1. The Function and Application of Welding Manipulator with Strip Surfacing:
1) The Welding Manipulator with Strip Surfacing is for making strip surfacing, or called strip cladding on the surface of cylindrical parts. The similar equipment available is “High Precision Roller Strap Cladding Machine for Cylinder”;
2) Formed strip surfacing welding seam produced from LHZ Strap Cladding Welding Column & Boom please check below photo: (Fig.1)
3) Put into practice, the Strip Cladding Cross Slide Column and Boom need to work together with Anti-Drifting Welding Rotator, and light duty Welding Positioner, to form up dedicated purpose Automatic Welding Center.
2. The Purpose and Working Element of Strip Cladding System in Welding Column and Boom with Strip Surfacing:
1) With the other name of built-up welding, strip cladding is for welding and forming a layer of wear resistant, or anticorrosive coating on the surface of barrel workpieces in the Automatic Welding Center;
2) Strap cladding is on the basis of SAW (submerged arc welding), or ESW(Electro-slag welding), equipped with the SAW or ESW welding power source to the Welding Manipulator, but with different welding head for replacement: (Fig.2)
3) Please check attached and the above small picture: A strip cladding head and steel strip of 50mm width is fit on the Strip Cladding Welding Column and Boom, in substitutes of conventional welding torch and wire in SAW Welding Column & Boom;
4) Such Strip Cladding Welding Manipulator can deliver deposition layer with 0.3~0.5mm thickness, on the surface of workpiece;
5) The most often used strip cladding system by Wuxi JACK for the LHZ series Strip Cladding Welding Manipulator is from world class ESAB. Please check attached pictures.
3. Working Features of Strip Cladding Welding Column & Boom:
1) Process Technology in the Strip Cladding High Precision Welding Manipulator:
a) The technology that is used in Automatic Welding Center, for cladding larger areas are strip cladding by submerged arc welding (SAW) or by electroslag welding (ESW). Both methods offer a high deposition rate, from perspective of both kg/h and area coverage m2/h., together with shallow penetration and high deposit quality produced from the Welding Manipulator;
b) Stainless steel strip cladding Automatic Welding Center is widely used, in the production facilities of chemical, petrochemical, and nuclear industries;
2) SAW Strip Cladding Automatic Welding Center:
a) The steel strip adopted in Strip Cladding Welding Manipulator, normally has dimensions of (50~60mm) width x(0.3~0.5mm) thickness, is used as electrode;
b) During work of the Strip Cladding Cross Slide Column and Boom, an electric arc is generated between the steel strip and workpiece in the process of working;
c) Flux is used to form a molten slag to protect the weld pool from the atmosphere surrounding the Automatic Welding Center, and helps to form a smooth weld bead surface, on the workpieces of Welding Column and Boom with Strip Surfacing;
3) ESW Strip Cladding Cross Slide Column and Boom:
a) This is upgrade model of SAW Strip Cladding Welding Manipulator, with advantages of better quality and higher deposition rate process;
b) ESW is an arc-less method utilizing ohmic heating to melt strip/flux/parent material. The heating is a result of current flowing through the strip electrode, and a comparatively shallow layer of liquid electro-conductive slag generated on the Welding Column and Boom;
c) The penetration is lower for ESW Automatic Welding Center, than for SAW Automatic Welding Center, since the molten slag pool is used to melt the strip and part of the parent material, instead of serving as an arc between the strip electrode and parent material;
d) As a rule of thumb, ESW Welding Manipulator reduces dilution up to 50% compared with SAW Welding Manipulator, under the condition of same heat input with significantly higher deposition rate;
4) Both SAW and ESW can be applied in the LHZ series Strip Cladding Welding Column and Boom, depending on practical condition of customers.
4. Example of SAW Strip Surfacing System Used in LHZ Strip Cladding Welding Manipulator:
The attached pictures show a group of LHZ5050 Automatic Welding Center Wuxi JACK exported to Russia, for a customer of pressure vessel industry. In this High Precision Welding Manipulator with strip cladding,
1) Welding power equipped in the Welding Column & Boom is ESAB LAF1601;
2) Wire feeder is ESAB A6S twin wire ratio 156:1;
3) Strip cladding head installed on the front end of boom in the Welding Manipulator is 30-100mm A6;
4) Boom horizontal working speed, or welding velocity of the Welding Manipulator is 120～1200mm/min;
5) Workpiece diameter range fitting for the Cross Slide Column and Boom is 1000～4500mm;
6) Boom horizontal travel transmission in the Strip Cladding Welding Column and Boom is gear and rack;
For this set of LHZ5050 high precision Welding Column and Boom with Strip Surfacing.
