 216 481 8100
14. rams 10 4 5 ma 5 AMPERES 2 3 _ 300 400 200 600 FOO 800 900 1000 Figure 11 APPLICATION Making Fillet Welds with Power Wave AC DC 1000 System Welding Guide Some Fillet Weld Results A number of fillet welds made with the Power Wave AC DC 1000 are shown as examples All of these welds comply with the AWS D1 1 Structural Steel Code and the AWS D1 5 Bridge Code and those codes that clone or refer to the AWS Codes All fillet welds conform to the acceptable size and gauge size requirements of the code There has been no intent to match any specific mechanical properties however the welding consumables used to produce these welds are commonly used Figure 12 Horizontal 5 16 8mm fillet welds shows an increase of 40 in travel speed over DC Both welds made with 5 32 4mm diameter electrode at 527 amperes Figure 13 Flat positioned 1 2 13mm fillet welds show an increase of 44 in travel soeed over DC Both welds made using 3 16 4 8mm diameter electrode at 885 amperes Figure 14 Horizontal 1 4 6mm fillet welds with an increase of 32 in travel soeed over DC Figure 12 The weld on the left is DC 15 ipm travel The weld on the right is AC Balanced 25 10 offset 30 Hz 21 ipm travel Figure 13 The weld on the left is with DC at 10 4 ipm travel The weld on the right is with AC 25 Balanced 20 Offset 30Hz at 15 ipm Figure 14 The wel
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