GCC Orbitalum Meeting Singen, June 30, 2014 · 2014-07-04 · Since 1964 seamless flux- and metal...
Transcript of GCC Orbitalum Meeting Singen, June 30, 2014 · 2014-07-04 · Since 1964 seamless flux- and metal...
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Production Process
and Benefits of Seamless Flux- and Metal-cored wires
particularly for offshore / oil & gas
GCC Orbitalum Meeting
Singen, June 30, 2014
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Summary
• Introduction of ITW Welding GmbH / Germany
(formerly STEIN wire & welding)
• Production process of seamless flux- and metal
cored wires including quality control
• Advantages of seamless cored wires
• Application examples
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ITW Welding - Your Route to Full
Performance in Welding
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ITW Welding location Germany
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Since 1964 seamless flux- and metal
cored wires are produced at the
location in Altleiningen / STEIN held
the patent on the system for the
production
Development of the patented
wire basket spool for welding
wire in 1975
Independent marketing and
sales of welding consumables
in 1997
Company‘s Welding History
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Became part of ITW Welding - 1st March 2013
STEIN name changed to ITW Welding GmbH – Sep. 13
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•Production process of Seamless
Flux- and Metal-cored wires
and quality control
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Divers cross sections of flux-cored wires
Seamless flux-cored wires
Folded flux-cored wires
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MEGAFIL - Seamless Cored Wire Production
Technology
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Production process seamless cored wires
High frequency welded tube
Initial annealing
and calibration to filling diameter
Uniform agglomerated flux core
densely filled by vibration
Drawing to final size, copper coating and spooling
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Approvals and Management Systems
We are certified by these
approval bodies for:
- Flux- and Metal Cored Wires
- The Production and
Quality Management
ISO 9001 and ISO 14001
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Technical Center
The Technical Center is equipped with all necessary
Testing Equipment for:
• 3.1 Certifications (100 % made in-house)
• Approvals for International Approval Bodies (TÜV, LR,
DNV, ...)
– Determination of all mechanical properties
– Chemical Analysis including N2, O2 and H
measuring
• Technical Equipment
– Spectrometer
– Scanning electron microscope (SEM)
– X-Ray fluorescence analyzer (RFA)
– Universal drawing machine, CHARPY-V,
hardness test equipment
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•Advantages of
Seamless FCAW/MCW
•Application examples for offshore /
oil & gas
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Characteristics of MEGAFIL
Seamless Flux- and Metal-Cored Wires
• Hydrogen content HD < 4 ml/100 g Weld
• Real value < 3 ml/100 g WM
• Absolute resistance to moisture pickup
during the entire usage/welding time
• Superior mechanical properties (than wire with seam) that stand up to extreme environments
• No particular storage necessary and longer shelf life! We tested after 10 years of production, wire showed same chemical/mechanical/hydrogen properties
• No need of baking / holding / quiver treatments even in humid conditions
• Reduced risk of Hydrogen related issues
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No Moisture Pick Up – Even Under Extreme Conditions
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Advantages of MEGAFIL seamless cored wires
• Copper-coating to improve current carrying capabilities
• Uniform shape (perfectly round) results in smoother wire feeding
• No torsion / tension / no twist, so stable process for robotic welding
• Low wear on feed rolls / liner / contact tip, … lesser maintanance
• Easy handling with stickout of 15 – 18 mm; no problems with Nitrogen /
Hydrogen (embrittlement). Lesser interpass cleaning
• Large range of approvals (DNV, ABS, LR, TÜV, BV, CWB, GL …)
• All certificates are with 3.1 chemical and mechanical values
• All certificates are batch certificates
• No flux filling gaps – 100 % control by flux filling check device
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Product Range
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Product Range
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Steel grade FCW
mixed Gas Co2 typical Ar / Co2 80/20 %
SAW
S355
( X42-X52)
(AH36-EH36)
(AH40-EH40)
yield ReH 355 Mpa
tensile Rm 470-630 Mpa
elogation 22 A [%]
S420
(AH420-FH420)
yield ReH 420 Mpa
tensile Rm 550-720 Mpa
elogation 20 A [%]
S460
(X60-X70)
(AH460-FH460)
yield ReH 460 Mpa
tensile Rm 500-640 Mpa
elogation 20 A [%]
S500
(AH500-FH500)
yield ReH 500 Mpa
tensile Rm 560-720 Mpa
elogation 18 A [%]
S550
( X80)
(AH550-FH550)
yield ReH 550 Mpa
tensile Rm 640 - 820 Mpa
elogation 18 A [%]
S620
(~X90 )
(AH620-FH620) (ABS EQ63)
yield ReH 620 Mpa
tensile Rm 710 - 880 Mpa
elogation 18 A [%]
S690
(X100)
(AH690-FH690) (ABS EQ70)
yield ReH 690 Mpa
tensile Rm 770 - 940 Mpa
elogation 17 A [%]
S890
( X120)
yield ReH 890 Mpa
tensile Rm 940 - 1100 Mpa
elogation 10 A [%]
S960 -
1100 -1300
yield ReH 960 Mpa
tensile Rm 980-1150 Mpa
elogation 10 A [%]
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PWT test welding for pipe with MEGAFIL 710 M
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MF 710 M
CTOD test results
MF 240 M
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Mechanical properties with and without PWHT
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with PWHT
without PWHT
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Typical Applications – Rig Fabrication
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Resume: We are Passionate about Welding
I want us all to walk away knowing and understanding that:
• ITW Welding GmbH has a know-how in the production of high quality seamless cored wires for 50 years.
• ITW Welding is a total solution provider for welding prosesses.
• Partnering with ITW Welding, you will have the deep knowledge and experience of engineers at your side.
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Thank you very much for your attention!
ITW Welding GmbH
Spechttal 1a
67317 Altleiningen
Germany
Phone: +49 (0) 6356 / 966-119
E-Mail: [email protected]
Homepage: www.itw-welding.com