ESAB

Aluminium Welding Wire

Aluminium Welding with regard to Quality & Cost

Michael Spiess, Productmanagement, Aluminium, Europe

 Which is the most popular aluminium product in the
world?

Aluminium is recyclable

ESAB, Michael Spie, Produktmanager Aluminium, Europa

 Aluminium is the most common metal on Earth

47% Oxygen

27% Silicon
Feldspar
8% Aluminum
common Mica
Clay
elements in 5% Iron
Earth's crust 4% Calcium

3% Sodium

2% Potassium

2% Magnesium

Michael Spiess, Productmanagement, Aluminium, Europe

 Total demand of Aluminum

In 1000 to 2005 2006 2007 2008 2009

Europe 11.500 12.000 12.700 12.400 9.300
Asia 15.900 17.900 21.800 22.500 23.300
Africa 400 500 500 700 800
America 12.300 13.000 12.500 11.400 9.900
Oceania 600 500 500 500 500
Total 40.700 43.900 48.000 47.500 43.800

Quelle: GDA

Michael Spiess, Productmanagement, Aluminium, Europe

 Aluminium Market Segments

Michael Spiess, Productmanagement, Aluminium, Europe

 Aluminium Alloy Groups

1XXX Pure Aluminium

2XXX Copper
3XXX Manganese
4XXX Silicon Main Alloying
Elements of the
5XXX Magnesium Alloy Group
6XXX Magnesium/Silicon
7XXX Zinc
8XXX Lithium

Michael Spiess, Productmanagement, Aluminium, Europe

 Aluminium Alloy Types

heat treatable
e.g. AlCu6Mn (2219)
AlMgSi0,5 (6060)
AlZn4,5Mg1 (7020)

Non heat treatable

e.g. AlMg3 (5754)
AlMg4,5Mn (5083)
AlMn1 (3103)

ESAB, Michael Spie, Produktmanager Aluminium, Europa

 Aluminium Material with a Future
Aluminium is the most abundant metal in the Earths crust and the third
most abundant Element

Light weight, 1/3 of the weight of Steel

Low Melt point of pure (660C for Al 99,99)

Very high thermal conductivity

High corrosion resistant and weatherproof

No loss of toughness by low temperature (face centered cubic lattice)

High solubility of hydrogen in the liquid state

Increase in Strength through alloy of Mg, Cu, Mn, Zn

Michael Spiess, Productmanagement, Aluminium, Europe

 Aluminium is a very ductile material
Perfect for crash management systems
Car and train elements that are designed to fold and collapse like an
accordion in a crash are capable of absorbing up to twice the crash energy of
steel

Michael Spiess, Product management, Aluminium, Europe

 Aluminium Consumption rising steadly

Michael Spiess, Productmanagement, Aluminium, Europe

 and Aluminium is

WELDABLE
employing methods,
equipment and skills similar to
those used for welding other
materials
Michael Spiess, Productmanagement, Aluminium, Europe
 Aluminium Welding Process FSW

- Friction-stir welding (FSW) is a solid-state joining

process (meaning the metal is not melted during the
process) and is used for applications where the
original metal characteristics must remain unchanged
as far as possible
Michael Spiess, Productmanagement, Aluminium, Europe
 Aluminium Welding Process MIG

GMAW is the most common industrial

welding process, preferred for its
versatility, speed and the relative ease
of adapting the process to robotic
automation.

Michael Spiess, Productmanagement, Aluminium, Europe

 Aluminium Welding Process TIG

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG)
welding, is an arc welding process that uses a non consumable tungsten
electrode to produce the weld. The weld area is protected from
atmospheric contamination by a shielding gas (usually an inert gas such as
argon), and a filler metal is normally used

Michael Spiess, Productmanagement, Aluminium, Europe

 Aluminium Welding Difficulties
What are the biggest problems for welding of aluminium?

- soft welding wire

- feedability of the aluminium welding wire
- (hot) cracks in aluminium
- porosity in the weld
- aluminium storage and handling
- lack of fusion
- wrong parameter settings
- etc..
Michael Spiess, Productmanagement, Aluminium, Europe
 Welding Difficulties Causes and corrections
Difficulty Causes Corrections
Dirty Welds Improper gas coverage Check for leaks in hoses, air drafts, loose fittings wrong gas
Proper storage or contact supplier
Dirty electrode Remove oils and grease before other mechanical cleaning.
Dirty base material Remove oxides using clean stainless steel brush.
Unstable Arc Connections, dirt, or wind Check all conductive surfaces for clean ground. Remove dirt
from weld joint. Eliminate drafts from weld area where shield
gas can be disturbed.
Penetration and Wrong weld parameters Adjust more amperage for more penetration and mor voltage
Fusion Problem for more width.
Wrong wire diameter Smaller wire will penetrate more. Larger wire will fill more
Dirty base material Clean weld area prior fit up. Remove oxide.
Wrong gas type Use only enough gas to create coverage. Verify gas for operation
Wrong joint preparation Thicker welds require U-Type joint versus V-type or square.
Dirty electrode Store electrode in warm, dry enviroment at all times to prevent
corrosion (its cheaper to buy it once).

Michael Spiess, Productmanagement, Aluminium, Europe

 Welding Difficulties Causes and corrections
Difficulty Causes Corrections
Porosity Hydrogen in the weld Check gas dew point (reject gas above 20 C. Check for Gas
leaks and defective hose conditions.
Store electrode properly.
Remove oils, grease and other hydrocarbons from base
material. Remove oxides within 24 hours of welding. Preheat
base material up to 65C. Do not use torches to preheat (hot air
guns work best!). Check gas flow.
Use larger wire if puddle is turbulent.
Weld cracking Improper filler alloy Refer to filler selection chart.
Joint or edge preparation Reduce dilution (more filler less base material).
Increase joint spacing or increase bevel angle.
Poor crater fill Fill crater completely through technique or system device.
Poor feeding Bird-nesting Reduce drive roll tension. Use slow run-in start system.
Check all surfaces where wire touches and reduce metal on
metal areas. Check contact tip condition. Check liner condition.
Check drive roll condition.
Arc hunting Check for proper contact tip I.D.
Liner Build-up Use a liner material hard enough that does not cut easily.
Check for wire galling items.
Drive rolls Check drive rolls for proper size, shape and surface finish.

Michael Spiess, Productmanagement, Aluminium, Europe

 Welding Difficulties Causes and corrections
Difficulty Causes Corrections
Poor Arc Starting Improper ground Check that all grounds are well made. Use slow run-in or hot
start features to assist start.
Contact tip size Check that contact tip is not oversized for alloy and diameter.
No shielding gas Use pre-purge feature for gas shield (also post purge to prevent
oxides from forming on end of wire).
Change welding parameters.

Michael Spiess, Productmanagement, Aluminium, Europe

 Quality Criteria for Aluminium Welding Wire

- raw material quality and purity

- shaving technology
- welding wire surface
- quality and maintenance of the drawing dies
- tolerance of the wire diameter!
- cast and helix
- final cleaning and coating

Cast Helix

Michael Spiess, Productmanagement, Aluminium, Europe

 Wire Surface Quality

Al 5356 1,2mm
200 times magnification

insufficient shaved

insufficient shaved

Michael Spiess, Productmanagement, Aluminium, Europe

 Wire Surface Quality
Would you like such an aluminium welding wire in your production ?

Michael Spiess, Productmanagement, Aluminium, Europe

 Fume Test
Alloy: 4043
Diameter: 1,60 mm
ESAB Manufacturer: ESAB
Pulse current 420 A
Peak value 0,206 mg/m Pulse time: 582 ms
Total 0,804 mg/m
Date : 02.10.2009

Results
Peak value: 0,206 mg / m
Total: 0,804 mg / m

Peak value: 0,776 mg/m

Total: 7,513 mg/m
Peak Value: 0,568 mg/m
Total: 3,245 mg/m

ESAB, Michael Spie, Produktmanager Aluminium, Europa

 Errors from Usage of Aluminium Welding Wire

Fume Test
What does the measurement of the residues from smoke tell us?

Storage or Usage
How long can you store aluminium welding wire until it is used?
Is it one week, three months, one year or?

ESAB, Michael Spie, Produktmanager Aluminium, Europa

 How do we test the quality of aluminium
welding wire ?

We test the aluminium welding

wire according the AWS Code 5.10

ESAB, Michael Spie, Produktmanager Aluminium, Europa

 Increase productivity by 40 % at a rail road car manufacturer

Wire diameter 1,60 mm 1,80 mm 2,00 mm

Customer Rail Rail Rail
Part Main carrier Main carrier Main carrier
Parent mat. 6005A 6005A 6005A
Filler mat. ER5356 1,60 mm ESAB OK Autrod 5356 ESAB OK Autrod 5356

Travel speed 36 38 cm /min 42 cm / min. 49 cm / min.

No. of beads 3 2 2

Michael Spiess, Productmanagement, Aluminium, Europe

 WPS

Michael Spiess, Productmanagement, Aluminium, Europe

 Cross section

Michael Spiess, Productmanagement, Aluminium, Europe

 Welding Cost Calculation

Michael Spiess, Productmanagement, Aluminium, Europe

 Applications

A weld without PAK TRAK and

OK Autrod 5183 d= 1,60 mm

A weld with the PAK TRAK and

OK Autrod 5183 d= 1,60 mm

Michael Spiess, Productmanagement, Aluminium, Europe

 New Development
If you like to:
- pay off the welding wire, out of big bulk packages
- get straight welding seams
- prevent tangled wire
- prevent twists in bulk packages
- have a stable arc during welding
- avoid disruption during welding process
- transport the wire over a long length, up to max. 60 m
- use standard PA wire conduits
Michael Spiess, Productmanagement, Aluminium, Europe
 New application for long straight welding seams
and long wire conduits

Michael Spiess, Productmanagement, Aluminium, Europe

Michael Spiess, Productmanagement, Aluminium, Europe
 Results with the PPT applications

Michael Spiess, Productmanagement, Aluminium, Europe

 What is special about the ESAB Aluminium Welding
wire ?
- ESAB has the most comprehensive product portfolio of welding
consumables for treatable alloys and also for harden able alloys.
- ESAB is the biggest manufacturer of aluminium welding wire in the market.
ESAB is continuously working on new developments to help our customers
increase their productivity.
- the ESAB Marathon Pac is the best, most reliable and most
environmentally friendly packaging system in the global market.
- the ESAB aluminium wire electrode has a unique surface and surface
coating. This ensures non porous welds and a very good feeding behavior in
the wire conduit.
- ESAB has a wide range of accessories for welding without disruption and
transporting the wire over long distances for use with our aluminium
Marathon Pac products.

Michael
Michael Spiess,
Spiess, Productmanagement,
Product Aluminium,Europe
management, Aluminium, Europe
 Thanks for listening

www.esab.com