Long Stick Out Welding technology with Lincoln Power Wave® AC/DC 1000® SD

WHAT IS NEXTWELD®?

Through our commitment to extensive research and investments in product development, Lincoln Electric has established an industry benchmark for applying technology to improve the quality, lower the cost and enhance the performance of arc welding processes. Advancements in power electronics, digital communications and Waveform Control Technology® are the foundation for many of the improvements.

NEXTWELD® brings you a series of Process, Technology, Application and Success Story documents. NEXTWELD® explains how technologies, products, processes and applications are linked together to answer the important questions that all businesses face:

  • How can we work faster, smarter, more efficiently?
  • How can we get equipment and people to perform in ways they’ve never had to before?
  • How do we stay competitive?

Ask your Lincoln Electric representative how to improve the flexibility, efficiency and quality of your welding operations to reduce your cost of fabrication.

What is Long Stick Out (LSO) Welding Technology?

Long stick out is one welding technology that was developed by Lincoln Electric company. This is one improved Submerged Arc Welding (SAW) using one Power wave® AC/DC 1000 SD welding source combine with MAXsaTM 10 Controller and MAXsaTM 22 Automatic Feeder. The key point here is this process using a long stick out kit, this help extended electrical stickout yields significant increase in deposit rate.

The use of Long stick out (LSO) is not new. This process variation has been limited in the past by the understanding of the process and the limitations in controlling traditional equipment. Lincoln Electric Waveform Control Technology®, embedded in the new Power Wave® AC/DC 1000® SD power source and the new MAXsa™ Controllers and Feeders provide the ability to take full advantage of this process.

Process Features

UNMATCHED PRODUCTIVITY INCREASE

  • Recommended for applications requiring a large amount of deposit per unit of length.
  • Use as a heat input reduction tool without sacrificing the deposition rate.
  • Up to 100% increase in submerged arc welding deposition rates over traditional DC+ procedures.

COMPLETE CONTROL

  • Eliminate arc striking problems by allowing complete tailoring of the arc start characteristics.
  • Precise control over the input of energy into the weld.

OTHER ADVANTAGES

  • Very low additional investment
  • High deposition rate
  • Low heat input (less distortion)
  • Flux / wire ratio reduction
  • Deposition rate up to 30 kg/h

By extending the stick-out length during welding, the Long Stick Out process preheats the electrode above the welding arc

LONG STICK OUT WELDING TECHNOLOGY

Voltage Considerations

When converting an existing procedure to take advantage of longer ESO, some upward voltage adjustment will be required. Use Figure 1 for estimating the increased voltage needed from an existing procedure.

LSO Aplication

This welding technology can use with both AC and DC current. Compare with traditional SAW process with DC+ stickout 25mm, LSO using DC+ current can increase speed from 1,2 m/min to 1,7 m/min, and increase 42% of deposition rate while remain heat input stable.

In the same case, LSO use AC current can increase wire feed speed from 1,2 to 2,1 m/min, and +75% of deposition rate. Following is example parameters for welding fillet weld size 8×8 mm and 12,8×12,8 mm.

            Long Stick Out process can apply for automatic and robotic application, and also using in tandem application to increase the welding productivity specially in heavy structure.

Conclusion

  • The Power Wave® AC/DC 1000® SD is very well suited for use with extended electrical stickout (EESO)/ Long Stick Out (LSO) which can make a major contribution to increasing submerged arc welding productivity.
  • LSO is very well suited to welds requiring large fill volumes to produce the weld.
  • LSO does not reduce penetration. Penetration is a function of current and keeping the arc on the weld joint at the leading edge of the weld puddle. As shown in the enclosed fillet weld examples, there is ample root penetration.
  • LSO may be a useful way to reduce heat input where this is desired yet not sacrifice deposition rate.
  • The use of LSO is compatible with the Power Wave® AC/DC 1000® SD waveforms. The AC 25% balanced waveform very closely approaches the deposition rates of DC- polarity operation but without the problems that can be encountered with DC- welding.
  • The use of LSO can be a very effective way to fully utilize the capacity of the Power Wave® AC/DC 1000® SD.

For more detail, please watch video:

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