INCREASE OF PRODUCTIVITY THROUGH HIGHER DEPOSITION RATE

Image:1 Scheme of a manual installation for welding with coated electrode

Deposition rate through manual metal arc welding (MMA), or also known as Shielded metal arc welding (SMAW)

•1.9 kg/hr weld metal by E7018, 4.0 mm at 160 Amps

•5.0 kg/hr weld metal by E7014, 5.0 mm at 275 Amps

•18 kg/hr by gravity feeding

Deposition rate through Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding

•3-3.5 kg/hr by 1.2 mm solid wire

•4.8 kg/hr by cored wire at 250 Amps

•Can be mechanized (50-60m/h)

•Low deformation

•No electrode change

Deposition rate through Submerged arc welding (SAW)

•Above 2.0 mm thickness

•20-25 kg/h based on the process

•100-120 m/h

•High speed, deep penetration

•Even quality,

•No hydrogen cracks

Pipe welding productivity through different processes

Time required to complete one joint 500 mm dia, 25 mm wall thickness, 60 degree single V preparation, rotated.

Image 2: Pipe welding

•MMA 4.4 hrs

•MIG 2.7 hrs

•SAW 1.7 hrs (MMA root)

Fillet welding productivity through different processes

Time required with different processes for welding 1 Meter of 6 mm leg length fillet weld

Image 3: Horizontal Fillet welding

•MMA 12.5 mins

•MIG 5.3 mins

•SAW 2.2 mins