[MW:25714] RE: 25707] Welding with FCAW 1.2mm wire - real life operating factor

Hi Denney,

Please be noted that there is no such exact guidelines given for the factor…

Lot of other factors will seriously affect the depositions…

Personally – I'm doing 3Mtr dia 18 mm thick pipe outside bevel at site welding for FCAW 1.2 mm dia with Co2.…. Even for me also lot of discrepancy in the deposition rates.

 

Please be noted to some of the factors which will influence the deposition rates…

1.       Welders expertise.

2.       Welders position – 1G, 2G, 3G, 4G,5G – 1G and 2G will good deposition rates….

3.       Welding situation – sufficient approach around to the job, proper access to the source and work, (just assume if a welder is working for the 4G position at site inside the trench, and etc)

4.       Weld progression – in pipeline up hill will give more deposition than downhill.

5.       If working for pipe line – diameter of the pipe is also a factor – if small dia pipe we will get more deposition rate than higher dia when working at 3-6 "O" clock and 6-9"O" clock position

6.       As you said shop welding and site welding is also a serious factor.

7.       At site, adverse open air conditions…

8.       Proper ventilation nearby welding area and exhaust of weld gasses…

9.       Even welder rest – good quality of rest in the last night will give you good rate of progress (I witnessed this personally)

10.   Continues motivation, appreciation, confidence building, compliments and trainings to the welders will definitely improve the progress and deposition rates…

11.   Weld joint configuration – higher thickness – welders will get bored for the same gesture for prolonged time. Cleanliness of the weld – you will get slightly improved deposition of the weld are is cleaned properly, any preheat requirements will also have the impact on deposition rates

12.   Weld joint fitup condition – improper fitup, mismatch, excess gaps, different base material, etc

13.   Consumable quality – if the dia of the consumable is properly not adhered u will not get good deposition(say if wire dia is 1.2 +/- 0.05 is good when compare to 1.2+/- 0.1)

14.   Equipment condition – say weld tip wear & tear, liner replacement on time, good set of rollers in the feeder, shielding gas choking all may affect the depositions…

15.   Power source (thyrisister, or inverter or any other means) – inverter will give more smooth arc and a little bit high deposition rate…

16.   Power intake – (DG, GRID, Factory supply board, other loads connected on the board etc)

17.   Cable sizes – if cable size is small, during continues welding cable will get heated up, and resistance will go up, and will lead to voltage drop to Machine and finally u will ended up with lower currents, and feed rate will get reduced.

18.   Equipment cooling efficiency.

 

All may have the effect on the deposition rates, and defining factor considering all the above if's and buts is not practically possible to my view…

 

Attached few pics for the out of position welds – for your reference only…

 

Thanks & Regards,

Lakshman Kumar B,

+91 9440031459.

 

From: materials-welding@googlegroups.com [mailto:materials-welding@googlegroups.com] On Behalf Of Alan Denney
Sent: Wednesday, November 16, 2016 4:07 AM
To: materials-welding@googlegroups.com
Subject: [MW:25707] Welding with FCAW 1.2mm wire - real life operating factor

 

I am looking for some data on operating factor for FCAW - that is the ratio between a theoretical deposition rate with 1.2mm FCAW and actual production relevant to a fabrication shop or site welding structural steel in thicknesses between 20mm and 60mm. Some work is in fabrication shops and some is in the yard.  Would 40% be constantly achievable, ignoring time for meal breaks and repairs? That is the sort of figure stated in recommendations from consumable suppliers.

 

All or any information would be welcome.

 

Alan Denney

AKD Materials Consulting Ltd

 

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