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Electro slag welding is a process where heat is generated by an electric current passing between a consumable electrode and workpiece through a molten slag. Flux is added to form the slag, which reaches 1930°C and melts the electrode and workpiece edges. Droplets join the workpieces. It is used for thick steel welding, with advantages of high deposition rates and low distortion, though the weld has low toughness and only vertical welding is possible. Variants include using a consumable guide or plate electrode instead of a wire electrode.
Electro slag welding is a process where heat is generated by an electric current passing between a consumable electrode and workpiece through a molten slag. Flux is added to form the slag, which reaches 1930°C and melts the electrode and workpiece edges. Droplets join the workpieces. It is used for thick steel welding, with advantages of high deposition rates and low distortion, though the weld has low toughness and only vertical welding is possible. Variants include using a consumable guide or plate electrode instead of a wire electrode.
Electro slag welding is a process where heat is generated by an electric current passing between a consumable electrode and workpiece through a molten slag. Flux is added to form the slag, which reaches 1930°C and melts the electrode and workpiece edges. Droplets join the workpieces. It is used for thick steel welding, with advantages of high deposition rates and low distortion, though the weld has low toughness and only vertical welding is possible. Variants include using a consumable guide or plate electrode instead of a wire electrode.
Electro slag Welding is a welding process, in which the heat is
generated by an electric current passing between the consumable electrode (filler metal) and the work piece through a molten slag covering the weld surface. Prior to welding the gap between the two work pieces is filled with a welding flux. Electro slag Welding is initiated by an arc between the electrode and the work piece (or starting plate). Heat, generated by the arc, melts the fluxing powder and forms molten slag. The slag, having low electric conductivity, is maintained in liquid state due to heat produced by the electric current. Electro slag Welding Electro slag Welding is a welding process, in which the heat is generated by an electric current passing between the consumable electrode (filler metal) and the work piece through a molten slag covering the weld surface. Prior to welding the gap between the two work pieces is filled with a welding flux. Electro slag Welding is initiated by an arc between the electrode and the work piece (or starting plate). Heat, generated by the arc, melts the fluxing powder and forms molten slag. The slag, having low electric conductivity, is maintained in liquid state due to heat produced by the electric current. Electro slag welding (ESW) is a highly productive, single pass welding process for thick (greater than 50 mm) materials in a vertical or close to vertical position. An electric arc is initially struck by wire that is fed into the desired weld location and then flux is added The slag reaches a temperature of about 3500F (1930C). This temperature is sufficient for melting the consumable electrode and work piece edges. Metal droplets fall to the weld pool and join the work pieces. Electro slag Welding is used mainly for steels. Electro slag welding (ESW) is a highly productive, single pass welding process for thick (greater than 50 mm) materials in a vertical or close to vertical position. An electric arc is initially struck by wire that is fed into the desired weld location and then flux is added The slag reaches a temperature of about 3500F (1930C). This temperature is sufficient for melting the consumable electrode and work piece edges. Metal droplets fall to the weld pool and join the work pieces. Electro slag Welding is used mainly for steels. Electroslag Welding equipments Power source Wire feeder Electrode guide tube Retaining Blocks Welding head and Controls Power source Wire feeder Electrode guide tube Retaining Blocks Welding head and Controls Power source 100 % duty cycle AC and DC (EP) power source 10,000 Amp OCV 60V (range is 30 V to 100 V) Remote controlled 100 % duty cycle AC and DC (EP) power source 10,000 Amp OCV 60V (range is 30 V to 100 V) Remote controlled Wire feeder Feed roller Drive motor Provide oscillation rack and pinion motion cam and crank arrangement Feed roller Drive motor Provide oscillation rack and pinion motion cam and crank arrangement Retaining Blocks Maintain the slag and molten metal with in the cavity Solid copper and water cooled copper shoe Travel upward as welding progress For low melting point graphite or steel can be used Maintain the slag and molten metal with in the cavity Solid copper and water cooled copper shoe Travel upward as welding progress For low melting point graphite or steel can be used Welding head and Controls It Consists :- wire feeder Electrode supply Wire guide tube Oscillation drive It Consists :- wire feeder Electrode supply Wire guide tube Oscillation drive Consumables Electrode Solid and metal-cored Wire range 1.6 to 4.0 mm diameter. Electrode Solid and metal-cored Wire range 1.6 to 4.0 mm diameter. Flux Should sufficient resistance to melt the filler material. Optimum viscosity. Melting point should lower then the material to be joined. 5 to 10 Kg for each 100kg of metal deposited. Two types of fluxes starting (low melting point, ) running Should sufficient resistance to melt the filler material. Optimum viscosity. Melting point should lower then the material to be joined. 5 to 10 Kg for each 100kg of metal deposited. Two types of fluxes starting (low melting point, ) running ESW variables Welding Current Welding Voltage Electrode diameter Electrode extension Electrode oscillation Slag Pool depth Number of electrode and their spacing Root gap Welding Current Welding Voltage Electrode diameter Electrode extension Electrode oscillation Slag Pool depth Number of electrode and their spacing Root gap Welding current It depend upon welding voltage and Electrode feed rate. Increases with increase in wire feed rate. Increasing in current means increasing in welding speed. Due to increase in welding speed depth of penetration will reduce and lack of fusion is likely occur. It may cause cracking Max level of current used bellow 500 A for wire dia 3.2 mm and bellow 400 A for 2.4 dia. It depend upon welding voltage and Electrode feed rate. Increases with increase in wire feed rate. Increasing in current means increasing in welding speed. Due to increase in welding speed depth of penetration will reduce and lack of fusion is likely occur. It may cause cracking Max level of current used bellow 500 A for wire dia 3.2 mm and bellow 400 A for 2.4 dia. Welding voltage Effect the depth of penetration and stability of process. Excessive voltage may cause overheating of metal, gassing of slag pool and even sparking. With Low voltage electrode may short-circuit to the pool of molten metal. Selection of voltage is governed by the type of flux used and is usually 32 to 55 volt per electrode. Higher voltage is used with thicker section. Effect the depth of penetration and stability of process. Excessive voltage may cause overheating of metal, gassing of slag pool and even sparking. With Low voltage electrode may short-circuit to the pool of molten metal. Selection of voltage is governed by the type of flux used and is usually 32 to 55 volt per electrode. Higher voltage is used with thicker section. Electrode diameter Greater the diameter of electrode more the depth of penetration and the suitable operation of process. In such cases use is made of electrode plates instead of large diameter wires. Greater the diameter of electrode more the depth of penetration and the suitable operation of process. In such cases use is made of electrode plates instead of large diameter wires. Electrode Extension Distance between contact tube and slag pool surface is referred to as dry electrode extension. And length of electrode dipped in slag is called wet extension. Electrode extension of 50-75mm are normally used. Bellow 50 mm resulting in overheating of contact tube and more then 75 mm resulting in overheating of electrode because of increasing in electrode resistance. Leads to melt the electrode at the surface of slag pool instead of inside it. Distance between contact tube and slag pool surface is referred to as dry electrode extension. And length of electrode dipped in slag is called wet extension. Electrode extension of 50-75mm are normally used. Bellow 50 mm resulting in overheating of contact tube and more then 75 mm resulting in overheating of electrode because of increasing in electrode resistance. Leads to melt the electrode at the surface of slag pool instead of inside it. Electrode Oscillation Plates upto 75 mm thick can be welded without oscillation but with high voltage. To achieve better fusion it is necessary to oscillate the electrode horizontally across the thickness. Oscillation speed normally varies between 10-40 mm/sec. Increasing in speed result in reduce weld width. Plates upto 75 mm thick can be welded without oscillation but with high voltage. To achieve better fusion it is necessary to oscillate the electrode horizontally across the thickness. Oscillation speed normally varies between 10-40 mm/sec. Increasing in speed result in reduce weld width. Slag Pool depth Excessive pool depth resulting slag inclusion. Lead to reduce weld penetration. Too shallow result arcing on the slag surface. Optimum depth of weld pool is about 40 mm And the range can be used between 25 mm to 60 mm. Excessive pool depth resulting slag inclusion. Lead to reduce weld penetration. Too shallow result arcing on the slag surface. Optimum depth of weld pool is about 40 mm And the range can be used between 25 mm to 60 mm. Root gap It effect the depth of penetration Decrease in root gap result in decrease in penetration and vice-versa. Narrow gap increase in short-circuit. Large gap required an extra amount of filler metal. Feasible root gap should between 20-35 mm. It effect the depth of penetration Decrease in root gap result in decrease in penetration and vice-versa. Narrow gap increase in short-circuit. Large gap required an extra amount of filler metal. Feasible root gap should between 20-35 mm. Applications of ESW Welding of structure, machinery, ships, pressure vessel and casting. Applicable to long butt weld. Welding of structure, machinery, ships, pressure vessel and casting. Applicable to long butt weld. Advantages of Electroslag Welding: High deposition rate - up to 45 lbs/h (20 kg/h); Low slag consumption (about 5% of the deposited metal weight); Low distortion; Unlimited thickness of work piece. Disadvantages of Electroslag welding: Coarse grain structure of the weld; Low toughness of the weld; Only vertical position is possible. Advantages of Electroslag Welding: High deposition rate - up to 45 lbs/h (20 kg/h); Low slag consumption (about 5% of the deposited metal weight); Low distortion; Unlimited thickness of work piece. Disadvantages of Electroslag welding: Coarse grain structure of the weld; Low toughness of the weld; Only vertical position is possible. Variants of ESW Consumable guide ESW ESW with plate electrode Electroslag butt welding Consumable guide ESW ESW with plate electrode Electroslag butt welding THANK YOU THANK YOU