Welding economy

The use of ceramic backing offers significant economic advantages. Take a look at a couple of examples based on labour cost and time to complete the job.

Switching from MMA to FCAW with Elga Ceramic Backing

In this example we have used an average welding speed (55 mm/min for MMA and 150 mm/min for FCAW with backing) and a labour cost of 40/h for the welder. Flux cored wire and backing (single-sided welding): Typical deposition rate is 2,5-3,0 kg/h. Welding speed 100-200 mm/min. Characteristic of flux cored wire with backing is a very high arcing time factor. A 1 meter long root pass can be welded non-stop. Using a 2,5 mm electrode: Typical deposition rate is 0,6-0,7 kg/h. Welding speed 40-70 mm/min. Characteristic of MMA is a low arcing time factor. With a 2,5 mm electrode, only a 50-70 mm weld length can be achieved between electrode changes.
120

Labour cost /m

100

80

60

40

20

MMA

FCAW wit h backing

Switching from two-sided welding to single-sided with flux cored wire and ceramic backing
100

Total time comparison

Two-sided welding means additional time for:

Single-sided welding with flux cored wire and backing:

90 80 70 60 50 40 30 20 10 0

Rewelding of reverse side Gouging & grinding Mounting of backing Root welding

1. Back-gouging

2. Grinding

Substantially higher productivity since all extra work has been eliminated.

3. Rewelding on the reverse side, depending on the construction.

Two-sided

welding

Single-sid ed with backi welding ng

Choose the right backing

Valid for all ceramic backing from Elga: Grey ceramic backing on Alu-tape Welding positions: PA, PC, PF Base material: stainless and mild or low alloy steels
Part No: 86640600 Typical application: Joint preparation: X and Kjoints Welding consumable: Rutile and metal cored wire Root gap: 3-5 mm

Note! NEW length per piece 600 mm

6,0

Technical specification: Diameter: 6 mm Length per individual tile: 30 mm

Product data: Length per piece: 600 mm Pieces per box: 40 Pieces per pallet: 4480

8,0

Part No: 86650600 Typical application: Joint preparation: X and Kjoints Welding consumable: Rutile and metal cored wire Root gap: 4-6 mm

Technical specification: Diameter: 8 mm Length per individual tile: 30 mm

Product data: Length per piece: 600 mm Pieces per box: 40 Pieces per pallet: 4480

10

Part No: 86660600 Typical application: Joint preparation: X and Kjoints Welding consumable: Rutile and metal cored wire Root gap: 5-7 mm

Technical specification: Diameter: 10 mm Length per individual tile: 30 mm

Product data: Length per piece: 600 mm Pieces per box: 40 Pieces per pallet: 4480

12

Part No: 86670600 Typical application: Joint preparation: X and Kjoints Welding consumable: Rutile and metal cored wire Root gap: 7-10 mm

Technical specification: Diameter:12 mm Length per individual tile: 30 mm

Product data: Length per piece: 600 mm Pieces per box: 30 Pieces per pallet: 3360

13 8,5 26 1,3

Part No: 86800600 Typical application: Joint preparation: V-joints Welding consumable: Rutile flux cored wire Root gap: 3-8 mm

Technical specification: Tile width: 26 mm Tile height: 8,5 mm Groove depth: 1,3 mm Groove width: 13 mm Length per individual tile: 25 mm

Product data: Length per piece: 600 mm Pieces per box: 30 Pieces per pallet: 3360

12,5 8 1,3 26

Elga AB, Box 277, 433 25 Partille, Sweden Tel: +46 (0)31-726 47 53, Fax: +46 (0)31-726 47 02

200506

Part No: 86990600 Typical application: Joint preparation: V-joints Welding consumable: Rutile flux cored wire Root gap: 3-7 mm

Technical specification: Tile width: 26 mm Tile height: 8 mm Groove depth: 1,3 mm Groove width: 12,5 mm Length per individual tile: 25 mm

Product data: Length per piece: 600 mm Pieces per box: 30 Pieces per pallet: 3360