Enhanced Surface Tension Transfer for Pipe Welding

Harry Sadler
Manager Military and Shipbuilding Sales

Customer Assistance Policy

The business of The Lincoln Electric Company is manufacturing and selling
high quality welding equipment and consumables, and cutting equipment. Our
challenge is to meet the needs of our customers and to exceed their
expectations. On occasion, purchasers may ask Lincoln Electric for advice or
information about their use of our products. We respond to our customers
based on the best information in our possession at that time. Lincoln Electric
is not in a position to warrant or guarantee such advice, and assumes no
liability, with respect to such information or advice. We expressly disclaim any
warranty of any kind, including any warranty of fitness for any customers
particular purpose, with respect to such information or advice. As a matter of
practical consideration, we also cannot assume any responsibility for updating
or correcting any such information or advice once it has been given, nor does
the provision of information or advice create, expand or alter any warranty with
respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of
specific products sold by Lincoln Electric is solely within the control of, and
remains the sole responsibility of, the customer.

Conventional Short Circuit Transfer

Traditional Short Circuit Transfer

click on picture to run video

STT Process
Research Began
July,1985
Purpose
Develop a semi - automatic short
circuiting welding process which
eliminates spatter when using 100%
CO2 shielding gas.

STT Process
Working Prototype
January,1987
Major Achievements
Reduced spatter in 100% CO2
Developed capability to use larger
diameter electrodes
Reduced fumes
Ability to control the welding current
independent of the wire feed speed.

STT Process
Working Prototype
January,1987
Results
The spatter reduction feature of the
technology also produced a very stable
arc, especially at low currents. This is a
big advantage when welding the open
root on pipe in the 5G position

STT Process
STT Welding Arc

STT Process

Background current
Arc current level prior to shorting to the
weld pool.
Contributes to the overall heat input
Keeps arc lit

STT Process

10

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

STT Process

11

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.

STT Process

12

Second Current Reduction

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

STT Process

13

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

STT Process

14

Tailout
Current is reduced from peak
to background level
Reduces agitation of the weld puddle
This control is a coarse heat control

Surface Tension Transfer

15

STT Process

High speed video of

arc

STT

click on picture to run video

16

STT Process

High speed video of

arc

click on picture to run video

17

STT

STT Process
Sheet Metal Welding With STT

Traditional CV
Short Arc Welding

Welding with STT

18

STT Process
Commercial System
Introduced at Essen
1993
Process Requires

19

Current and Voltage Sensing

High Speed Switching System
Rapid Control of Output
Rapid Response Power Source

Basic Transformer Design

Reactor
Selects Output
Welding Current

20

Inductance Coil
Smoothes / Filters
DC Output

Transformer

Bridge Rectifier

Single Phase Input

High Volts
High Amps
Low Amps
Low Volts

Changes AC to DC

Inverter Technology

DC - Smooth
Low Voltage
High Amperage

DC - Smooth AC - 20,000+ Hz
High Voltage
High Voltage
Low Amperage Low Amperage

AC - 50/60 Hz
DC - Rippled
High Voltage
High Voltage
Low Amperage Low Amperage

21

AC - 20,000+ Hz DC - Rippled
Low Voltage
Low Voltage
High Amperage High Amperage

Analog Power Source with Analog Feeder

22

Digital Power Source and Digital Feeder,

Software Controlled

23

Build it Yourself

24

STT Process, Analog Control

Controls
Wire feed speed
Adjusts deposition rate
Peak Current
Controls the arc length
Background Current
Fine heat input control
Tailout
Coarse heat input control
Hot Start
Controls the starting heat

25

STT Process, Non-Synergic Digital Control

26

Controls
Wire feed speed
Adjusts deposition rate
Peak Current
Controls the arc length
Background Current
Fine heat input control
Tailout
Coarse heat input control
Hot Start
Controls the starting heat
Start/End Options
Preflow, Run-in, Start Time,
Crater, Burnback, Postflow

STT Process, Synergic Digital Control

Controls
Wire feed speed
Adjusts deposition rate
Trim
Adjust ball size and arc energy
Weld Mode/Arc Control
Dynamically modifies Hot Start,
Peak, Background, and Tailout
Current
Start/End Options
Preflow, Run-in, Start Time,
Crater, Burnback, Postflow

27

STT Process
STT open root (viewed from inside
of pipe)

click on picture to run video

28

STT Process
Open Root Welding With STT
Benefits
Welded open root
ligament or
thickness is large
~ 0.22 (5.6mm)
Large ligament
eliminates burn
0.22
(5.6mm) through on next
weld pass.

29

STT on Pipe

30

With Good Root Fusion

31

STT Process
Process Advantages
STT Replacing TIG
4 Times Faster
Vertical Down Welding
Possible
Consistent X-ray Quality
Welds
Shorter Training Time
Welds Stainless, Nickel
Alloys and Mild Steel
100% CO2 (on mild steel)
Various gas mixtures
32

STT Replacing Short-arc

No Lack of Fusion
Good Puddle Control
Consistent X-ray Quality Welds
Shorter Training Time
Low Fume Generation & Spatter
100% CO2 (on mild steel)
Various gas mixtures

STT Process
Open Root Welding With STT

Single-sided
welding

33

STT Process
Open Root Welding With STT

34

PROCESS CERTIFICATION

STT Process
STT process may
be used in the
following variants
of pipe welding:
Root pass & basic
coated electrode
for other passes
Root pass, semiauto welding with
Innershield for
other passes
For root, fill & cap
passes of pipe up
to 10 mm wall
thickness
35

Dual Process Capabilities

Optimize Quality and Productivity by allowing
process changes in same station

36

U.S. Based Organizations with PUBLISHED Rules

for qualification of Short Circuit Transfer Modes

37

American Welding Society

American Bureau of Shipping
American Society of Mechanical Engineers
American Petroleum Institute
Any other code that references ASME SEC IX for
Procedure and Operator Qualification

Welding Cost Analysis, Assumptions

Labor and Overhead--$70/hr
Operating Factors
GTAW35%
SMAW30%
STT40%
FCAW35%
GTAW Root Pass at 1.7 ipm
SMAW Root Pass at 4.4 ipm
STT Root Pass at 5.5 ipm
Same Net Material Costs
38

Eight Inch Schedule 40 A106B Pipe, 5G

Position
Process

Time at 100%

Time at
Operating
Factor

Net Labor Cost

per Joint

GTAW Root,
Fill, and Cap

54.35 Minutes

155.3 Minutes

$181.18

GTAW Root,
Balance
SMAW

36.2 Minutes

113.7 Minutes

$132.65

46.9 Minutes

$54.72

STT Root,
17.0 Minutes
Balance FCAW

39