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We are using this Shield-Bright ESAB wire and cannot shake the slag issues. The slag sticks to the welds and they look incredibly nasty... The odd thing is is that it welds incredibly nice also.. When you go to chip the slag away it has this crazy ridge on the top and it makes for a dirty looking weld and is never smooth. However once I run it horizontal it runs great and flat. I enclosed photos of the problem and i have had esab out here trying to dial it in and they seem to be baffledV 25.4WFS 250 Inductance 8675/25 as recommend by esab Attached Images
Reply:I double checked the spec sheet on that wire, and it is a T-1 all position filler metal. I wasn't sure from the photos you posted. I'm not familiar with the power supply you're using, so I'm not sure what 86 Inductance means in real world terms. Have you tried lowering the inductance? Do the shorts become more frequent and less violent? I ask because it appears that you're getting some really large, stubborn spatter deposits. This suggests to me that the ball forming on the wire tip while welding is very large. This makes for a big "splash" when the ball transfers to the puddle. If this is occurring, then the weld puddle will be more unstable, and harder to control; with more large spatter.Your horizontal beads across the surface of the pipe look like they have a lot of sag. How fast are you moving while welding? Too slow a travel speed could cause this and contribute to the other issues you're seeing. What happens when you move faster and weld smaller beads?If you're welding duplex or super duplex pipe, how much freedom do you have in the weld procedure to adjust voltage, wire feed speed(amperage), and travel speed? These materials have issues with too much or too little heat input while welding.Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:we have the freedom to move in this WPS... What are your suggestions? lower everything? ill go out back right now and have him change the inductance!
Reply:I don't know if the inductance on your power supply works as I imagine it does, or not. That's why I asked if you had tried lowering the inductance. What I think might help is getting the short circuit to produce a smaller ball on the end of the wire. This should make the transfer less spattery and the puddle easier to control. A smaller puddle will freeze faster, should be flatter, and look better overall. Your settings are close to the minimums in the datasheet. That's why I suggested traveling faster. You probably can't turn things down much lower without having arc stability issues. So you've got to move faster to get a smaller, flatter bead.If that doesn't work, you might actually need to turn the voltage and wire feed speed UP. Coupled with traveling faster, this might net a smoother bead with better arc stability. Higher voltage and WFS may push you towards a smoother, more "spray-like" arc. But if you run hotter you have to move faster! Sometimes it's doing the opposite of what common sense suggests that gets you results...All this is very tough to advise on without actually seeing a weld being made. So take what I've said and see what you can make of it with a little experimenting. Originally Posted by MrWeldSoCalwe have the freedom to move in this WPS... What are your suggestions? lower everything? ill go out back right now and have him change the inductance!
Reply:Originally Posted by A_DAB_will_doI double checked the spec sheet on that wire, and it is a T-1 all position filler metal. I wasn't sure from the photos you posted. I'm not familiar with the power supply you're using, so I'm not sure what 86 Inductance means in real world terms. Have you tried lowering the inductance? Do the shorts become more Your horizontal beads across the surface of the pipe look like they have a lot of sag. How fast are you moving while welding? Too slow a travel speed could cause this and contribute to the other issues you're seeing. What happens when you move faster and weld smaller beads?
Reply:we are using a miller 450 MPA power supple and fluxcore wire so its in spray transfer... we cant run a short circut on this job
Reply:In my experience, super duplex is not easy to weld, even for the best of guys. We just finished up a job where we welded 2507 with 2594 filler. The WPS calls for us to run it on pulse with .045 hardwire. If possible, I highly recommend doing the same, using a tri-mix/argon gas mixture. 25cfh argon, 8cfh tri mix. However it seems that this stuff does not like to weld in any position except flat. This material and filler types will give you a lot of trouble if your not careful with it. Even running the subarc was a mess at first. We failed quite a few x rays due to porosity before we got a grip on it. Hope this helps
Reply:Yea we have been doing over a month of trouble shooting and figuring it out. We have 4 WPS's I wrote for this, from 4 different PQR's we had to write. We have two tig wps's one 98/2 argon nitrogen with 98/2 backing gas.... then a 100 argon over 98/2 backing gas. We have a fluxcore wps and a .045 hard wire pulse mig wps. You are right on it being a real bitch to tune up. The flux core i spent days and day trying to dial in right. It will not run verticle... I eventually got it close at 23.5 V and a 280 WFS that is perfect for pipe joints at least. This is a lot like 2507... its Zeron 100... fun to flux when its dialed in though
Reply:Our customer defined our procedures for us, and they gave us the 98/2 ar/oxy for gas and it was garbage. The pqr went smoothly, but soon as we bought the wire, **** went downhill. We ran trial and error trying to get it to run right. Only straight argon was passing x rays. Seems like this material has a horrendous tendency to get porousity. Even with the sub arc! When you run tig, you can see it trying to make holes along the edges of the weld. Point being, this material is difficult to weld and requires alot of caution.
Reply:I didnt run to any porosity issues at all with this stuff. The Tig was smooth as silk and super buttery. The only real issue was has was when we sent the Fluxcore sample in to get G48 tested (ferric chloride) although it passed the macro came back with slag inclusions and of lack of pen, almost a cold lap on the first few passes.
Reply:Sorry for the dumb question, but did you check which polarity that wire needs to be run on?TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:yea everything was run on the correct polarity |
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发表于 2021-8-31 23:31:24