Tipmate Systems: Electrode extension nozzles (Ceramic) for dramatically increasing weld deposition rates in Submerged arc Welding, without affecting penetration.

The use of increased Electrode Extension with single wire welding allows that process to compete with other higher deposition rate processes, while maintaining process flexibility all at a fraction of their capital or operating costs.

Its size & design makes its use very versatile in a typical job shop where welds are constantly changing from vessels of 8” through 42” diameter and plate thicknesses of 1/4" through 5”.

 

Increase welding productivity by upto 50% without modifying your PQR's/WPS's.

Conventional single wire welding usually gives 8 – 16 lbs/hr deposition rates. 

Single wire Submerged Arc Welding with 3/32” & 1/8" diameter wire and 2-1/4” Electrode extension has been validated for use on the full range of plate thickness and diameter, while yielding a deposit rate up to about 22 lbs/hr.

The cooler HAZ (heat affected zone) reduces stops for inter-pass temperatures & allows reducing a 60 degree bevel angle to 45 for greater production efficiencies.

Unlike the Lincoln (Power Wave) option, there is no requirement to change flux or to re-qualify a welding procedure. 

The  Electrode Extension is always a non-essential variable. 

Consistent, defect-free welds, is maintained while significantly increasing deposition rates & decreasing production costs through lower consumable use.

 Success on our first EE weld made today.  1/8 wire,  WFS 40, VOLTS 30,  AMPS 350. 10 INCH  Heavy Wall.  8 minutes for Fill and Cap. It is obvious the temperature showing through the flux is much lower than a machine just opposite that did NOT have the EE.  No stopping for excessive interpass temperature. Many thanks and kind regards, Jack Sims, General Manager -Fabrication Division Nasser S. Al-Hajri corporation,
Kingdom Of Saudi Arabia

RANDY, I HAVE STARTED OUR HEAVY WALL VESSELS AND I AM REAL IMPRESSED WITH THE TIME SAVINGS AND THE X-RAYS. ON 1 5/8" X 42" I.D. WE CUT OUR WELDING TIME IN HALF. Danny McGowan, Dixie Weld Fab, Belcher, LA.

Wire speed rates of 190 IPM with 3/32" solid wires for carbon steel, B2, and B3 consumables. The decreased heat input allows good solidification of the puddle for circumferential butt welds.With 3/32" FC-SAW we achieved a wire speed of 220 IPM on carbon steel. The coupon radiographed clean, and the bead appearance was excellent as was the case with solid wires.After performing all necessary ASME Section procedure qualification testing regimes we found no noticeable difference in mechanical properties.The narrow configuration of the ceramic nozzle itself, as compared to the current standard SAW nozzles, allows two distinct advantages. Either a more narrow groove design can be utilized for less volume deposition, or more flexibility and maneuverability can be afforded within the groove itself, or both. This maneuverability within the groove helps the welder to determine the placement of individual beads more precisely, and thereby improve on radiographic reject rates.Jeff Scott, Technical Advisor, Welding Engineering and Welding Metallurgy,  B.F. Shaw Inc.

 

Submerged Arc process on light (3/16") HSLA material. Our operators would make frequent adjustments to the flux nozzle, which covered the contact tip. It was common in our SAW process to generate substantial rework when electrode extension was substantially and accidentally reduced, thus, current increased, resulting in bum through. By adding TipMate ceramic tip extensions operators were able to see the end of the extension and know they were using the required electrode extension. The consistency and process control that the TipMate System gave us eliminated the bum through/rework of these joints.

Paul W. Cameron - Welding Engineer American Car and Foundry (ACF), Huntington, WV.

 

 The TipMate Nozzle System allows us to get a 36% increase in deposition on carbon steels and we are getting a 25% increase on our P91 materials. Not only has our deposition rate increased, but our arc time has increased as well. This is due to the lower rate of heat buildup in the base material, which means less stopping, or setup for inter-pass control. The weld quality is excellent; to date we have had no repairs due to the use of TipMate Nozzles.Terry Soeffker, Senior Manufacturing Engineer, Deltak LLC

 

Flowline currently maintains a welding operation that is comprised of five sub-arc welding stations, all of which are equipped with the TipMate EE nozzles. Since the implementation of the extended stick out technique Flowline has enhanced production by an estimated 25%. Enhanced productivity can be directly related to the greater weld metal deposition rates that are achieved using the TipMate Systems nozzles. Flowline now has the ability to achieve the greater deposition rates while still maintaining the required interpass temperature limits as allowed by specification; The reduction in arc time hours per weld, along with a shorter process time per weld, has lead to these enhanced production rates. We have found that the EE process has shown no detrimental effects towards the quality of our welding processes. All welds provided to the North Slope are subject to 100%VT and RT inspection processes. We have noticed a significant reduction in any "burn through" type problems that are commonly inherent to the thin wall pipe welding when using the SAW process. Jim Keegan;  Project Manager, Flowline Alaska Inc.

 

Deposition rates have been increased by 15% to 30% depending on pipe diameter and wall thickness. • Lower heat input values allow our operators to weld longer and maintaining inter-pass temperatures. John R. Panetti, Executive Vice President, Team Industries Inc.