Product category:
Welding consumables, rods, wires, fluxes, powders
News Release from: TPS-Fronius | Subject: Flat-wire electrodes
Edited by the Manufacturingtalk Editorial
Team on 06 June 2003
Flat-wire electrodes weld faster than
round
Fronius is making a promise to the vehicle, ship and rail vehicle construction industry, of high deposition performance combined with process safety during welding using flat wire electrodes
The Fronius welding experts are making a promise in particular to users from the vehicle, ship and rail vehicle construction industry, of high deposition performance combined with process safety during welding using flat wire electrodes Perfect weld seam quality, higher productivity and therefore lower costs are further arguments
This article was originally published on Manufacturingtalk on 14 Jul 2008 at 8.00am (UK)
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Cold metal transfer pulsed arc welds CrNi steels
Successful tests have been carried out using cold metal transfer/pulsed arc welding on butt, overlapped, fillet, corner and flanged welds in 0.5-3.0mm thick CrNi steel and aluminum alloys.
Deposition rates of more than 11 kg/h for steel and up to 4 kg/h for Aluminium are achievable according to key data.
High performance welding processes are defined by deposition rates of more than 8 kg/h.
Fronius offers the user three gas metal arc welding processes in this area: Single wire-welding with round electrode, TimeTwin-welding with two round electrodes and single wire welding with flat wire electrode.
Welding using the flat wire electrode (cross-section approx.
0.5 x 4.5 mm, dependent on material and manufacturer) offers clear advantages in a range of applications.
The higher welding speed is convincing, compared with a conventional round wire, for example, an overlap seam of 3 mm-Aluminium sheets can now be welded at approx.
165 cm/min instead of 80 cm/mm.
Aluminium wires with greater diameters serve to increase the deposition rate, but are very soft and thus not easy to handle.
The higher process security speaks for the flat wire here, as well.
The TimeTwin-process achieves even higher deposition rates, but requires additional outlay for the wire feed.
Additionally the parameters of the arc can be more easily controlled with only one electrode.
The main advantage of the flat wire electrode lies in the greatly increased rate of deposition.
The user can turn this into a higher welding speed or a larger seam cross section and as a consequence he can complete his welding task faster or in less layers.
The process is particularly economical in mechanised or automated welding of straight beads or if a handling robot moves the workpiece.
A standard TPS 9000 power source with special software as well as a modified wire feed and welding torch are available for flat wire welding.
Whilst a pulsed arc requires up to 1,200 amp, pulse currents of up to 500 amp are sufficient for Aluminium.
Consequently a TPS 5000 is adequate for Aluminium.
This means that the investment costs are lower than for other processes.
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