Wave Form Controlled

Technology
GMAW Pulse
Power Mode
Rapid Arc

STT

Agenda

1.
2.
a)
b)
c)
d)
e)
f)
3.
4.
5.
6.
7.
8.
9.
10.
11.

Introduction
STT process
Background current
Initial shorting
Pinch current
Secont current reduction
Peak current
Tailout
STT visualization
STT settings and guidelines
Application - austenitic stainless. Cr-Mo low alloyed
STT vs. TIG, austenitic stainless, welding time
Comparing STT to CV, quality
Welding fumes
Possible applications
Summary benefits
FCW for austenitic & duplex stainless

Introduction

Conventional CV
Arc voltage/Welding current
50

100

150

200

250

300

350

35
30
25

Fill
ROOT

20

Spray arc

15
10

Short arc

Globular Transfer

5
0

SG2
SG21.0mm
1.0mm
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
25

Fill
ROOT

20

Pulse / Spray

15
10
5

Power Mode

Pulse

RapidArc

STT

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
Reasonfor
forlower
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
Keeps arc lit

Background current (T0

- T1): This is the current
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
actual ball/weld puddle contact
Extremely low current promotes ball
wetting instead of repelling
Reason for lower spatter in STT

Ball time: When the

electrode initially shorts (at
the background current), the
"arc
voltage"
detector
provides a signal that the
"arc" is shorted. The
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 Current
High current is applied immediately after
the initial short
Current increases, causing the molten
droplet to separate from the electrode
STT electronically calculates when
droplet separation is to occur and
reduces the current before this happens,
eliminating the explosive spatter.

Pinch mode (T2 - T3): Following

the ball time, a high current is
applied to the shorted electrode in
the form of an increasing, dual slope ramp. This accelerates the
transfer of molten metal from the
electrode to the weld pool by
applying electronic pinch forces.

STT Process

Second Current Reduction

Current is quickly reduced before
electrode separates, eliminating
spatter
STT circuitry
re-establishes the welding arc at a
low current level

The dv/dt calculation: This

calculation is included within the
pinch mode. It is the calculation
of the rate of change of the
shorted electrode voltage vs.
time. When this calculation
indicates that a specific dv/dt
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,
producing high heating of the plate,
insuring good fusion and setting
the proper arc length

Plasma boost (T5 - T6): This

mode follows immediately the
separation of the electrode from
the weld pool. It is the period of
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 current
Providing the overall heat
More or less wetting.
Most used control on the STT.

Back ground = Wetting

Tail out
In the same way as background
To be use with high travel speed
Automation not for pipe welding

Application; Stainless
preparation

Preparation; Stainless
Tack weld with bar

Tape

Application:
Pipe diameter 10
Position:
Material: AISI 316L

x 8 mm
G3

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
LNM316LSI 1,0mm
Gas: Ar + 2%Co2
22V, 175Amp
Position 3GU (!)

Pulse CAP
LNM316LSI 1,0mm
Gas Ar + 2%CO2
22 V, 175Amps
Position 3GU

Cor a Rosta

Welding stainless
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-1

10 mm

2
1

LNB

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

Bead#

Method,
wire

d, mm

I, A

U, V

Gas

Current,
polarity

Welding
Speed,
mm/sek

HI
kJ/mm

136,
Cor aArosta 316L

1,2

155

24

M21

DC+

5,5-6

0,5

2 -n

136,
Cor- a Rosta 316L

1,2

182

26

M21

DC+

5,5-6

0,65

Overmaching corrosion resistance

Remark

Application: Pipe
welding

Application; Steel Root Pass

Application:
Pipe diameter 6
Position:
60
Material: X42

x 10mm
G3(D)

3mm

Fill
Outershield 71E-H 1,2mm
Gas: 80%Ar 20%Co2
26V, 215Amp
Position 3GU

STT Root
Supra MIG 1,0mm
Gas: Ar + 20%CO2
Peak 280A
Background 70A
WFS 148/min
Position 3GD

CAP
Outershield 71E-H 1,2mm
Gas Ar + 20%CO2
26 V, 215Amps
Position 3GU

Setting STT
Procedures

STT Welding Parameter Guideline & Joint Configuration

Applicable for Un-, Low, & High Alloyed Materials (wire 1.0 mm)
Welding Position

Wall Thickness

1G / PA (Rotating)

5G Down / PG

< 3.5 mm

>3.5 mm
Wall Thickness

Peak Current

Backgrond Current

Wire Feed Speed

<3.5 mm

230-240

50-65

290-330

< 8 mm

260-270

55-65

330-360

>8 mm

260-270

65-85

360-420

Peak Current

Backgrond Current

Wire Feed Speed

230-240

45-55

290-330

250-260

50-65

320-360

Gas Selection

Shielding & Backing Gas Selection Table

Mild & Low
Alloyed Steel
++

Regular 3xx
Stainless Steel
-

(Super) Duplex
Stainless Steel
-

Fully Austenitic
Stainless Steel
-

Nickel Alloys
-

Ar + 20% CO2 + He

Ar + 2% CO2

++

Ar + 28% He + 2%CO2

+*

++

++

Ar + 30% He
Ar + 28% He + 2%H2

+
++

(+)
(+)
-

+
+
++

++
++
-

+
+
++

+
+
++

Ar + 20% CO2

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
Material
Welding Position
Pipe Diameter

1.4462 (Duplex)
1G Rotating
25"

3-4 mm
Material
Welding Position
Pipe Diameter

GMAW-STT
Consumable
Classification
Diameter
Shielding gas
Flow
Backing gas
Stick-out
Peak Current
Background Current
Arc voltage
Wire Feed Speed
Welding Time

LNM 4462
G 22 9 3 N L
1,2 mm
98% Ar + 2% CO2
13 l/min
100% Ar
12 mm
280 A
80 A
100 "/min
6 minutes

1.4462 (Duplex)
1G Rotating
25"

GTAW
Consumable
Classification
Diameter
Shielding gas
Flow
Backing gas
Stick-out
Current

LNT 4462
W 22 9 3 N L
2,4 mm
100%
8 l/min
100% Ar
-90 A

Arc voltage
Wire Feed Speed
Welding Time

11-13 V
-22 minutes

Low Spatter, Defect Free Rootpass

Welding Fume

Fume emission (g/hour)

Solid wire (MIG/MAG, TIG & STT)

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