Cor-A-Rosta Pulse: Customized Welding Mode For Stainless Flux Cored Wires


In today’s world of increased competitiveness and high pressure on manufacturers to reduce costs, using flux cored wires for your welding jobs can provide competitive edge.

Main advantages of Cor-a-Rosta flux cored wires while welding with on standard CV mode are:
- cost savings comparing to SMAW and GMAW CV and Pulse,
- short training time,
- improved quality of welds,
- very good weld appearance and regularity.

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Development of modern types of power sources has created new possibilities. Precise control of current, voltage and power waveforms, as well as invertor based power sources have completely changed welding reality and are responsible for dynamic growth of GMAW processes. As a consequence growing interest in application of pulsed welding modes for cored wires is observed and expected by the industry. Whereas design of pulse modes for cored wires requires wider approach:

- analysis of flux formula and metal/flux ratio,
- other melting pattern than for solid wire,
- unique pulse shape designed for individual grade of cored wire.

Pulse welding modes have been successfully applied for metal cored wires and are carefully studied for rutile types.

 

Taking a look at a particular properties of austenitic stainless steels (electrical resistance, melting temperature), Cor-a-Rosta flux cored wires are the best candidates for welding with special modes. In case of cored wires, such modes are individually designed for specific type of wire, including fill ratio, and strongly depend on the type of power source. Shape of pulse signal is always fixed for specific type, grade and manufacturer of cored wire for a given type of power source. Cor-a-Rosta Pulse for Speedtec 405/505 SP applied for 304, 316 and 309 grades offers advantage over CV welding and guaranties metallurgical properties of molten metal.

 


 Typical industrial practises refer to classic FCAW torch angles and welding techniques. Suggested starting parameters for fillet welds on 6-12mm plates:
- 1F/PB: mode 92, WFS=12m/min, Trim*=1,05, U=29V, I= 225A,

- 3Fup/PF: WFS=9m/min, Trim=1,00, U=24-24,5V, I=160A.

Lincoln Electric customized pulse mode for Cor-A- Rosta standard austenitic grades:
- helps to minimize Heat Input distortions,
- produces welds with exceptional regularity and bead appearance,
- works with standard Ar/CO2 shielding gas on multiprocess Speedtec SP inverter power sources,
- offers higher deposition rate and welding speed for all welding positions


Deposition rate in 3Fup/PF welding. Fillet weld a4-5 (throat size), plate thickness 10-15mm. Speedtec 405 SP + PF46.



- generates savings by reduction of total welding cost


 Reduction of welding cost by the application of Cor-A-Rosta Pulse in PB/1F position at the same welding current and voltage. Speedtec 405 SP + PF46.
Cor-A-Rosta 316L, CaR Pulse #92: WFS=12m/min; Trim=1,05; U=29V; I= 225A; TS=6,15mm/s
Cor-A-Rosta 316L, CV mode: WFS=10m/min; U=29V; I= 230A; TS=5,15mm/s

 

Cor-a-Rosta wires are available in the most common stainless steel grades and the increased productivity is the main factor explaining their successful application in general fabrication, production of food and brewery equipment, petrochemical and chemical industry, offshore, oil and gas or civil architectural constructions. Typical packaging systems are 5kg and 15kg vacuum sealed S200 and S300 coils.

*Trim controls the arc length


See more details:
Speedtec 505SP
Digital wire feeders
Cor-A-Rosta wires