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Michael Spiess, Productmanagement, Aluminium, Europe

ESAB Aluminium Welding Wire

Aluminium Welding with regard to Quality & Cost

Vorführender

Präsentationsnotizen

The theme is aluminium welding with regard to quality & cost.

ESAB, Michael Spieß, Produktmanager Aluminium, Europa

Aluminium is recyclable

Which is the most popular aluminium product in the world?

Vorführender


instead which, you can use what Soda cans

common elements in

Earth's crust

47%

27%

8%

5%

4%

3%

2%

2%

Oxygen

Silicon

Aluminum

Iron

Calcium

Sodium

Potassium

Magnesium

Aluminium is the most common metal on Earth


Feldspar Mica Clay

Vorführender


Aluminium is the most abundant metal and the third most abundant element after oxygen and silicon. You will never find Aluminium in its elemental state. You will find Aluminium only in oxides or silicates


Total demand of Aluminum

Quelle: GDA

In 1000 to 2005 2006 2007 2008 2009

Europe 11.500 12.000 12.700 12.400 9.300

Asia 15.900 17.900 21.800 22.500 23.300

Africa 400 500 500 700 800

America 12.300 13.000 12.500 11.400 9.900

Oceania 600 500 500 500 500

Total 40.700 43.900 48.000 47.500 43.800

Aluminium – Market Segments


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The approach to the market goes over the above mentioned segments like transportation (automotive, trains, ship building etc... Aluminium market is diveded into several functions/segments like transportation etc…


1XXX → Pure Aluminium

2XXX → Copper

3XXX → Manganese

4XXX → Silicon

5XXX → Magnesium

6XXX → Magnesium/Silicon

7XXX → Zinc

8XXX → Lithium

Main Alloying Elements – of the Alloy Group

Aluminium – Alloy Groups


heat treatable

Non heat treatable e.g. AlMg3 (5754) AlMg4,5Mn (5083) AlMn1 (3103)

e.g. AlCu6Mn (2219) AlMgSi0,5 (6060) AlZn4,5Mg1 (7020)

Aluminium – Alloy Types


Aluminium – Material with a Future

• Aluminium is the most abundant metal in the Earths crust and the third

most abundant Element

• Light weight, 1/3 of the weight of Steel

• Low Melt point of pure (660°C for Al 99,99)

• Very high thermal conductivity

• High corrosion resistant and weatherproof

• No loss of toughness by low temperature (face centered cubic lattice)

• High solubility of hydrogen in the liquid state

• Increase in Strength through alloy of Mg, Cu, Mn, Zn

Perfect for crash management systems Car and train elements that are designed to fold and collapse like an accordion in a crash are capable of absorbing up to twice the crash energy of steel

Aluminium is a very ductile material

Michael Spiess, Product management, Aluminium, Europe


Aluminium – Consumption rising steadly

Vorführender


Which product on the slide, consumes the most aluminium welding wire?

WELDABLE employing methods, equipment and skills similar to those used for welding other materials

Aluminium is and



Aluminium – Welding Process “FSW”

- Friction-stir welding (FSW) is a solid-state joining process (meaning the metal is not melted during the process) and is used for applications where the original metal characteristics must remain unchanged as far as possible


Aluminium – Welding Process “MIG”

GMAW is the most common industrial welding process, preferred for its versatility, speed and the relative ease of adapting the process to robotic automation.


Aluminium – Welding Process “TIG”

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc welding process that uses a non consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by a shielding gas (usually an inert gas such as argon), and a filler metal is normally used


Aluminium – Welding Difficulties What are the biggest problems for welding of aluminium?

- soft welding wire

- feedability of the aluminium welding wire

- (hot) cracks in aluminium

- porosity in the weld

- aluminium storage and handling

- lack of fusion

- wrong parameter settings

- etc..

Vorführender


These difficulties are the most serious problems


Welding Difficulties – Causes and corrections

Difficulty Causes Corrections Dirty Welds Improper gas coverage

Dirty electrode Dirty base material

Check for leaks in hoses, air drafts, loose fittings wrong gas Proper storage or contact supplier Remove oils and grease before other mechanical cleaning. Remove oxides using clean stainless steel brush.

Unstable Arc Connections, dirt, or wind Check all conductive surfaces for clean ground. Remove dirt from weld joint. Eliminate drafts from weld area where shield gas can be disturbed.

Penetration and Fusion Problem

Wrong weld parameters Wrong wire diameter Dirty base material Wrong gas type Wrong joint preparation Dirty electrode

Adjust more amperage for more penetration and mor voltage for more width. Smaller wire will penetrate more. Larger wire will fill more Clean weld area prior fit up. Remove oxide. Use only enough gas to create coverage. Verify gas for operation Thicker welds require U-Type joint versus V-type or square. Store electrode in warm, dry enviroment at all times to prevent corrosion (it´s cheaper to buy it once).

Vorführender


Feel free to ask me questions.



Difficulty Causes Corrections Porosity Hydrogen in the weld Check gas dew point – (reject gas above 20 °C. Check for Gas

leaks and defective hose conditions. Store electrode properly. Remove oils, grease and other hydrocarbons from base material. Remove oxides within 24 hours of welding. Preheat base material up to 65°C. Do not use torches to preheat (hot air guns work best!). Check gas flow. Use larger wire if puddle is turbulent.

Weld cracking Improper filler alloy Joint or edge preparation Poor crater fill

Refer to filler selection chart. Reduce dilution (more filler less base material). Increase joint spacing or increase bevel angle. Fill crater completely through technique or system device.

Poor feeding Bird-nesting Arc hunting Liner Build-up Drive rolls

Reduce drive roll tension. Use slow run-in start system. Check all surfaces where wire touches and reduce metal on metal areas. Check contact tip condition. Check liner condition. Check drive roll condition. Check for proper contact tip I.D. Use a liner material hard enough that does not cut easily. Check for wire galling items. Check drive rolls for proper size, shape and surface finish.

Vorführender





Difficulty Causes Corrections Poor Arc Starting Improper ground

Contact tip size No shielding gas

Check that all grounds are well made. Use slow run-in or hot start features to assist start. Check that contact tip is not oversized for alloy and diameter. Use pre-purge feature for gas shield (also post purge to prevent oxides from forming on end of wire). Change welding parameters.

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Quality Criteria for Aluminium Welding Wire

- raw material quality and purity

- shaving technology

- welding wire surface

- quality and maintenance of the drawing dies

- tolerance of the wire diameter!

- cast and helix

- final cleaning and coating

Cast

Helix

Vorführender


Feel free to ask me questions. to (achieve) get predetermined diameter


Wire Surface Quality

Al 5356 1,2mm 200 times magnification

insufficient shaved

insufficient shaved

Vorführender


Insufficiently shaved wire surface


Would you like such an aluminium welding wire in your production ?

Wire Surface Quality

Fume Test

ESAB

Peak Value: 0,568 mg/m³ Total: 3,245 mg/m³

Peak value 0,206 mg/m³ Total 0,804 mg/m³

Peak value: 0,776 mg/m³ Total: 7,513 mg/m³

Alloy: 4043 Diameter: 1,60 mm Manufacturer: ESAB Pulse current 420 A Pulse time: 582 ms Date : 02.10.2009

Results

Peak value: 0,206 mg / m³ Total: 0,804 mg / m³


Errors from Usage of Aluminium Welding Wire

Fume Test What does the measurement of the residues from smoke tell us?

Storage or Usage How long can you store aluminium welding wire until it is used? Is it one week, three months, one year or…?


How do we test the quality of aluminium welding wire ?

We test the aluminium welding wire according the AWS Code 5.10


Vorführender


Less expensive way to measure the welding way.


Increase productivity by 40 % at a rail road car manufacturer

Wire diameter Ø 1,60 mm Ø 1,80 mm Ø 2,00 mm

Customer Rail Rail Rail

Part Main carrier Main carrier Main carrier

Parent mat. 6005A 6005A 6005A

Filler mat. ER5356 Ø 1,60 mm ESAB OK Autrod 5356 ESAB OK Autrod 5356

Travel speed 36 – 38 cm /min 42 cm / min. 49 cm / min.

No. of beads 3 2 2

Vorführender


You can have several different approaches for your application.


WPS

Cross section



Welding Cost Calculation


A weld without PAK TRAK and OK Autrod 5183 d= 1,60 mm

A weld with the PAK TRAK and OK Autrod 5183 d= 1,60 mm

Applications


New Development

If you like to:

- pay off the welding wire, out of big bulk packages

- get straight welding seams

- prevent tangled wire

- prevent twists in bulk packages

- have a stable arc during welding

- avoid disruption during welding process

- transport the wire over a long length, up to max. 60 m

- use standard PA wire conduits

New application for long straight welding seams and long wire conduits


Vorführender


Stadler allowed us to conduct tests under real conditions



Results with the PPT applications


- ESAB has the most comprehensive product portfolio of welding consumables for treatable alloys and also for harden able alloys.

- ESAB is the biggest manufacturer of aluminium welding wire in the market. ESAB is continuously working on new developments to help our customers increase their productivity.

- the ESAB „Marathon Pac“ is the best, most reliable and most environmentally friendly packaging system in the global market.

- the ESAB aluminium wire electrode has a unique surface and surface coating. This ensures non porous welds and a very good feeding behavior in the wire conduit.

- ESAB has a wide range of accessories for welding without disruption and transporting the wire over long distances for use with our aluminium Marathon Pac products.

What is special about the ESAB Aluminium Welding wire ?

Michael Spiess, Product management, Aluminium, Europe

Thanks for listening

www.esab.com

Date post:	25-Mar-2018
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