swr 10056 ok aristorod welder guidebook

7/30/2019 SWR 10056 OK AristoRod Welder Guidebook

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NoN copper-coated solid gmaw wires with

advaNced surace characteristics

Ok AristoRod Non-Copper-Coated Wire

Welder Guidebook


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Visit the oK ar and learn why OK AristoRod wires bring

trouble-ree, high productivity welding in robotic, mechanized, or manual operation

supported by unique video animation in 24 languages, scientic data and high

speed arc recording. Discover the quality and productivity benets in detail and

review the ull range o wire types or non- and low-alloyed steels.

.bn./

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inn 2

B Y s wn 3

ContactTipsandGasNozzle 3

Liners 4

GasandWater 4

WireFeedUnit 4

MarathonPac

Installation 5 CheckDriveRollsandWireFeeding 7

ShieldingGas 8

cn t an g Nzz 9

CorrectStick-OutLength 9

GasNozzleDiameter 10

wn p sn 11

HowtoGetanOptimumSetting 11

oK ar - t c rn 13

esaB s a tn

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http://esabna.com/aristorodhttp://esabna.com/aristorod


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inn

OK AristoRod is a amily o non copper-coated GMAW wires with superior welding

perormance. The unique Advanced Surace Characteristics (ASC) increase

perormance and eciency, whether the process is manual, mechanized,

or robotic, helping reduce overall welding costs.

OK AristoRod non-copper-coated wires do not contaminate wire eeders, liners,

torches and contact tips with copper particles. This results in trouble ree eeding,

high process stability, reduced consumption o wear parts, and superior welding

properties.

The unique eatures o OK AristoRod translate into clear user benets which,

together, add up to increased productivity and lower welding costs.

To get the most benet rom using OK AristoRod welding wires, there are someimportant steps to keep in mind, in particular compared to using copper-coated

wires. This guide provides practical step-by-step inormation on how to install and

use OK AristoRod non-copper-coated solid wires.

Bnf

Consistent welding perormance Consistent weld results

Stable arc with low eeding orceHigh weld quality and reduced rework or post weld

cleaning

Excellent arc ignition Reduced post weld cleaning

High current operability Higher productivity

Extremely low spatter level Reduced post weld cleaning

Trouble-ree eedability, even at high wire eed speeds

and long eed distancesHigher productivity, reduced equipment downtime

Low ume emission Cleaner working environment


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To ully beneft rom the excellent weldability o OK AristoRod GMAW

wires, the welding equipment needs to be maintained in good condition.

The ollowing checklist serves as a guide.

cn t an g Nzz

Remove spatter and replace worn or

damaged contact tip.

For the best welding performance and

longest tip life, ESAB contact tips are

recommended for use with

OK AristoRod wires.

Grind the end of the liner conical for

optimal fitting of the contact tip.

Ensure that the contact tip is the correct

size and fits tightly.

Ensure the gas nozzle is free from

spatter.

correct incorrect

For contact tip sizes and packages, please contact ESAB or your local Distributor.


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ln

Spiral steel liners are recommended.

Never use liners which have been

used for copper-coated wires.

Copper residuals may stick onto the

OK AristoRod wire and deteriorate itsexcellent wire feeding.

Ensure that the liner has the correct

inner diameter for the wire size to be

used.

Check liners regularly for kinks and

excessive wear and replace when

needed.

Clean liners regularly using compressed

air, removing the contact tip first.

g n w

Check gas and water connectionsfor leaks.

Check that the water cooler is filled and

that the pump is operating effectively.

w un

Position wire guide tubes as close aspossible to the rollers to prevent kinking

of the wire.

A substantial amount of fine metallic

shavings underneath the drive rolls

indicates misalignment.

Correct

Incorrect


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Special cone for Jumbo Marathon Pac with1050 lbs (475 kg) non- or low-alloyed wire.

ESAB's Marathon Pac is the most

advanced bulk wire packaging system

available to abricators. The complete

Marathon Pac amily consists o

(rom let to right):

Endless Marathon Pac

Mini Marathon Pac

Standard Marathon Pac

Jumbo Marathon Pac

B Y s wn

The Marathon Pac is accompanied by

a ull range o accessories or ecient

internal transport and handling and easy

installation.

Always make sure ESAB original

Marathon Pac accessories* are used

or best perormance.

*For a complete list of Marathon Pac

accessories, contact ESAB.

Use the Marathon Paclifting yoke to handle thedrum safely and to avoid damage to the drumor wire.

mn p inn


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Step 6. Attach the wire conduit to the wire feeder.Avoid liner bends or point pressure on the liner.

Step 1. Remove the rubber strap and VCI paper.

Step 4. Place the carton or plastic lid (Standardand Mini Marathon Pac) or cone (JumboMarathon Pac) on top of the Marathon Pac.

Step 2. Place the wire conduit attachment orspider on top of the Marathon Pac.

Step 5. Attach the wire conduit to the lid or conewith the quick connector.

Step 3. Feed the welding wire through the centreof the spider.

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Use drive rolls with smooth, double

V-grooves. U-shaped grooves or knurled

rolls may damage the welding wire

surface.

Check that the groove size is correct for

the wire diameter.

Apply the correct pressure on feed rolls.

Too much pressure flattens the wire,

resulting in feeding problems and higher

liner and contact tip wear. Insufficient

pressure may cause wire to slip in the

feed rolls, resulting in irregular feeding

and possible wire burnback.

A good approach is to set the roll

pressure so it is possible to stop a bent

wire at the gas nozzle by applying light

pressure.

Check that the wire is feeding correctly

from the contact tip.

Never use felt pads or liquids to clean

the wire surface. This may damage

the advanced surface condition of

OK AristoRod wires.

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Smooth Knurled


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Check that the appropriate gas is used.

Adjust gas flow rate to between 0.5-0.7

cfm (15-20 l/min) or according to gas

nozzle size.

Check the gas flow rate again if the gas

nozzle diameter is changed. Always

check the gas flow on the gas nozzle

as well.

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cn t n g Nzz

It is essential to t the gas nozzle and

contact tip at the right distance relative

to each other. The ideal distance o the

contact tip is 0.080 in. (2 mm) recessed.

A longer distance will orce the welder to

use too long a stick-out, resulting in poorweldability. This may lead to lack o usion,

particularly in narrow joints. Contact tips

protruding beyond the gas nozzle can

result in insucient gas shielding.

c sk-o ln

The stick-out is the distance between the

contact tip and workpiece and must be

kept between 1/2 in. and 3/4 in. (12 and

20 mm ) 0.040 in. and 0.047 in. ( 1.0

and 1.2 mm). Excessive stick-out results

in too short an arc length, larger droplets,

an unstable arc and spatter leading to poor

weldability. Additionally, it may reduce the

gas protection which can lead to porosity.

When welding in spray arc with too short o

a stick-out, the arc length can become too

long. The weldpool will get hotter and more

dicult to control.

Incorrect. Contact tip too recessed.

Incorrect. Contact tip protruding beyondgas nozzle.

2 mm

Correct positioning of contact tip.

1/2 - 3/4 in. (12-20 mm)

Ideal stick-out for wire diameters 0.040and 0.047 in. (1.0 and 1.2 mm.).


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cn t n g Nzz

g Nzz d

Various nozzle diameters must be available

to allow adequate access to the joint, to

maintain the above recommended stick-

out, and to ensure proper shielding gas

protection. Small diameter gas nozzles

are used or the rst layers only. Revert to

the standard gas nozzle diameter when

access to the weld joint allows, so ull

gas protection can be assured.

Incorrect. Use of standard gas nozzlerestricts access to narrow joints, resultingin too long a stick-out.

Correct. Use a smaller diameter nozzle ora conical nozzle for the 1st layers in theroot area.

Correct. Use of standard gas nozzle forcompleting the joint ensures good gasprotection and correct stick-out.

When welding in short arc transer, the arc stability and start properties will improve

when reducing the stick-out.

1/2 - 3/4 in. (12-20 mm)

> 3/4 in. (> 20 mm)


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Incorrect. Arc length too long. Arc becomestoo wide, with insufficient penetration. Also arisk of burnback to the contact tip. This maybe caused by the arc voltage being too high,the wire feed speed too low or the stick-outbeing too short.

Use positive polarity or OK AristoRod

solid welding wires. A given welding current

requires a specic arc voltage or optimum

weldability. The welding current is set by

adjusting the wire eed speed control. The

arc voltage is regulated by the open circuit

voltage (OCV) setting o the power source.

h g n o sn

For the ollowing procedure, it is critically

important to keep the stick-out constant

within the correct range or each welding

position.

Select a welding current which suits your

application from the graph on page 12.

Start welding with the lowest voltage

value from the given range. This may

result in stubbing, however wireburnback will be avoided.

Increase the arc voltage in steps of 1

or 2 V until the arc becomes stable,

smooth and spatter free, with a slightly

crackling sound. Ensure the correct

stick-out length is maintained.

wn p sn

Correct. Correct arc length. Stable andconcentrated arc with a quiet spray droplettransfer.

Incorrect. Arc length too short. Wire dipsinto weld pool (stubbing) caused by too lowan arc voltage, too high a wire speed or toolong of a stick-out.


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wn p sn

Note: As mentioned, stick-out control is very important. I the recommended

stick-out length is not constantly maintained, weldability will fuctuate. Shortening

the stick-out will result in an increasing current and a longer arc. Lengthening thestick-out will result in a lower current and the arc being too short.

Due to OK AristoRods Advanced

Surface Characteristics (ASC) the

optimal voltage is typically 5-10%

higher than with a copper-coated

wire at the same arc length.

If a different current is required,

i.e change of welding position, the

procedure described on the previous

page needs to be repeated.

50

38

36

34

32

30

28

26

24

2220

18

16

14

12

100 150 200 250 300 350 400

3

3

2

2

4

4

1

1Welding in short arc area. Use for thin plate, tack welding

or positional welding.

When arc length is tooshort increase voltage.

When arc length is too

long decrease voltage.

Welding in spray arc transfer. High productivity,

thick plate, downhand welding, low spatter.

Excessive weld metal. Dicult to control.

Welding in globular area. Unstable arc and excessive spatter.

Try to avoid.

Amperage

Voltage

OK AristorodTM

0.040 in.

(1.0 mm)

0.047 in.

1.2 mm


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oK ar - t c rn

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aws eN-iso eN-iso 14175

a5.18 a5.28 14341-a 16834-a 21952-a /-B m21 c1

12.50 ER70S-6 G3Si1 G 42 4 G 38 2Normal

strength

12.57 ER70S-3 G2Si G 38 3 G 35 2Normal

strength

12.62 ER70S-2 G2Ti G 46 4 G 42 3Normal

strength

12.63 ER70S-6 G4Si1 G 46 4 G 42 2Normal

strength

12.65 ER70S-6 G4Si1 G 46 4 G 42 2

Normal

strength

13.08 ER80S-D2 G4Mo G 50 4 G 46 0Creep

resistant

13.09 ER80S-G G2MoG MoSi /

G 1M3G 46 2 G 38 0

Creep

resistant

13.12 ER80S-GG CrMo1Si /

G 55M 1CM3

Creep

resistant

13.16 ER80S-B2 Z CrMo1Si /G 55A 1CM

Creepresistant

13.22 ER90S-GG CrMo2Si /

G 62M 2C1M3

Creep

resistant

13.26 ER80S-G G Z 3Ni1Cu G 46 4 G 42 0Weather

resistant

55 (13.13) ER100S-G G Mn3NiCrMo G 55 4High

strength

69 (13.29) ER110S-G G Mn3Ni1CrMo G 69 4High

strength

79 (13.31) ER120S-G G Mn4Ni2CrMo G 79 4High

strength

89 (1B96) ER120S-G G Mn4Ni2CrMo G 89 4High

strength


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Swit Arc Transer is a high productivity

GMAW process using OK AristoRod

non-copper coated welding wires at

very high wire eed speeds. The SAT

process produces fat welds with good

penetration and no undercut.

t y .

ESABs Aristo U82

robotic package

enables SAT welding. It is a complete

set o welding consumables and

equipment, based on ESABs latest

digital power source technology.

The package consists o:

The Aristo MIG 5000i inverter power

source or ESAB's MIG 4002c, 5002c

and 6502c chopper power sources.

The AristoU82

control unit with SAT

synergic lines or The Aristo U82

interface for different robot brands.

The Robofeed 3004w ELP

encapsulated wire feeder with up to

98.4 ipm (30 m/min) wire feed speed.

Cable packages.

The Marathon Pac bulk wire drum

with robot quality welding wire and

optional bobbin holder.

SATTM

Sh

ort

arc

Mix

ed

arc

Spray

arc

Forced short arc

Wire feed speed (m/min)

Arcvoltage

Rotating

arc


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iNd us acebook.com/esabna twitter.com/esabna youtube.com/esabweb

SWR-10056

11/2012

TheESAB

groupis

certifed

accordingto

ISO14001&

OHSAS18001

Unrivaled Service and SupportEvery ESAB product is backed by our commitment to superior customer service and support.Our skilled customer service department is prepared to quickly answer any questions,

address problems, and help with maintenance and upgrading o your

equipment. Our products are backed with the most comprehensive

warranty in the business.

With ESAB, you can be sure that you purchased equipment that will meet your needs

today and in the uture. Product and process training is also available.

Ask your ESAB sales representative or distributor or a complete ESAB solution.

usa:P.O. Box 100545, 411 South Ebenezer Road, Florence, SC 29501-0545

cn:6010 Tomken Road, Mississauga, Ontario L5T-1X9

mx: Ave. Diego Daz de Berlanga No. 130, Col. Nogalar San Nicols

de los Garza N.L. CP 66480 Monterrey, Mexico

esaB wn & cn p/bn./1.800.esaB.123

NOTICE:

Test results described above were obtained under controlled laboratory conditions, and are

not guarantees or use in the eld. Actual use o the product may produce varying results due

to conditions and welding techniques over which ESAB has no control, including but not

limited to plate chemistry, weldment design, abrication methods, wire size, welding procedure,service requirements and the environment. The User should conrm by qualication testing,

or other appropriate means, the suitability o any welding consumable and procedure beore

use in the intended application.

CAUTION:

Users should be thoroughly amiliar with the saety precautions reerenced in the product label

or the relevant product and the Saety Data Sheet or the product. Saety Data Sheets are

available at www.esabna.com or by calling 1-800-ESAB-123.

swr 10056 ok aristorod welder guidebook

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