RES: [MW:25728] RE: 25714] RE: 25707] Welding with FCAW 1.2mm wire -reallife operating factor

Gentleman;

 

Please attention that:

 

For a specific consumable

 

1.       Each wire has its proper melting rate, it can be different for materials with same specification but from different supplier

2.       Melting rate is directly result of current density

3.       The current density is associated to the welding parameters (Current "A"&  wire "Ø")

4.       Welding parameters are defined by the welding procedure qualification

 

A)     Increasing Stickout will increase the deposition rate because part of the current will be absorbed by Joule effect, care shall be taking regarding lack of fusion, poor penetration and porosity

B)      3G position will increase heatinput, care shall be taking regarding WPS limits and material properties that can be affected by this change

 

Many times good results can be achieved only improving the man working factor which means to reduce as much as possible the "dead times" or mechanizing the process.

 

Best regards

 

 

 

De: PUB:'NEILASHKUMAR' via Materials & Welding [mailto:materials-welding@googlegroups.com]
Enviada em: quarta-feira, 16 de novembro de 2016 11:16
Para: Kannayeram Gnanapandithan; materials-welding
Assunto: RE: [MW:25723] RE: 25714] RE: 25707] Welding with FCAW 1.2mm wire -reallife operating factor

 

Dear Sir,

 

I agree with all the below points, Also we need to observe the Wire formation in FCAW process. Normally Manufacturer of Welding consumable supply two types,

1.       Seamless wire FCAW – Flux recovery less Weld metal more  (Wire will be harder to pull, So need to use knurl roller)

2.       Tubular coated flat type FCAW – Flux recovery more Weld metal deposit less. Wire will be soft easy to weld in normal solid roller.

Try to identify the core wire formation in FCAW process.

 

Secondly Average weld deposition rate in FCAW is 2.2Kg/hr. Considering 6mm fillet with single pass of 45meter length.

 

Next We need to check the Weld deposition rate given by welder in terms of weighing system before start and end of shift hours. So that welder will be motivated themselves to achieve the daily target. I am weighing the spool output daily basis and displayed it in notice board to enhance the productivity.

 

Any other clarification let me know to clear.

 

Sent from Mail for Windows 10

 

From: Kannayeram Gnanapandithan
Sent: Wednesday, November 16, 2016 3:58 PM
To: materials-welding
Subject: Re: [MW:25717] RE: 25714] RE: 25707] Welding with FCAW 1.2mm wire -reallife operating factor

 

The  following also will increase deposition rates

!. More stick out

2. 3G uphill position

3. Water cooled torches

4.Shielding gas ( Argon+Co2 mixture) less spatter level

THANKS & BEST REGARDS,

KG.PANDITHAN, IWE,  AWS-CWI, CSWIP 3.1,

CONSULTANT-WELDING & QUALITY

Mobile no: +919940739349

 

On Wed, Nov 16, 2016 at 3:46 PM, Alan Denney <alan@denney1.freeserve.co.uk> wrote:

This message is eligible for Automatic Cleanup! (alan@denney1.freeserve.co.uk) Add cleanup rule | More info

 

Thank you Lakshman Kumar for this very comprehensive, interesting and useful response. You say you are getting wide discrepancy in the deposition rate. Are you able to share with me the limits, high and low, in terms of actual deposition rate in kg/hr, or whatever measure you put on this? I need to get some reality into an estimate which I am reviewing.

 

Alan Denney

AKD Materials Consulting Ltd

 

From: materials-welding@googlegroups.com [mailto:materials-welding@googlegroups.com] On Behalf Of Lakshman Kumar. B
Sent: 16 November 2016 05:29
To: materials-welding@googlegroups.com
Subject: [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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