Wave Form Controlled

Technology™

•GMAW Pulse
•Power Mode
•Rapid Arc

•STT
 Agenda

1. Introduction
2. STT process
a) Background current
b) Initial shorting
c) Pinch current
d) Secont current reduction
e) Peak current
f) Tailout
3. STT visualization
4. STT settings and guidelines
5. Application - austenitic stainless. Cr-Mo low alloyed
6. STT vs. TIG, austenitic stainless, welding time
7. Comparing STT to CV, quality
8. Welding fumes
9. Possible applications
10. Summary – benefits
11. FCW for austenitic & duplex stainless
 Introduction

Conventional CV
Arc voltage/Welding current
50 100 150 200 250 300 350
35
30 Fill
25 ROOT

20
Spray arc
15
Globular Transfer
10
Short arc

5
SG2
SG21.0mm
1.0mm
0 80/20
80/20MIX-gas
MIX-gas

Popular
Popularbut..limitations
but..limitationsand
andclear
cleardisadvantages
disadvantages
 Alternatives

Wave Form Controlled™ Alternatives

Arc voltage/Welding current
50 100 150 200 250 300 350
35
30 Fill
25 ROOT
20
Pulse / Spray
15
Pulse
Power Mode® RapidArc™
10
5 STT®
0

Lincoln
Lincoln Electric
ElectricAlternatives
Alternativesto
tooffer
offer
STT Process
 STT

STT principle

Good
Goodfusion
fusionand
and
setting
settingof
ofthe
the
proper
properarc
arclength
length

OOveral
veralheat
heat
input
input(wetting)
(wetting)

Movie
Reason
Reasonforforlower
lower
spatter
spatterin
inSTT
STT
 STT Process

Background current
– Arc current level prior to
shorting to the weld pool.
– Contributes to the overall heat
input Background current (T0
- T1): This is the current
– Keeps arc lit level of the arc prior to
shorting to the weld pool.
It is a steady-state current
level, between 50 and
100 A
 STT Process

Initial Shorting
– Response to the “arc voltage” detector
sensing that the arc has shorted
– Current is reduced even further at Ball time: When the
actual ball/weld puddle contact electrode initially shorts (at
the background current), the
– Extremely low current promotes ball "arc voltage" detector
wetting instead of repelling provides a signal that the
"arc" is shorted. The
– Reason for lower spatter in STT background current is futher
reduced to 10 A for
approxiametly 0.75
milliseconds. This time
interval is referred to as the
ball time.
 STT Process

Pinch mode (T2 - T3): Following

the ball time, a high current is
Pinch Current applied to the shorted electrode in
– High current is applied immediately after the form of an increasing, dual -
slope ramp. This accelerates the
the initial short transfer of molten metal from the
– Current increases, causing the molten electrode to the weld pool by
droplet to separate from the electrode applying electronic pinch forces.

– STT electronically calculates when

droplet separation is to occur and
reduces the current before this happens,
eliminating the explosive spatter.
 STT Process

Second Current Reduction

– Current is quickly reduced before The dv/dt calculation: This
electrode separates, eliminating calculation is included within the
spatter pinch mode. It is the calculation
of the rate of change of the
– STT circuitry shorted electrode voltage vs.
re-establishes the welding arc at a time. When this calculation
indicates that a specific dv/dt
low current level value has been attained,
indicating that fuse separation is
about to occur, the current is
reduced to 50 A in
microseconds. (Note, this event
occurs before the shorted
electrode separates. T4indicates
the separation has occurred, but
at a low current.
 STT Process

Peak Current
– High current is applied immediately
after the arc is reestablished
– Arc is momentarily broadened, Plasma boost (T5 - T6): This
producing high heating of the plate, mode follows immediately the
insuring good fusion and setting separation of the electrode from
the weld pool. It is the period of
the proper arc length high arc current where the
electrode is quickly "melted
back." (The geometry of the
melted electrode at this point is
very irregular.)
 STT Process

Tailout
– Current is reduced from peak
to background level
– Reduces agitation of the weld
puddle
– This control is a coarse heat
control
Plasma (T6 - T7): This is the
period of the cycle where the
arc current is reduced from
plasma boost to the
background current level.
movie
Movie
 Peak & Background
Current

STT settings
Peak current
•Providing the energy to set the arc length.
•Setting according wire diameter and composition.
•Pressure in both ways; wire and weld bead.

Peak current = arc pressure & length

Low
High Back ground = Wetting
Back ground current Tail out
•Providing the “overall heat” •In the same way as background
•More or less wetting. •To be use with high travel speed
•Most used control on the STT. •Automation not for pipe welding
 Application; Stainless
preparation

Preparation; Stainless
Tack weld with bar Tape Application:
Pipe diameter 10” x 8 mm
Position: G3
Material: AISI 316L

60°

3mm

Backing gas: 95%Ar 5%N2

 Application
Stainless pipe

Application: Stainless Root Pass

STT Root
LNM 316LSI 1,0mm
Gas: Ar + 2%CO2
Peak 270A
Background 80A
WFS 168”/min
Position 3GD

PULSE Fill Pulse CAP

LNM316LSI 1,0mm LNM316LSI 1,0mm
Gas: Ar + 2%Co2 Gas Ar + 2%CO2
22V, 175Amp 22 V, 175Amps
Position 3GU (!) Position 3GU
 Welding stainless
Cor – a – Rosta Example 7

Cor – a – Rosta wires are available in most used grades and

increased productivity justifies the move to premium quality wires!!!
Example 7
 Gates for shipbuilding… Example 7

n
n-1

2 10 mm
1

LNB

PA, 10 mm thick palte, gap 3-4mm, root 1,5, beveling V60

Bead# Method, d, mm I, A U, V Gas Current, Welding HI Remark

wire polarity Speed, kJ/mm
mm/sek
1 136, 1,2 155 24 M21 DC+ 5,5-6 0,5
Cor – a-
Arosta 316L
2 -n 136, 1,2 182 26 M21 DC+ 5,5-6 0,65
Cor- a -
Rosta 316L

Overmaching corrosion resistance…

 Application: Pipe
welding

Application; Steel Root Pass

Application: STT Root
Pipe diameter 6” x 10mm Supra MIG 1,0mm
Position: G3(D) Gas: Ar + 20%CO2
Material: X42 60° Peak 280A
Background 70A
WFS 148”/min
3mm Position 3GD

Fill CAP
Outershield 71E-H 1,2mm Outershield 71E-H 1,2mm
Gas: 80%Ar 20%Co2 Gas Ar + 20%CO2
26V, 215Amp 26 V, 215Amps
Position 3GU Position 3GU
 Setting STT
Procedures

STT Welding Parameter Guideline & Joint Configuration

Applicable for Un-, Low, & High Alloyed Materials (wire ø1.0 mm)
Wall Thickness
Welding Position
1G / PA (Rotating) 5G Down / PG

< 3.5 mm

>3.5 mm

Wall Thickness Peak Current Backgrond Current Wire Feed Speed Peak Current Backgrond Current Wire Feed Speed

<3.5 mm 230-240 50-65 290-330 230-240 45-55 290-330

< 8 mm 260-270 55-65 330-360
250-260 50-65 320-360
>8 mm 260-270 65-85 360-420
 Gas Selection

Shielding & Backing Gas Selection Table

Mild & Low Regular 3xx (Super) Duplex Fully Austenitic
Alloyed Steel Stainless Steel Stainless Steel Stainless Steel Nickel Alloys
Ar + 20% CO2 ++ - - - -
Ar + 20% CO2 + He + - - - -
Ar + 2% CO2 - ++ + + -
Ar + 28% He + 2%CO2 - +* ++ ++ -
Ar + 30% He - - - - +
Ar + 28% He + 2%H2 - - - - ++

Backing gas
Ar (+) + ++ + +
N2 (+) + ++ + +
N2 + 5%H2 - ++ - ++ ++
++ First option
+ Second option
(+) Optional
Not
- recommended
* Recommended when wall thickness > 6 mm LSW06/AvdS-DR
 Procedure Comparison

Procedure Comparison
25 mm 25 mm

3-4 mm 3-4 mm
Material 1.4462 (Duplex) Material 1.4462 (Duplex)
Welding Position 1G Rotating Welding Position 1G Rotating
Pipe Diameter 25" Pipe Diameter 25"
GMAW-STT GTAW
Consumable LNM 4462 Consumable LNT 4462
Classification G 22 9 3 N L Classification W 22 9 3 N L
Diameter 1,2 mm Diameter 2,4 mm
Shielding gas 98% Ar + 2% CO2 Shielding gas 100%
Flow 13 l/min Flow 8 l/min
Backing gas 100% Ar Backing gas 100% Ar
Stick-out 12 mm Stick-out --
Peak Current 280 A Current 90 A
Background Current 80 A
Arc voltage Arc voltage 11-13 V
Wire Feed Speed 100 "/min Wire Feed Speed --
Welding Time 6 minutes Welding Time 22 minutes
Low Spatter, Defect Free Rootpass
 Welding Fume

Solid wire (MIG/MAG, TIG & STT)

Fume emission (g/hour)

Welding current (A)

STT: 50% reduction in fume emission versus

conventional GMAW
 Industry Segments

Markets where STT can be applied

Oil & Gas Industry
Cross Country Pipelines
Power Generation
Chemical Industry
Pulp & Paper Industry
Food & Dairy Industry
 Base materials

Applications with the STT process

Pipe Root-pass Welding
Mild- & Fine Grained Steel
Low Alloyed Steel
Creep Resistant Steel (qualified and certified in
Poland)
Standard 3xx-series Stainless Steel
Fully Austenitic Stainless Steel
(Super)Duplex Stainless Steel
Nickel Alloys
 STT advantages

The
The premium
premium “root
“root pass”
pass” process
process
Full electronically controlled arc.
No risk of cold fusion.
Different wires and gasses are applicable.
Extremely low spatter
Reduced smoke
4X faster compared to TIG welding
Large ligament (5.5mm)

Thank you
ksadurski@lincolnelectric.eu +48746461155