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Hot wire rev 3

[ Hot wire - narrow gap welding ]. Z.I. du Bois Briand 2, rue Paul Beaupère F 44300 NANTES FRANCE. Hot wire rev 3. Hot wire narrow gap welding. Hot wire welding with narrow gap preparation permits :. Increase of productivity up to a factor of 9 compared to standard TIG welding.

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Hot wire rev 3

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  1. [ Hot wire - narrow gap welding ] Z.I. du Bois Briand 2, rue Paul Beaupère F 44300 NANTES FRANCE Hot wire rev 3

  2. Hot wire narrow gap welding Hot wire welding with narrow gap preparation permits : Increase of productivity up to a factor of 9 compared to standard TIG welding Maintain the best affordable quality produced by the TIG process

  3. Hot wire narrow gap welding Other advantages of the TIG hot wire process: Can be used on root, filling and finish passes • As the TIG process, the TIG HW offers the great advantage to control separately the energy in the arc and the quantity of metal in the weld pool: • easy to control the starting and down slope stages • control of welding energy permits to weld delicate materials as duplex, super duplex, titanium… • fusion operations for repair are simplified

  4. Hot wire technique Hot wire welding principle

  5. Wide bevel /Building up Narrow gap Position TIG Cold Wire (Kg/h) TIG Hold Wire (Kg/h) TIG Cold Wire (Kg/h) TIG Hold Wire (Kg/h) 1G 0.5 to 1.0 3.5 0.5 2 to 2.5 2G 0.5 to 0.7 2.5 0.5 1.5 to 2.0 3G1 0.5 to 1.0 1 to 1.5 0.4 1 to 1.5 5GT (4G, 3G2) 0.3 to 0.4 1 to 1.5 0.3 to 0.4 1 to 1.5 Narrow gap technique Welding deposit rates for TIG cold and hotwire

  6. L1 L set L1.3 L1.2 HW current (A) L1.3 L1.3 L1 L1 L1.2 L1.2 H1 L1 Wire speed (m/mn) Narrow gap technique Influence of the variation of stick-out on the theoretical heating length of filler wire

  7. Torche inclinaison angle Wire angle Welding direction h L1 Narrow gap technique Influencing parameters of TIG hot wire welding Influencing parameters: (Except Vs = constant) • I arc • h (electrode/work piece) • gas (type) • Hot wire current, Wire speed and associated L1 • Torch inclination angle • Filler wire / torch angle Length h and L1 correspond to theoretical adjustment made before welding. Their adjustments characterise the mechanical parameters directly associated to the welding parameters

  8. Advantages Disadvantages Welding with tungsten oscillation Lower productivity Good torch accessibility Sophisticated torch Easy for wide range Less side wall penetration Welding with two passes per layer Lower productivity Good torch accessibility Two positions for the tungsten Problem for AVC Easy for wide range Difficult in orbital configuration Welding with one pass per layer High productivity Less tolerance for the prep. Easy to operate Sophisticated weld procedure Good side penetration Hot wire Narrow gap technique Different type of narrow gap technique SOLUTION POLYSOUDE’S

  9. 37°+10° 6° 60 mm 60 mm • Compound bevel 37°+10° • Narrow gap bevel 6° • SNG = 1617 mm² • SCB = 498 mm² • SNG • = 3.2 • SCB Narrow gap technique Surface comparisons between std and narrow gap bevel

  10. Weld material Base material Joint configuration (un-restrained shrinkage ?) Weld position Operating weldability Shrinkage Weld configuration result Weld parameters (for each sequence) Groove design (shape and tolerances) Weld test objective Groove width control (LB) Pass thickness control Weld procedure Hot wire Narrow gap technique Welding procedure for hot wire narrow gap

  11. LB LB LB •  “LB” must be constant for the complete weld •  For orbital and fixed station welding: 7.5 mm < LB < 10 mm • The groove angle is adjusted according to thickness, material and welding parameters Narrow gap technique Definition of the bevel design

  12. Th •  “Th” must be constant for the complete weld •  For orbital welding: 2.0 mm < Th < 2.5 mm •  For fixed station welding: 2.0 mm < Th < 3.5 mm • The wire preheating and wire speed is adjusted for a constant heat input (+/- 10%) Narrow gap technique Definition of the bevel design (cont.)

  13. > 40 mm < 70 mm > 70 mm PIPE THICKNESS < 40 mm WP27 Weldcraft torch WP27 Weldcraft torch with the narrow gap nozzle Narrow gap toch (150mm & 200 mm) Narrow gap technique Different type of welding torches

  14. S4: Cap sequence • For reinforcement and cosmetic appearance • S3: Final passes • Cooling of side walls is lower (edge effect cooling), therefore heat input will be less • S2: Filler passes with high productivity • Each filler pass in the same condition • S1b: Root reinforcing (1 or 3 passes) • S1a: Root • S5: Weld programs for repair according to the requirements of each sequences Narrow gap technique Welding sequences

  15. Welding cycle comparison Welding cycle compari mm pipeson between TIG cold wire and TIG hot wire for 168 mm pipe : Filler wire: 0.8 mm Time for preflow of shielding gas, arc time and maintenance of shielding gas after a weld pass are taken into consideration. Time to re-coil hoses, to change electrode and to respect interpasses temperature (when applied) are not considered. Working scope of the camera

  16. Hot wire welding procedure example Working scope of the camera

  17. Narrow gap TIG welding Application examples Working scope of the camera

  18. Narrow gap TIG welding Orbital TIG Hot wire welding Narrow gap (5GT) TOSHIBA on site • Carbon steel STPG38 • 508 x 50 mm • 356 x 54 mm • 24 layers Working scope of the camera

  19. Narrow gap TIG welding TOSHIBA on site (cont.) Working scope of the camera

  20. Narrow gap TIG welding Orbital TIG Hot wire welding Narrow gap (5GT) TODEN - Japan • 508 x 70 mm Working scope of the camera

  21. Narrow gap TIG welding Fix station TIG Hot wire welding Narrow gap HOLMING WORKS FINLAND • Carbon steel • 280 x 100 mm • 460 x 85 mm Working scope of the camera

  22. Narrow gap TIG welding Orbital TIG Hot wire welding Narrow gap Application: 250 bars / 600°C SIEMENS KWU 180 mm • X10CrMoVNb91 • 700 mm x 180 mm • Position 5GT • Total arc time: 40 hours Working scope of the camera

  23. Narrow gap TIG welding SIEMENS KWU (cont.) Working scope of the camera

  24. Narrow gap TIG welding SCHWING - Austria Welding of Cardan shafts for concrete mixing vehicles Material: carbon steel 1.5217 / St 690. Dimensions: O.D.: 50 - 450 mm Wall thickness: 5 - 40 mm Length: 500 - 4000 mm Equipment: Power source: 600 PC TIG hot wire Precision TIG Welding Lathe with AVC (control distance: 350 mm) with motorized, programmable AVC-slide running gear for the complete length. Working scope of the camera

  25. Narrow gap hot wire TIG welding: The solution for the best Quality with the highest productivity level !

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