1. The Function and Application of Welding Manipulator with Strip Surfacing:
1) Usage: 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 Wuxi JACK LHZ5050 model Strap Cladding Welding Column & Boom please check below photo:
Close view on finished seam of SAW hard facing from Wuxi JACK LHZ machine: (Fig.1)
3) Application Form: 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) Feature of the Welding: 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 (Electroslag welding), equipped with the SAW or ESW welding power source to related welding machine tool, but with different welding head for replacement:
Strip cladding welding head equipped in Wuxi JACK exported to East European country LHZ5050 welding equipment: (Fig.2)
3) Please check attached and the above small pictures: 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 conventional SAW welding system;
4) Such Strip Cladding Welding Manipulator can deliver deposition layer with 0.3~0.5mm thickness, on the surface of finished workpiece;
5) Welding Power Supply Supplier: The most often used strip cladding system by Wuxi JACK for the LHZ series strip cladding welding manipulating machine 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 welding 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) Where Used: 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) Electrode: The steel strip being 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 period, an electric arc is generated between the steel strip and workpiece in the process of working;
c) Welding flux is used to form a molten slag to protect the welding pool from the atmosphere surrounding the automatic welding machine tools group, and helps to form a smooth weld bead surface, on the workpieces;
3) ESW Strip Cladding Cross Slide Column and Boom:
a) This is upgrade model of the previously discussed SAW Strip Cladding Welding Manipulator, with advantages of better quality and higher deposition rate process;
b) ESW is a no arc method utilizing ohmic heating to melt strip/ welding 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 conventional SAW type welding mode, 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 the welding equipment equipped with SAW type welding mode, under the condition of same heat input with significantly higher deposition rate;
4) Both SAW and ESW can be applied either individually, or integrally in the LHZ series Strip Cladding Welding Column and Boom, depending on practical condition of customers.
4. Technical Specifications of SAW Strip Surfacing System Example Adopted in LHZ Strip Cladding Welding Manipulator:
The attached pictures show a group of LHZ5050 Automatic Welding Center Wuxi JACK exported to Russia in the year 2015, for a customer of pressure vessel industry. In this high precision manipulator welding machine with strip cladding,
1) Welding power equipped in the equipment is Sweden ESAB, LAF1601 model;
2) Welding wire feeder is Sweden ESAB, with technical specifications of: A6S twin wire ratio 156:1;
3) Strip cladding welding head installed on the front end of horizontal boom is 30-100mm A6;
4) Horizontal Boom back and forth working speed, or welding velocity of the Welding Manipulator is 120～1200mm/min;
5) Workpiece diameter range fitting is in the scope of: Φ1000～ Φ4500mm;
6) Horizontal Boom back and forth movement transmission gear and rack.
