MIG-MAGPROCESS

Globalsolutionsfor automaticwelding:• innovation,• quality,• productivity.

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THE MIG-MAG PROCESSSingle wire or double wire (TOPMAG),two process variants guaranteeingan excellent result and high-performance welding.

• Single wire process* • Performance

• Various transfers for high productivity

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1 - electrode wire2 - gas nozzle3 - contact tube4 - protection gas5 - electric arc6 - molten pool7 - part to be welded

Weldingspeed(m/min)

Deposition rate(kg/h)

TOPMAG (double wire)

MAG TGV flux-cored wire

Spray+

Short-arc+

MAGstandard

Arc voltage(volts)

Arc current(amperes)

Rotatingliquid vein

Axialatomisation(Spray-arc)

Pulsed

Globular

Short-arc

50

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0

20

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00 1 2 3 4 5

150 300 450 650

Short-arc

Short-arc

+Globular

Spray

Rotating vein

Spray+

* see page 11 for double wire process.

The combination of the welding gas with the filler metal plays adetermining role in achievingquality, productivity and ergonomic objectives.AIR LIQUIDE group proposesa major asset in the form of its global solution:• shielding gas,• high-quality and reliable

filler products,• packaging that allows

higher productivity.

Drawing on its longexperience ofMIG/MAG welding,SAF can propose the best automationsolution for your application.In a partnership guaranteeing your success, SAF can support your manufacturing process:• process control,• welding equipment,• consumables

(wires and gas),• services (training,

maintenance, etc.)

Equipment

Various ranges of power sources, torches and wire-feed units on basic standard machines or highly automated equipment (including robots)and engineering machines.

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MIG-MAG :SAF global solutions for automatic welding

Consumables Services

Are you looking for ways to improve productivity?In addition to high-performance equipment and consumables, you can benefit from the experience of our experts. As your partners, we can assess your situation and propose innovating solutions:• advice on your process

and welding procedures,• preventive or after-sales

maintenance,• logistics for managing

consumables and wearing parts,• training.

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Welding armoured cabinets.Carbon steel or stainless steel.- Thickness: 4 to 12 mm.- Solid wire diameter: 1.0 and 1.2 mm- Part dimensions L x W x H:

800 x 800 x 1200 mm.- Welding speed: 0.5 m/min.

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The welding performance information in this document is given as a guide and may vary according to process implementation and the quality of part preparation.

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"Uncomplicated and economic" mechanisation solutions for single wire applications

As a first step to automation, these uncomplicatedmachines deployingmechanisationequipment from the SAF catalogue(slides, supports, etc.) are usually fitted with welding facilitiesbased on manual equipment.They provide a considerable productivity increaseover manual welding for a reasonable budget.They feature user-friendly controlsand reduced, low-costmaintenance.

Welding machine for pressure tank bottoms (1 or 2 simultaneous welds depending on application) - Carbon steel.- Thickness: 1.2 to 3 mm.- Solid wire diameter 1.2 mm or TGV flux-cored wire diameter 1.2 mm.- Part dimensions: diameter 550 x 500 mm (length).- Welding speed:

•0.8 m/min to 1.5 m/min with solid wire•up to 2.8 m/min with flux-cored wire.

The OPTIMAG range of power sources features: • fast access to the correct

welding parameters;• reduced spatters;• full welding cycle with

hot start and crater filler;• arc extinction system

for better striking;• optional torch-cooling

system.

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You manufactureall types of steel,stainless steel, aluminiumand light alloyparts for light boilermaking and basic parts for mid-range boilermaking.

OPTIMAG 300S OPTIMAG 400SPrimary specifications

Three-phase power supply 230/400 V 50-60 Hz 230/400 V 50-60 HzPrimary power consumption 12.6 kVA 20.2 kVAMaximum current 19 A 29.1 A

Secondary specifications

No-load voltage 38.5 V 45 VWelding current mini 40 A 50 A

at 60 % 280 A 350 Amaxi 280 A 400 A

Welding wires steels/stainless steel 0.8 - 1.2 mm 0.8 - 1.6 mmaluminium 1.0 - 1.2 mm 1.0 - 1.6 mmflux-cored wires 1.0 - 1.2 mm 1.0 - 1.6 mm

Welding cycle 2 T/4 T/4 T with crater filler 2 T/4 T/4 T with crater fillerNet weight 114 kg 144 kgProtection factor IP 23 IP 23

Name STARMATIC 650 DCFull duty cycle 650 A - 44 VWelding range 1Primary power supply 230/400/440 V 50-60 Hz tri*Technology thyristorsMaximum current input at primary 72 APower consumption 34,5 kVACharacteristics:- horizontal- vertical Protection factor IP 21Insulation class HCooling driven airNet weight 247 kg

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Rotating electrode machine for circular welding (drain tap or flange on tank bottom) with stationary part and rotating torch.

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Circular welding of small pressure tanks.Stainless steel 304 L.- Thickness: 2 mm.- Solid wire diameter: 1.0 mm.- Part dimensions: diameter 400 x 350 mm (length).- Welding speed: 1.2 m/min.

Machine for welding household gas cylinders.Carbon steel.- Thickness: approx. 2 mm.- Solid wire diameter: 1.0 mm or 1.2 mm.- Part dimensions: diameter 285 or 365 mm- Welding speed: 0.8 m/min.

The STARMATIC 650 DChas a full use range:• solid wires• flux-cored wires

dia. 0.8 to 1.6 mm,• steel• stainless steel• light alloys

up to dia. 2.4 mm.Smooth welding possible up to 650 A, full duty cycle.

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* contact us for other primary three-phase power supply ratings.

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Machine for welding drain taps at the bottom of boiler shells.Carbon steel or stainless steel.- Thickness: 1.8 mm to 3.5 mm.- Solid wire diameter 1.0 or 1.2 mm.- Welding speed: 0.5 to 1 m/min.

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TM15 torch mounted directly in the powered

wire-feed unit. Joint monitoring

by laser device.

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Welding of low pressure tanks - Carbon steel.- Thickness: 2 to 3 mm.- Solid wire or TGV flux-cored wire: diameter 1.2 mm.- Part dimensions:

diameter 600 x 1000 mm (length).- Welding speed: 1.2 to 1.8 m/min depending on wire used.

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Main specificationsWelding current 45 to 450 ADuty cycle 450 A at 100%Welding voltage 14 to 44 VNo-load voltage 70 VPulse frequency 10 to 500 HzPrimary voltage 230/400/415/440 V

+ 20% -15% - 50-60 HzWeight 230 kgDimensions (h x l x d) mm 1010 x 625 x 1030

STARMATIC A450power source using transistorchopper technology for welding steel and lightalloys.• Synergic - Pulsed• Built-in hot-start• 50 storable programs• Crater filler• Burn back• Display of welding

parameters• Monitoring of welding

parameters• Loading/unloading

of welding parameters to/from PC.

Type of welding• Standard MIG-MAG

- current range 20 to 450 A- voltage range 10 to 44 V- wire speed range 1 to 20 m/min

• Pulsed MIG-MAG- current range 20 to 350 A- voltage range 20 to 40 V- wire speed range 1 to 20 m/min

• MIG-MAG Short-arc+- current range 20 to 360 A (steel wire 1.6 mm)- wire speed range 1 to 20 m/min- arc height fine adjustment

Constructedin compliance with all safety standards and ECstandards, these machines with basic throughto sophisticated automation systems,are fitted with powerfulSTARMATIC A450power sources.

You manufacturemechanically-weldedframework,casing,civilengineeringmaterials,agriculturalequipment,constructionvehicles,hot watertanks,fire extinguishers,home radiators,structure stiffeners,vehicle axles...

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"High productivity" automatic solutions for single wire applications.

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Horizontal welding of stiffeners on flat panels - Coated steel.- Thickness: 6 to 15 mm.- Solid wire diameter 1.2 mm..- Part dimensions: length 12 m maximum.- Welding speed: up to 1.2 m/min depending on thickness.

TR400 torches mounted apartwith coaxial beam and fitted

with fume extractor unit.

Welding centrifuge screws (purification station) - Stainless steel 304L.- Thickness: 3 to 4 mm.- Solid wire diameter 1.2 mm..- Part dimensions diameter 450 x up to 6000 mm (length).- Welding speed: 0.45 m/min.

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Welding control unit on remoteMIGMATIC console.

FunctionsControl:

- gas yes- blowing yes- suction yes- wire-feed yes- wire lifting yes- on/off yes- error cancellation yes- pulsed yes- synergy yes

Safety:- water yes- gas yes- torch yes- end of coil yes

Setpoint:- wire speed yes- voltage yes

Welding cycle storage yes (50)Remote program change yesProgram stringing(any order) yesRS 232 interface:

- for printer yes- for PC option

Remote start-up optionProcess control:

- for current yes- for voltage yes

Contact- ready to weld yes- movement authorisation yes- removal authorisation yes

- error yes- gas control yes- blowing control yes- suction control yes- current relay(adjustable threshold) yes- voltage relay yes

Display:- wire feed speed yes- voltage yes- current yes

Pre-set internal synergies 100Possible additional external synergies 5

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Robotic solutions for single wire applications.

STARMATIC R450 power sourceLike the STARMATIC A450, the STARMATIC R450 takes its currentfrom a power transistor source delivering a smooth or pulsed currentup to 500 Hz and maximum intensity of 450 A at full duty cycle. It is designed to adapt to all types of robotic cell (SAF and others).• Cycle management

by the power source or robot.• Monitoring and management of robot

inputs/outputs and the various safetydevices of the facility.

• Storage of up to 50 welding programs.

Torches and wire-feed• Welding facilities fitted with a range

of liquid-cooled torches with coaxialbeams of various lengths.

• A powerful motor-driven wire-feedunit with 4-roller plate and wirestraightener for perfect electrode wire feed.

For improved traceability:• Basic process control built into

the power source software with parameter stop processing (current, voltage and wire speed) as a percentage of a value or as an absolute value.

• Wire-feed motor current monitoring(option).

• Loading and unloading of weldingprograms by direct link to PC or remote link via PCMCIA card.

STARMATIC R450

Robotic cell DR 3000 + X 100 .Multiple welding of vehicle oil gauge tubes - Carbon steel.- Thickness: 1.5 mm- Solid wire diameter 1.0 mm.- Tack welding and bead segment welding.

Improved productivity for welding of all types of steel, aluminium and light alloys.Robotic handling of welding operationsis one of the possibilities availableto industrialists looking to improvetheir productivity.SAF, your weldingpartner, proposes its current range of economic andeasily-implementedrobotic welding solutions.

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PRODUCTOR 7X cell. Welding of agricultural gates. Square tubes, 40 x 40 mm, thickness 2.5 mm - Carbon steel- Solid wire diameter: 1.2 mm.- Part dimensions: length 5000 mm - height 2000 mm.- Welding speed: 0.7 m/min.- Galvanisation after welding.

Functions of the STARMATIC R450Control:

- gas yes- blowing yes- suction yes- wire-feed yes- wire lifting yes- on/off yes- error cancellation yes- pulsed yes- synergy yes

Safety:- water yes- gas yes- torch yes- end of coil yes

Setpoint:- wire speed yes- voltage yes

Welding cycle storage yes (50)Remote program change yesProgram stringing(any order) yesPCMCIA interface optionRS 232 interface:

- for printer yes- for PC yes

Remote start-up yesProcess control:

- for current yes- for voltage yes- wire feed speed yes- wire-feed motor current option

Contact- ready to weld yes- movement authorisation yes- removal authorisation yes

- error yes- gas control yes- blowing control yes- suction control yes- current relay(adjustable threshold) yes- voltage relay yes

Display:- wire feed speed yes- voltage yes- current yes

Pre-set internal synergies 100Possible additional external synergies 5

Welding of hospital equipments.Carbon steel.- Thickness: 0.8 to 2 mm.- Solid wire diameter 1.0 mm.- Tack welding

and bead segment welding.- Chromium plating after welding.

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TOPMAG:TANDEM or TWIN is the Air LiquideWelding solutioncombiningprocessassistance(specificdouble wire synergies),completefittings,specific gases andconsumablesfor considerablyincreasedproductivity(welding speedand depositionrate).Depending onthe application,single wire welding speeds are multiplied by 2, 3 or more.

MIG-MAG double wire processes:TOPMAG

Carbon steelDouble wire test conditions: ARCAL 14 (M 14) gas - NERTALIC 70S (ER 70 S 3) solid wire, diameter 1.2 mmExampleThickness 2 mm 6 mmPosition lap joint flat fillet weldSingle wire welding speed 0.8 m/min 0.45 m/minDouble wire welding speed 2.4 m/min 1.0 m/min (4.5 mm channel)

BA

TOPMAG TANDEM - Pulsed/pulsed configuration

Carbon steelDouble wire test conditions: ARCAL 14 (M 14) gas - NERTALIC 70S (ER 70 S 3) solid wire, diameter 1.2 mmExampleThickness 2 mm 4 mm 6 mmPosition flat lap joint flat fillet weld flat butt

on support on support on backing barSingle wire welding speed 1.1 m/min 0.5 m/min 0.35 m/minDouble wire welding speed 3.2 m/min 2.8 m/min (2.8 mm channel) 3.2 m/min

EDC

TOPMAG TANDEM - Spray/pulsed configuration

Light alloys

ExampleMaterial AG 3 AG 4 AluminiumThickness 1.5 mm 3 mm 8 mmPosition butt (special butt (special profile) butt joint on

profile) reinforcing flangeSingle wire welding speed 0.85 m/min 0.9 m/min 0.6 m/minDouble wire welding speed 1.7 m/min 1.5 m/min (2.8 mm channel) 1.2 m/min

JIH

TOPMAG TANDEM - Pulsed/pulsed configuration ( & ) or spray/pulsed ( )

Austenitic stainless steelDouble wire test conditions: ARCAL 12 (M 12) gas - NERTALIC 50 (ER 308 L Si) solid wire, diameter 1.2 mmExampleThickness 4 mm 4 mmPosition lap joint butt jointSingle wire welding speed 0.9 m/min 0.7 m/minDouble wire welding speed 2.4 m/min (4.5 mm channel) 2.4 m/min

GF

TOPMAG TANDEM - Pulsed/pulsed configuration

Carbon steelDouble wire test conditions: ARCAL 14 (M 14) gas - NERTALIC 70S (ER 70 S 3) solid wire, diameter 1.2 mmExampleThickness 2 mm 8 mmPosition butt joint - inserted lap joint flat fillet weldSingle wire welding speed 1.15 m/min 0.3 m/minDouble wire welding speed 3 m/min 0.8 m/min

LK

TOPMAG TWIN - pulsed/pulsed configuration

H I J

Double wire test conditions: ARCAL 1 (I 1) gas - NERTALIC 10 (ER 1100), 20 (ER 5183) or 30 (ER 5356) solid wire, diam. 1.2 mm

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TOPMAG TWINFor use with carbon steels

STARMATIC R450TOPMAG master

STARMATIC R450TOPMAG slave

The 2 electrode wires are at the same potential.

1 - electrode wire2 - gas nozzle3 - contact tube4 - shielding gas5 - electric arc6 - molten pool7 - part to be welded

TOPMAG TANDEMFor use with all types of steel and light alloys

STARMATIC R450TOPMAG slave

STARMATIC R450TOPMAG master

1 - electrode wire2 - gas nozzle3 - contact tubes4 - shielding gas5 - electric arc6 - molten pool7 - part to be welded

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The 2 electrode wires areelectrically isolated.Independent weldingparameter setting for each electrode wire.

A B

C D E

F G

H I J

K L

Welding speed : 3.2 m/min Welding speed : 2.8 m/min Welding speed : 3.2 m/min

Welding speed : 2.4 m/min

Welding speed : 2.4 m/min Welding speed : 1.0 m/min

Welding speed : 2.4 m/min

Welding speed : 1.7 m/min Welding speed : 1.5 m/min Welding speed : 1.2 m/min

Welding speed : 3 m/min Welding speed : 0.8 m/min

2 mm

1,5 mm

4 mm4 mm

4 mm6 mm

6 mm

2 mm

2 mm

3 mm8 mm

8 mm

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Automatic or robotic solutions for TOPMAGdouble wire applications: welding speeds that increa

Welding of aluminium silo panels.Edge-to-edge assembly on reinforcementflanges.- Thickness: 8 mm.- Solid wire diameter 1.2 mm.- Double wire Tandem welding speed

(2 wires of 1.2 mm): 1.2 m/min.

Fire extinguisher body - Carbon steel.

Construction of metal framework and construction vehicles.

Vehicle engine support cradle.Coated carbon steel.Thickness: approx. 3 mm.

Construction of aluminium railwaycarriage roofs.

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The TOPMAG offer in automatic and robotic double wire welding:• fast welding speed, two to three times

standard single wire speeds,• high-quality bead,• excellent penetration,• versatile (depending on your application,

these facilities can be used in single wire mode),• easy to

implement.

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Your application:• fire

extinguishers,• small tanks,• metal framework,• automotive

and railwayconstruction,

• constructionvehicles,

• mechanically-welded casing,

• welded compositegirders and metalframework.

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ase productivity.33

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Double wire welding facility for truck side members - Carbon steel.- Thickness: core 5 mm, wing 10, 12 or 16 mm.- Flux-cored wire diameter 1.2 mm.- Welding speed: 2 m/min.

Double wire welding of fire extinguisher body- Thickness: 1.8 to 2.2 mm.- Solid wire diameter 1.2 mm- Part dimensions: diameter 165 x 350 (length).- Welding speed: 2.7 m/min.

Boiler body welding.Carbon steel.- Thickness: 4 to 6 mm.- Solid double wire diameter 1.2 mm.- Circular welding, bead segment

and tack welding.- Jacket and heat insulation applied

after welding.- Welding speed variable from 0.6

to 1.8 m/min.

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Tandem double wire machine. Longitudinal and circular welding.Solid stainless steel wire or flux-coredwire. Welding speed: - circular welding > 3 m/min- longitudinal welding > 2 m/min.

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Double wire torch Tandem TTA 900 (2 x 450 A - 100 %).

Comprises:• 2 STARMATIC R450 - TOPMAG (450 A - 100 %), • an interface controlling process and cycle,• 2 wire feeders,• 1 double wire torch TTA 900.

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Consumables: wires.

The choice of a welding consumable for MIG/MAG processesdepends mainly on the material to be assembled.

For aluminium and light alloys,only solid wire is used.

On the other hand,for non-alloy,low-alloy or stainlesssteels either solid wire or flux-cored wire can be chosen.Welding speeds,deposition rates and the bead qualityobtained are generallybetter with flux-coredwires, but these wires are more expensive.To get a clear picture of the advantage of flux-cored wires,a cost calculation needs to be drawn up takinginto account all the parametersinfluencing the costprice of a welding operation.

The tables to the rightshow a selection of the most commongrades in the SAF range.

Getting the right combination of weldinggas and filler metal is a determining factor in achieving quality,productivity and ergonomic objectives.

For automatic welding of non-alloy and low-alloy steels, the use of large volumepackaging has several advantages that will help you to increase productivity:• machines do not need to be stopped

so frequently to change the wire coil (16 kg for coils, 200/250 kg for large volu-me packaging);

Large volume packaging

• the wire is cleaner because the packaging is protected againstambient dust;

• better wire feed, especially withENDURO drums and PENELOPEreels, and therefore less risk of stoppage;

• wire impact point more accurateand repeatable.

Grade to be Grade SAF name Packagingassembled of filler metal(homogeneous) as per AWS A 5.101000 ER 1100 NERTALIC 10 6 kg coil .

Ø 1.2 - 1.6 and 2.4 mm3000 ER 4043 NERTALIC 15 6 kg coil.

Ø 1.2 and 1.6 mm 5000 ER 5356 (5183) NERTALIC 30 (26) 6 kg coil.

Ø 0.8 - 1.0 - 1.2 and 1.6 mm6000 ER 4043 NERTALIC 15 6 kg coil.

Ø 1.2 and 1.6 mm

Grade to be Grade of filler metal SAF name Packagingassembled as per(homogeneous) EN 440 AWSNon-alloy steels G 3 Si 1 ER 70S-6 STARMAG 16 kg coil and

250 or 300 kg ENDURO barrel.Ø 0.8 - 1.0 - 1.2 and 1.6 mm

Low-alloy steels G 4 Mo ER 80S-D2 NERTALIC 86 16 kg coiland 250 kg ENDURO barrel.Ø 0.8 - 1.0 and 1.2 mm

stainless steels - ER 308 L Si NERTALIC 50 16 kg coil.steels 304 Ø 0.8 - 1.0 - 1.2 and 1.6 mmstainless - ER 316 L Si NERTALIC 52 16 kg coil.steels 316 Ø 0.8 - 1.0 and 1.2 mm

Grade to be Grade of filler metal as per SAF name Packagingassembled(homogeneous) EN AWSNon-alloy steels T 42 2 R M 3 H 10 E 70 T1 SAFDUAL 127 16 kg or 20 kg coil and

200 kg ENDURO drum, 300 kg PENELOPE reel.Ø 1.2 - 1.4 - 1.6 and 2.4 mm

T 42 2 MM 2 H 10 E 70 C 3M H8 SAFDUAL 206A 18 kg coil and 230 kg ENDURO drum or 230 kg reelØ 1.0 - 1.2 and 1.6 mm

T 3T Z MM 3 H 10 E 70 C GS SAFDUAL TGV 18 kg or 20 kg coil and 230 kg ENDURO drum,170 kg PENELOPE reel.Ø 1.0 - 1.6 et 2.4 mm

stainless T 19 9 L R M5 E 308 LT 0 - 4 SAFDUAL 650 15 kg coil.steels 304 Ø 1.2 and 1.6 mmStainless T 19 12 3 R M5 E 316 LT 0 - 4 SAFDUAL 652 15 kg coilsteels 316 Ø 1.2 and 1.6 mm

Solid wires for welding aluminium and light alloys

Solid wires for non-alloy or low-alloy steels and stainless steels

Flux-cored wires for non-alloy or low-alloy steels and stainless steels*

* for double wire process use only metal cored wire (SAFDUAL serie 200 or TGV).

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Productivity through qualified services.

QEOPS Service - Advice and testing Take advantage of our personnel's expertise, come and test our processes and equipment on the materials you actually work with.

PHENIX Service - Equipment upgradingWith this service you can retrofit or upgrade your current facilities.A low-cost way of modernising your work tool.

TrainingOur training teams are available to refresh your operators' skills, optimise the use of the equipment,prepare and qualify your operators.Training can be carried out at your site or in an SAF centre.We can also supply a vast range of teaching material on welding-cutting technologies.

LogisticsYou would like to optimise stock and procurement management of welding consumables,you are looking for supply continuity at the place where you use support products, accessories or wearing parts.We can propose "made-to-measure" solutions, already tested and successfully set up with other customers.

SESAME - After-Sales ServiceVarious arrangements are possible for repairing your facilities. Our after-sales team will put your equipment back in working order in the shortest possible time.

ALLIANCE - Maintenance ContractALLIANCE or PPM (programmed preventive maintenance) contracts are your insurance policy guaranteeing permanent use of your facilities at peak performance.

Full Service Rental or Finance LeasingThese solutions allow you to acquire high-performance equipment without capital expenditure.Very flexible terms are available with the possibility of including a maintenance contract.

LOC'SAF Service - Equipment RentalRental of welding-cutting equipment.Diversify your production for automatic applications without excessive machinery stock,test the equipment before purchasing it.

CAP Productivity and CAP Partner Service - AuditingCAP Productivity and CAP Partner Service - AuditingYou would like to optimise your manufacturing process and improve productivity.Our experts can "audit" your welding operations, calculate real costs and propose a global savings program.We can also inspect the safety level of your facilities.

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SAF - 13, RUE D'EPLUCHES - SAINT-OUEN L'AUMÔNE95315 CERGY-PONTOISE - CEDEX FRANCETEL. : + 33 1 34 21 33 33 - FAX : + 33 1 34 21 31 30

SAF WELDING PRODUCTS LTD - LOW MARCHLONDON ROAD - DAVENTRY - NORTHANTS NN 11 4 SDTEL. : 01327 705511 - TELEFAX : 01327 701310

E mail : info.saf@airliquide.comInternet : www.saf-airliquide.com

Imagine what your performance could be

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