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Proven in Europe, a complete line of Pipeweld filler metals now available in North America.
Annapolis Junction, Md. – ESAB Welding & Cutting Products has launched its Pipeweld series of filler metals with formulations that have been specifically tailored for welding X52 to X100 grade pipe. They include cellulosic electrodes, low-hydrogen vertical up and vertical down electrodes, solid wires, gas-shielded flux-cored wires, and submerged arc welding fluxes.
“The ESAB series of Pipeweld products was designed by pipeline welders, for pipeline welders,” says Gordon Eadie, Global Pipeline Segment Manager, ESAB. “They deliver excellent mechanical properties and outstanding operator appeal. We also use field-friendly vacuum-sealed packaging on our low-hydrogen electrodes that guarantee the electrodes will remain dry until the package is opened.”
ESAB will demonstrate select Pipeweld filler metals in booth B17087 at FABTECH 2019, held at Chicago’s McCormick Place Nov. 11 – 14. The demonstration will also feature the new Pipeweld Orbiter, a mechanized welding system that can lower cost-per-joint by 40 percent and complete tie-in welds 50 percent faster by using the flux-cored process for fill and cap passes.
ESAB experts at FABTECH will also discuss the benefits of shifting from the pipeline industry’s standard “2-run” procedure to a “3-run” procedure. The 2-run procedure uses cellulosic electrodes for the root and hot passes, then a rutile flux-cored wire directly after. This method often causes issues with gas pops or blowholes coming from the cellulose layer underneath the first flux-cored fill pass. Deep grinding can overcome this problem (but not entirely), plus it is time-consuming and wastes filler metal.
The 3-run procedure also starts with a cellulosic root and hot pass but then uses a Pipeweld DH basic Stick electrode for a vertical down first fill pass. This avoids heavy grinding and leaves a clean basis for the flux-cored process without the need for any treatment other than slag removal. Filling continues with Pipeweld T-1 flux-cored wires, which were specially formulated for mechanized pipe welding. The 3-run procedure was developed for tie-in welds, but its productivity (up to 9 lbs. per hour deposition rate) and high weld acceptance rate may also make it suitable for mainline work.
Extremely welder friendly, Pipeweld low-hydrogen flux-cored wires are designed for applications involving the welding of pipe and pipe components with impact toughness requirements down to -60°C (-76°F). They include Pipeweld 71T-1, Pipeweld 91T-1, Pipeweld 101T-1 and Pipeweld 111T-1. Operating in the spray arc mode, Pipeweld flux cored wires make it easy to obtain flat welds with good penetration and smooth wetting onto the pipe edges. Brittle slag is easily removed, and typical positional welding defects are avoided, such as a lack of fusion and slag inclusions. The wires also have a good tolerance to less-than-ideal fit-up, a common issue during field fabrication.
Pipeweld cellulosic electrodes produce high-integrity welds and excellent mechanical properties on pipeline steels up to X80. With a range of products designed for both vertical up and down positions, Pipeweld cellulosic electrodes deliver excellent performance for root pass and fill welds. Products include Pipeweld 6010P, Pipeweld 6010 Plus, Pipeweld 7010 Plus, Pipeweld 8010 Plus, and Pipeweld 9010 Plus.
Pipeweld Plus electrodes have a more constricted arc and are commonly used for the root pass where operators want a faster-freezing puddle. Pipeweld 6010P allows for a more fluid weld bead, which improves side-wall fusion and wet-out during fill and cap passes.
ESAB Pipeweld 7016, Pipeweld 8016 and Pipeweld 10018 basic low-hydrogen Stick electrodes offer good penetration during vertical up welding and can be used for the root, fill, and cap passes (including weaving). They provide high weld metal strength and impressive low-temperature toughness and can be used for pipe steel grades up to X80. Pipeweld 10018 can be used on X80 (strain-based) and X100 pipes.
ESAB Pipeweld 80 DH, Pipeweld 90 DH and Pipeweld 100 DH are designed for vertical down welding. Pipeweld DH electrodes feature patented technology that offers consistently perfect starts, higher current density, and greater weld penetration. Unlike other electrodes with a conical start end, the coating of Pipeweld DH products does not easily chip off. All Pipeweld DH electrodes carry the H4R designation, indicating less than 4 ml of diffusible hydrogen per 100 g of the deposited weld.
ESAB Pipeweld 70S-6, Pipeweld ER70S 6 PLUS (copper-free) and Pipeweld 100 S wires are suitable for a variety of pipe applications. These products feature a controlled wire surface condition and produce consistently high mechanical properties of welds. For even higher productivity, improved weld quality and cleaner work environment, Pipeweld Plus is a non-copper-coated solid wire with advanced surface characteristics (ASC) that prevents contamination of wire feeders, liners, torches, and contact tips.
Pipeweld 78LH flux is a low-hydrogen and moisture resistant agglomerated, basic flux, specifically designed for multi-wire welding of line pipe steel grades like X70 and X80. It can be used in the production of spiral or longitudinal welded line pipe. The flux adds some Si and Mn to the weld metal, and it works equally well on DC and AC current. Pipeweld 78LH flux produces welded joints with minimal reinforcement, low transition angles, and a smooth surface finish even at high welding speeds. A proper reinforcement means cost savings in the later pipe coating operation since the coating thickness can be reduced. With different wires, it is suitable for all mild and high-strength pipeline steels.
ESAB Welding & Cutting Products is a recognized leader in the welding and cutting industry. From time-honored processes in welding and cutting to revolutionary technologies in welding and cutting automation, ESAB’s filler metals, equipment, and accessories bring solutions to customers around the globe. For more information contact us.