What’s New: Electrodes and Filler Metals

NEW FLUX CORED WIRES ADDED TO DUAL SHIELD X-SERIES

ESAB Welding & Cutting Products (Florence, SC) added two additional wires to its popular Dual Shield X-Series flux cored wires. The X-Series wires are more forgiving than traditional flux cored wires, especially for less experienced welders, with an easily controlled arc and improved operation at both lower and higher current levels. Dual Shield X wires also offer high deposition rates, fast travel speeds, flat bead profile, limited spatter and extremely easy slag removal for overall productivity, ease of use and outstanding operator appeal.

Dual Shield 810X-Ni1 is an all-position 1 percent Nickel flux cored wire for general purpose welding of low alloy steel. Dual Shield 810X-Ni1 is designed for use with 100 percent CO2 and is an excellent choice for welding on CORTEN steel in applications where weathering grade wires are not desirable. Common applications include power transmission, bridges, shipbuilding, railroad cars, barges, light equipment/heavy structural and general fabrication. This wire meets AWS A5.29; E81T1-Ni1C classifications, is certified by C.W.B. – CSA W48 and is certified for seismic applications.

Dual Shield 710X-M is an all-position flux cored wire for general purpose welding of mild steel. Dual Shield 710X-M is designed to be used with a 75/25 Argon/CO2 gas mix, however pure CO2 may also be used. Typical applications include railroad cars, shipbuilding, barges, light equipment, civil construction and general fabrication. Classifications and approvals include AWS A5.20; E71T-1C-D/T-9C-D; AWS A5.20; E71T-1M/T-9M; ASME SFA 5.20; A.B.S., and C.W.B. – CSA W48. This wire is certified for seismic applications.

With more than 100 years of experience, ESAB Welding & Cutting Products is one of the world?s largest and most skilled manufacturers of welding and cutting equipment and welding filler metals. Ensuring customer satisfaction, a wide range of ESAB products carry the 100 percent Satisfaction Guarantee. www.esabx.com

ACCU-PAK® BOXES FOR SUPERARC MIG WIRE
Lincoln Electric?s (Cleveland, OH) 500 and 1,000 lb Accu-Pak® boxes for SuperArc® MIG wire are designed to meet the needs of robotic welding applications for bulk recyclable packaging. The new boxes incorporate forklift-ready, corrugated cardboard mini-pallets on the 500 lb Accu-Pak box and wooden mini-pallets on the 1,000 lb Accu-Pak box. Both Accu-Pak boxes and mini-pallets are 100-percent recyclable to reduce waste and environmental impact.

Accu-Pak boxes are designed for stacking two high for a 50 percent increase in storage space. New side view windows are standard on both boxes to identify low wire levels. SuperArc wires available in the new Accu-Pak 500 and 1,000 lb boxes include L-50, L-56, and L-59. SuperArc LA-90 is available in the 500 lb Accu-Pak box. www.lincolnelectric.com

FLUX-CORED WIRES FOR CHROME-MOLY APPLICATIONS
Hobart Brothers (Troy, OH) introduced a new patent-pending family of flux-cored welding wires designed to provide superior low temperature impacts and improve productivity on chrome-moly welding applications. The new Hobart® FabCO® XTREME B2, XTREME B3 and XTREME 120 wires are the first flux-cored wires of their kind to provide the type of mechanical properties previously attainable only by using slower stick or submerged arc welding processes.

Unlike other welding products with T-5 slag systems, the XTREME wires are designed to operate on DCEN (direct current electrode negative) and offer all-position welding capabilities. In fact, laboratory testing has shown the 3/32-inch diameter B2 wires are cable of welding in the vertical-up position?a feature that is unique to this XTREME product.

The FabCO XTREME B2 and B3 wires are both designed for high temperature service applications requiring high tensile strengths and creep resistance, such as welding boiler and pressure vessel piping, fittings and high temperature valves. The XTREME B2 is designed for use with 1 ¼ Chrome ? ½ Moly steels (P11 piping, for example) and can replace E8018-B2 stick electrodes to increase productivity, while the XTREME B3 deposits a weld chemistry needed for 2¼ Chrome ? 1 Moly steels (P21 and P22 piping) and is speed-enhancing alternative to E8018-B3 electrodes. Both products create low spatter levels and provide an easy-to-remove slag to help minimize post-weld clean up. They also create low hydrogen weld deposits (less than 6 ml per 100 g of weldment) to minimize the chance of weld cracking.

The FabCO XTREME 120 is the only flux-cored wire in the industry to meet DNV Y69MS (H5) for welding on offshore jackup rigs where high strength, excellent impact properties and defect-free welds are critical. It also meets ABS to AWS E121TG-GC H4. The wire?s composition is balanced to produce welds in the 120 to 130 ksi tensile strength range, yield strengths over 105 ksi and Charpy impact properties of 51 ft-lbs at -76 deg F, even when subject to a wide range of heat inputs and cooling rates. Like the B2 and B3 versions, the XTREME 120 wires provide all-position welding capabilities, plus it welds similar to filler metals with T-1 slag systems, making it easier to use. The wire offers a low hydrogen weld deposit of less than 4 ml per 100 g of weldment to defend against cracking, reducing the need for costly rework and helping companies maintain a high level of productivity.

Other applications that can benefit from XTREME 120 wires are high strength crane booms and sub-assemblies, and applications using A514 grade, N25HN, WeldTen 710 or 780, ABS EQ63 or 70, Dillimax 690 or HY100 steels.

Hobart Brothers offers the FabCO XTREME wires in diameters ranging from .045 to 1/16 in diameters and on 33 lb vacuum-packed spools. Diameters and packaging are each product specific. www.hobartbrothers.com

ECO-FRIENDLY BULK PACKAGING FOR AUTOMATED WELDING WIRE
ESAB Welding & Cutting Products (Florence, SC) introduces the EcoCoil, a new economical and eco-friendly bulk package for submerged arc welding wire. Designed for high production applications, the EcoCoil contains 2,200 lb of wire, random-wound in a one-way coil around a cardboard former. All materials are fully recyclable and there is no need to return empty spools or stems.

The wire is wrapped from bottom to top, providing protection from moisture and dust during transport and allowing the overwrap to be partially removed at the top. The bottom stays wrapped for continued protection. PET strips with four lifting eyelets are provided to lift the spool into place. PET strips are safer for workers than steel strips. The upper end of the wire is guided inside the cardboard former for easy material inspection on site.

With more than 100 years of experience, ESAB Welding & Cutting Products is one of the world?s largest and most skilled manufacturers of welding and cutting equipment and welding filler metals. Ensuring customer satisfaction, a wide range of ESAB products carry the 100 percent Satisfaction Guarantee. www.esabna.com

ECO-FRIENDLY STICK PLASTIC TUBES FOR ELECTRODES
Eco-friendly plastic tubes from Lincoln Electric (Cleveland, OH) are made from recycled plastic and are recyclable. These 5 lb tubes help protect electrodes from breakage. The plastic tubes can be used for storage as electrodes are consumed. They feature
a patent-pending design for easy stacking, with large colorful labels that make the stick electrode easy to identify. www.lincolnelectric.com

EVERYTHING YOU NEED TO KNOW ABOUT HARDFACING AND HIGH ALLOYS
Stoody (St. Louis, MO) announces a new in-depth Hardfacing and High Alloy Product Selection Guide that includes its latest alloys, product descriptions, application photos that demonstrate the varied potential uses for the products, and vast amounts of other relevant information.

The guide comes complete with packaging and part number information, and is divided into easy-to-read sections dealing with coated electrodes and bare rods, open-arc and gas-shielded wires, submerged arc wires, and high alloy joining and cladding.

Topics such as metal to metal wear, metal to earth for moderate to severe impact and moderate to severe abrasion, metal to earth for extreme abrasion and low impact, and abrasion accompanied by corrosion and/or high temperatures are all covered.

Stoody® is a global leader in the design and manufacture of hardfacing and joining welding electrodes used to combat various types of wear and corrosion. Its extensive family of products includes iron, nickel, cobalt, tungsten carbide and vanadium carbide based alloys. Some of the major industries Stoody serves are power generation, mining, construction, railroad, steel, foundry, oil and gas production and exploration, as well as the pulp and paper industry. www.thermadyne.com

HIGH EFFICIENCY MIG WIRES IN EXPANDED PACKAGE SIZES
ESAB Welding & Cutting Products (Florence, SC) AristoRod MIG welding wires are designed to be a dependable, high efficiency wire for production applications. AristoRod features a uniquely engineered surface for consistent trouble-free feeding, low contact tip wear, excellent arc start properties, extremely low spatter and an exceptionally stable arc. These properties translate into less downtime and superior weld appearance with minimal post-weld cleaning.

AristoRod is now available in three package sizes to suit a variety of applications: a precision-wound 40 lb spool, a 550 lb Marathon Pac and a 900 lb Marathon Pac with ESAB?s endless drum technology that provides a continuous supply of welding wire to high-production weld cells without halting production to change out empty packages. All packages are available with .035, .045 and .052 diameter wires.

Precision-wound 40 lb spools offer the perfect balance of productivity, ease of handling and portability. These wire spools create a sturdy package that mounts to the feeder?s spindle without cumbersome adapters. Precision winding reduces the occurrence of tangles. All-steel construction allows the spool to be easily recycled along with steel scrap, unlike traditional fiber and plastic spools.

Designed for high-volume and automated welding applications, Marathon Pac uses a special coiling technique that ensures that the wire pays out straight, without cast and helix that can cause arc wander. With Marathon Pac, welds are always well-positioned and perfectly straight. The automatic unwind process eliminates the need for separate de-coiling equipment. Marathon Pacs can be easily recycled, a consideration that becomes continually more important as tougher waste handling restrictions are implemented.

The 900 lb Endless Marathon Pac features a unique design that allows the Pac to be used as a single drum or allows a second drum to be seamlessly connected, providing a continuous supply of welding wire to high-production weld cells. A continuous supply of wire improves arc on time, improving operating efficiency, and reduces rework of parts that are only partially welded as the wire runs out. Endless Marathon Pac operation improves productivity and reduces downtime.

Regardless of the packaging selected, all AristoRod solid wires offer outstanding welding performance a step above conventional bare or copper-coated MIG wires. ESAB?s Advanced Surface Characteristics technology improves feedability and arc stability, resists corrosion during storage and reduces tip wear. AristoRod also offers excellent start properties and consistent trouble-free feeding, making these wires ideal for production applications.

With more than 100 years of experience, ESAB Welding & Cutting Products is one of the world?s largest and most skilled manufacturers of welding and cutting equipment and welding filler metals. Ensuring customer satisfaction, a wide range of ESAB products carry the 100 percent Satisfaction Guarantee. www.esabna.com

LOW-HYDROGEN STICK ELECTRODE FOR HIGHER DEPOSITION RATES AND FASTER TRAVEL SPEEDS
Lincoln Electric (Cleveland, OH) added the Excalibur® 7028 low-hydrogen stick electrode to its premium line of Excalibur mild steel stick electrodes. The 7028 ? designed specifically for structural fabricators working with high depositions in the flat and horizontal positions ? offers the same superior characteristics of the Excalibur line with the enhanced capabilities of higher deposition rates and increased travel speeds.

Smooth, even burn-off, easy re-strikes and a clean weld puddle make Excalibur 7028 the ideal choice for maximum operator appeal. Its excellent arc characteristics give welders the ability to deposit fillet and lap welds without undercutting, while its superior operability makes it easy to repeat high quality, consistent welds.

Impact toughness gives Excalibur 7028 the mechanical properties necessary for a wide range of applications that demand strict weld requirements. This includes ship and bridge structures, storage tanks and general heavy fabrication. It exceeds AWS specifications for impact properties at temperatures well below the required 0 deg F. www.lincolnelectric.com

REVOLUTIONARY NEW METAL-CORED WIRE FOR ROBOTIC WELDING
Hobart Brothers (Troy, OH) has developed a revolutionary new metal-cored welding wire designed to maximize performance and increase productivity on high-volume robotic welding applications, especially those for heavy equipment manufacturing. The new Matrix? wire from the company?s Tri-Mark® brand is a first of its kind in the industry ? a proprietarily manufactured product formulated specifically to provide uncompromised arc starting and wire feeding consistency. The exacting nature of this proprietary manufacturing process ensures that Matrix performs the very same ? time and again ? regardless of the application.

Matrix?s reliable arc starting and excellent wire feedability are the result of a Hobart Brothers? exclusive technology. This special technology has also been shown to extend the life of robotic gun liners and to eliminate buildup at the drive rolls. Combined, each of these features reduces downtime for maintenance and post-weld activities, and ensures greater overall welding productivity. Testing also shows Matrix creates a consistent weld bead shape, offers excellent crack resistance and minimizes silicon island formation. Combined, these attributes make it an excellent choice for heavy equipment and similar manufacturing.

?We are definitely excited about Matrix,? says Steve Barhorst, general manager, heavy equipment division, Hobart Brothers. ?Our engineers closely control and monitor every variable of the manufacturing process, guaranteeing that our customers receive the most consistent and the highest performance robotic welding wire in the marketplace.?

Hobart Brothers created Matrix in response to a growing industry demand for a welding wire that could provide better performance and minimize downtime on robotic welding applications. Field tests have shown the wire offers precise arc starts and smooth wire feeding, along with excellent seam tracking and touch sensing.

Matrix metal-cored wire is available on 33 lb plastic spools that are precision layer wound to support consistent wire feeding, and each spool ships in a heat-sealed, VCI (Vapor Corrosion Inhibitor) impregnated bag to protect against contaminants. Hobart Brothers also offers the Matrix wire in its exclusive 750 lb X-Pak drum. For additional protection, the fiber drum is sealed with a rubber gasket and the inside portion is impregnated with VCI. www.hobartbrothers.com