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Home / A New State of Flux

A New State of Flux

Take a look at how these new submerged arc welding systems meet the demands of heavy fabrication, shipbuilding, pressure vessel, beam fabrication, wind tower and pipe manufacturing.

The unique Integrated Cold Electrode technology for submerged arc welding applications from ESAB can substantially increase productivity while exceeding critical welds requirements by exploiting the excess heat from the Twin SAW process to melt an additional non-powered welding electrode. This doubles the productivity in deposition rates and in root welds when compared to single wire welding. (First view)
The unique Integrated Cold Electrode technology for submerged arc welding applications from ESAB can substantially increase productivity while exceeding critical welds requirements by exploiting the excess heat from the Twin SAW process to melt an additional non-powered welding electrode. This doubles the productivity in deposition rates and in root welds when compared to single wire welding. (Second view)
The highly reliable SubArc Digital Series of power sources, interface controls and accessories from Miller Electric are easier to setup and operate and ensure continuous delivery of flux to the arc through digital control and communication electronics that improve weld performance and simplify the integration of the equipment in more advanced applications.
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DIGITAL EQUIPMENT FOR ARC STABILITY, RELIABILITY
The new SubArc Digital Series of power sources, interface controls and accessories from Miller Electric Mfg. Co. (Appleton, WI) include digital control and communication electronics designed to improve weld performance and simplify the integration of the equipment in more advanced applications. The SubArc Digital Series offers a number of significant enhancements, including easier setup and operation and an improved flux delivery system that ensures continuous delivery of flux to the arc. The series combines the latest in digital process control technology with tested and highly reliable power regulation and the ease of use and reliability of a traditional machine — resulting in equipment that stands up to use in all heavy industrial applications.

“This new equipment with digital controls is easy to operate and understand, thereby providing proper penetration and optimum deposition through controlled regulation of parameters, making it less dependent on the skill level of the operator,” said Pieter Keultjes, the global product manager of SubArc Equipment for Miller. “This extremely reliable process meets the quality and mechanical properties required by even the most demanding industries — such as shipbuilding, heavy fabrication, pressure vessel, wind tower and pipe manufacturing — using tested power technology that has offered continuous reliability for decades. It really offers the best of both worlds.”

The product line includes two DC power source models — the SubArc DC 650/800 Digital and the SubArc DC 1000/1250 Digital — and one AC/DC model, the SubArc AC/DC 1000/1250 Digital. The power sources have the capacity to handle Submerged Arc (SAW) and Electroslag (ESW) welding applications, from traditional DC single-arc to multi-wire tandem welding. In the case of ESW welding or other high-current demand, two or more power sources can easily be paralleled. In addition to these power source options, the series offers two interface controls — analog and digital — and a range of wire drive motors and accessories, including single- and twin-wire torches,  narrow gap torches, and internal and external cladding heads. The accessories are powered with a safe, low control- voltage (24 VAC) from the power source.

New digital communication within the equipment recognizes the power source and wire drive connected and automatically configures the system for proper operation, providing easier setup and operation. The easy-to-understand interface provides the operator with the necessary controls to set process parameters and control output, and the power sources feature simplified parallel and tandem setups — just plug the cable into the appropriate connectors. The SubArc Digital Series power sources are easy to integrate by using the standard Modbus® connection and different levels of integration are possible, from simple remote operation to more complex automated systems.

The improved flux delivery system uses a valve mechanism to assure continuous delivery of flux to the arc, and also provides a barrier between the flux and the actuation device to prevent jamming of the solenoid actuator due to dust and debris. A sight glass on the front of the flux hopper allows the welding operator to visually monitor the remaining flux. Additionally, an increased environmental rating to IP-23 for all products in the SubArc Digital Series provides the high level of protection required for applications in harsh environments.

Miller Electric Manufacturing Co., 1635 W. Spencer Street, PO Box 1079, Appleton, WI 54912-1079, 920-734-9821, www.millerwelds.com.

DOUBLE THE PRODUCTIVITY OF SAW APPLICATIONS
ESAB Welding & Cutting Products (Florence, SC) offers their innovative Integrated Cold Electrode (ICE™) technology for submerged arc welding (SAW) applications. This unique process can substantially increase a fabricator’s productivity while exceeding the requirements for critical welds. ICE is an elegantly simple technology. Instead of adding energy, it exploits the excess heat from the Twin SAW process to melt an additional non-powered welding electrode. This results in double the productivity in deposition rates and in root welds when compared to single wire welding.

ICE boosts output significantly without the investment in new welding systems, extra capacity, or additional skilled welding labor. It also enables the use of tandem welding in root passes for improved penetration, providing high productivity and eliminating the need for back gouging. Other advantages include reduced heat input, energy consumption, and flux consumption. At a 50 percent higher deposition rate, flux consumption can be reduced by as much as 20 percent. Unlike conventional SAW methods, ICE reduces the energy requirement, ensuring greener production and a smaller carbon footprint. The multiple gains offered by the ICE process stretch across a broad range of applications in many industries, including on-and-offshore wind towers and other offshore components, pipe welding, general heavy fabrication, pressure vessels, beam fabrication and shipbuilding.

ESAB Welding & Cutting Products, PO Box 100545, 411 South Ebenezer Road, Florence, SC 29501, 717-630-3439, dspackman@esab.com, www.esabna.com.

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