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7/30/2019 SWR 10056 OK AristoRod Welder Guidebook
1/16
NoN copper-coated solid gmaw wires with
advaNced surace characteristics
Ok AristoRod Non-Copper-Coated Wire
Welder Guidebook
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2
Visit the oK ar and learn why OK AristoRod wires bring
trouble-ree, high productivity welding in robotic, mechanized, or manual operation
supported by unique video animation in 24 languages, scientic data and high
speed arc recording. Discover the quality and productivity benets in detail and
review the ull range o wire types or non- and low-alloyed steels.
.bn./
cnn
inn 2
B Y s wn 3
ContactTipsandGasNozzle 3
Liners 4
GasandWater 4
WireFeedUnit 4
MarathonPac
Installation 5 CheckDriveRollsandWireFeeding 7
ShieldingGas 8
cn t an g Nzz 9
CorrectStick-OutLength 9
GasNozzleDiameter 10
wn p sn 11
HowtoGetanOptimumSetting 11
oK ar - t c rn 13
esaB s a tn
14
http://esabna.com/aristorodhttp://esabna.com/aristorod7/30/2019 SWR 10056 OK AristoRod Welder Guidebook
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inn
OK AristoRod is a amily o non copper-coated GMAW wires with superior welding
perormance. The unique Advanced Surace Characteristics (ASC) increase
perormance and eciency, whether the process is manual, mechanized,
or robotic, helping reduce overall welding costs.
OK AristoRod non-copper-coated wires do not contaminate wire eeders, liners,
torches and contact tips with copper particles. This results in trouble ree eeding,
high process stability, reduced consumption o wear parts, and superior welding
properties.
The unique eatures o OK AristoRod translate into clear user benets which,
together, add up to increased productivity and lower welding costs.
To get the most benet rom using OK AristoRod welding wires, there are someimportant steps to keep in mind, in particular compared to using copper-coated
wires. This guide provides practical step-by-step inormation on how to install and
use OK AristoRod non-copper-coated solid wires.
Bnf
Consistent welding perormance Consistent weld results
Stable arc with low eeding orceHigh weld quality and reduced rework or post weld
cleaning
Excellent arc ignition Reduced post weld cleaning
High current operability Higher productivity
Extremely low spatter level Reduced post weld cleaning
Trouble-ree eedability, even at high wire eed speeds
and long eed distancesHigher productivity, reduced equipment downtime
Low ume emission Cleaner working environment
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B Y s wn
To ully beneft rom the excellent weldability o OK AristoRod GMAW
wires, the welding equipment needs to be maintained in good condition.
The ollowing checklist serves as a guide.
cn t an g Nzz
Remove spatter and replace worn or
damaged contact tip.
For the best welding performance and
longest tip life, ESAB contact tips are
recommended for use with
OK AristoRod wires.
Grind the end of the liner conical for
optimal fitting of the contact tip.
Ensure that the contact tip is the correct
size and fits tightly.
Ensure the gas nozzle is free from
spatter.
correct incorrect
For contact tip sizes and packages, please contact ESAB or your local Distributor.
7/30/2019 SWR 10056 OK AristoRod Welder Guidebook
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B Y s wn
ln
Spiral steel liners are recommended.
Never use liners which have been
used for copper-coated wires.
Copper residuals may stick onto the
OK AristoRod wire and deteriorate itsexcellent wire feeding.
Ensure that the liner has the correct
inner diameter for the wire size to be
used.
Check liners regularly for kinks and
excessive wear and replace when
needed.
Clean liners regularly using compressed
air, removing the contact tip first.
g n w
Check gas and water connectionsfor leaks.
Check that the water cooler is filled and
that the pump is operating effectively.
w un
Position wire guide tubes as close aspossible to the rollers to prevent kinking
of the wire.
A substantial amount of fine metallic
shavings underneath the drive rolls
indicates misalignment.
Correct
Incorrect
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Special cone for Jumbo Marathon Pac with1050 lbs (475 kg) non- or low-alloyed wire.
ESAB's Marathon Pac is the most
advanced bulk wire packaging system
available to abricators. The complete
Marathon Pac amily consists o
(rom let to right):
Endless Marathon Pac
Mini Marathon Pac
Standard Marathon Pac
Jumbo Marathon Pac
B Y s wn
The Marathon Pac is accompanied by
a ull range o accessories or ecient
internal transport and handling and easy
installation.
Always make sure ESAB original
Marathon Pac accessories* are used
or best perormance.
*For a complete list of Marathon Pac
accessories, contact ESAB.
Use the Marathon Paclifting yoke to handle thedrum safely and to avoid damage to the drumor wire.
mn p inn
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7
Step 6. Attach the wire conduit to the wire feeder.Avoid liner bends or point pressure on the liner.
Step 1. Remove the rubber strap and VCI paper.
Step 4. Place the carton or plastic lid (Standardand Mini Marathon Pac) or cone (JumboMarathon Pac) on top of the Marathon Pac.
Step 2. Place the wire conduit attachment orspider on top of the Marathon Pac.
Step 5. Attach the wire conduit to the lid or conewith the quick connector.
Step 3. Feed the welding wire through the centreof the spider.
B Y s wn
mn p inn
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ck d r an w n
Use drive rolls with smooth, double
V-grooves. U-shaped grooves or knurled
rolls may damage the welding wire
surface.
Check that the groove size is correct for
the wire diameter.
Apply the correct pressure on feed rolls.
Too much pressure flattens the wire,
resulting in feeding problems and higher
liner and contact tip wear. Insufficient
pressure may cause wire to slip in the
feed rolls, resulting in irregular feeding
and possible wire burnback.
A good approach is to set the roll
pressure so it is possible to stop a bent
wire at the gas nozzle by applying light
pressure.
Check that the wire is feeding correctly
from the contact tip.
Never use felt pads or liquids to clean
the wire surface. This may damage
the advanced surface condition of
OK AristoRod wires.
B Y s wn
Smooth Knurled
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9
sn g
Check that the appropriate gas is used.
Adjust gas flow rate to between 0.5-0.7
cfm (15-20 l/min) or according to gas
nozzle size.
Check the gas flow rate again if the gas
nozzle diameter is changed. Always
check the gas flow on the gas nozzle
as well.
B Y s wn
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cn t n g Nzz
It is essential to t the gas nozzle and
contact tip at the right distance relative
to each other. The ideal distance o the
contact tip is 0.080 in. (2 mm) recessed.
A longer distance will orce the welder to
use too long a stick-out, resulting in poorweldability. This may lead to lack o usion,
particularly in narrow joints. Contact tips
protruding beyond the gas nozzle can
result in insucient gas shielding.
c sk-o ln
The stick-out is the distance between the
contact tip and workpiece and must be
kept between 1/2 in. and 3/4 in. (12 and
20 mm ) 0.040 in. and 0.047 in. ( 1.0
and 1.2 mm). Excessive stick-out results
in too short an arc length, larger droplets,
an unstable arc and spatter leading to poor
weldability. Additionally, it may reduce the
gas protection which can lead to porosity.
When welding in spray arc with too short o
a stick-out, the arc length can become too
long. The weldpool will get hotter and more
dicult to control.
Incorrect. Contact tip too recessed.
Incorrect. Contact tip protruding beyondgas nozzle.
2 mm
Correct positioning of contact tip.
1/2 - 3/4 in. (12-20 mm)
Ideal stick-out for wire diameters 0.040and 0.047 in. (1.0 and 1.2 mm.).
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cn t n g Nzz
g Nzz d
Various nozzle diameters must be available
to allow adequate access to the joint, to
maintain the above recommended stick-
out, and to ensure proper shielding gas
protection. Small diameter gas nozzles
are used or the rst layers only. Revert to
the standard gas nozzle diameter when
access to the weld joint allows, so ull
gas protection can be assured.
Incorrect. Use of standard gas nozzlerestricts access to narrow joints, resultingin too long a stick-out.
Correct. Use a smaller diameter nozzle ora conical nozzle for the 1st layers in theroot area.
Correct. Use of standard gas nozzle forcompleting the joint ensures good gasprotection and correct stick-out.
When welding in short arc transer, the arc stability and start properties will improve
when reducing the stick-out.
1/2 - 3/4 in. (12-20 mm)
> 3/4 in. (> 20 mm)
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Incorrect. Arc length too long. Arc becomestoo wide, with insufficient penetration. Also arisk of burnback to the contact tip. This maybe caused by the arc voltage being too high,the wire feed speed too low or the stick-outbeing too short.
Use positive polarity or OK AristoRod
solid welding wires. A given welding current
requires a specic arc voltage or optimum
weldability. The welding current is set by
adjusting the wire eed speed control. The
arc voltage is regulated by the open circuit
voltage (OCV) setting o the power source.
h g n o sn
For the ollowing procedure, it is critically
important to keep the stick-out constant
within the correct range or each welding
position.
Select a welding current which suits your
application from the graph on page 12.
Start welding with the lowest voltage
value from the given range. This may
result in stubbing, however wireburnback will be avoided.
Increase the arc voltage in steps of 1
or 2 V until the arc becomes stable,
smooth and spatter free, with a slightly
crackling sound. Ensure the correct
stick-out length is maintained.
wn p sn
Correct. Correct arc length. Stable andconcentrated arc with a quiet spray droplettransfer.
Incorrect. Arc length too short. Wire dipsinto weld pool (stubbing) caused by too lowan arc voltage, too high a wire speed or toolong of a stick-out.
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wn p sn
Note: As mentioned, stick-out control is very important. I the recommended
stick-out length is not constantly maintained, weldability will fuctuate. Shortening
the stick-out will result in an increasing current and a longer arc. Lengthening thestick-out will result in a lower current and the arc being too short.
Due to OK AristoRods Advanced
Surface Characteristics (ASC) the
optimal voltage is typically 5-10%
higher than with a copper-coated
wire at the same arc length.
If a different current is required,
i.e change of welding position, the
procedure described on the previous
page needs to be repeated.
50
38
36
34
32
30
28
26
24
2220
18
16
14
12
100 150 200 250 300 350 400
3
3
2
2
4
4
1
1Welding in short arc area. Use for thin plate, tack welding
or positional welding.
When arc length is tooshort increase voltage.
When arc length is too
long decrease voltage.
Welding in spray arc transfer. High productivity,
thick plate, downhand welding, low spatter.
Excessive weld metal. Dicult to control.
Welding in globular area. Unstable arc and excessive spatter.
Try to avoid.
Amperage
Voltage
OK AristorodTM
0.040 in.
(1.0 mm)
0.047 in.
1.2 mm
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oK ar - t c rn
aws n eN cfn
oK
ar
cfn
wcfn w n w m sn g
s
ty
aws eN-iso eN-iso 14175
a5.18 a5.28 14341-a 16834-a 21952-a /-B m21 c1
12.50 ER70S-6 G3Si1 G 42 4 G 38 2Normal
strength
12.57 ER70S-3 G2Si G 38 3 G 35 2Normal
strength
12.62 ER70S-2 G2Ti G 46 4 G 42 3Normal
strength
12.63 ER70S-6 G4Si1 G 46 4 G 42 2Normal
strength
12.65 ER70S-6 G4Si1 G 46 4 G 42 2
Normal
strength
13.08 ER80S-D2 G4Mo G 50 4 G 46 0Creep
resistant
13.09 ER80S-G G2MoG MoSi /
G 1M3G 46 2 G 38 0
Creep
resistant
13.12 ER80S-GG CrMo1Si /
G 55M 1CM3
Creep
resistant
13.16 ER80S-B2 Z CrMo1Si /G 55A 1CM
Creepresistant
13.22 ER90S-GG CrMo2Si /
G 62M 2C1M3
Creep
resistant
13.26 ER80S-G G Z 3Ni1Cu G 46 4 G 42 0Weather
resistant
55 (13.13) ER100S-G G Mn3NiCrMo G 55 4High
strength
69 (13.29) ER110S-G G Mn3Ni1CrMo G 69 4High
strength
79 (13.31) ER120S-G G Mn4Ni2CrMo G 79 4High
strength
89 (1B96) ER120S-G G Mn4Ni2CrMo G 89 4High
strength
7/30/2019 SWR 10056 OK AristoRod Welder Guidebook
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s a tn
Swit Arc Transer is a high productivity
GMAW process using OK AristoRod
non-copper coated welding wires at
very high wire eed speeds. The SAT
process produces fat welds with good
penetration and no undercut.
t y .
ESABs Aristo U82
robotic package
enables SAT welding. It is a complete
set o welding consumables and
equipment, based on ESABs latest
digital power source technology.
The package consists o:
The Aristo MIG 5000i inverter power
source or ESAB's MIG 4002c, 5002c
and 6502c chopper power sources.
The AristoU82
control unit with SAT
synergic lines or The Aristo U82
interface for different robot brands.
The Robofeed 3004w ELP
encapsulated wire feeder with up to
98.4 ipm (30 m/min) wire feed speed.
Cable packages.
The Marathon Pac bulk wire drum
with robot quality welding wire and
optional bobbin holder.
SATTM
Sh
ort
arc
Mix
ed
arc
Spray
arc
Forced short arc
Wire feed speed (m/min)
Arcvoltage
Rotating
arc
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iNd us acebook.com/esabna twitter.com/esabna youtube.com/esabweb
SWR-10056
11/2012
TheESAB
groupis
certifed
accordingto
ISO14001&
OHSAS18001
Unrivaled Service and SupportEvery ESAB product is backed by our commitment to superior customer service and support.Our skilled customer service department is prepared to quickly answer any questions,
address problems, and help with maintenance and upgrading o your
equipment. Our products are backed with the most comprehensive
warranty in the business.
With ESAB, you can be sure that you purchased equipment that will meet your needs
today and in the uture. Product and process training is also available.
Ask your ESAB sales representative or distributor or a complete ESAB solution.
usa:P.O. Box 100545, 411 South Ebenezer Road, Florence, SC 29501-0545
cn:6010 Tomken Road, Mississauga, Ontario L5T-1X9
mx: Ave. Diego Daz de Berlanga No. 130, Col. Nogalar San Nicols
de los Garza N.L. CP 66480 Monterrey, Mexico
esaB wn & cn p/bn./1.800.esaB.123
NOTICE:
Test results described above were obtained under controlled laboratory conditions, and are
not guarantees or use in the eld. Actual use o the product may produce varying results due
to conditions and welding techniques over which ESAB has no control, including but not
limited to plate chemistry, weldment design, abrication methods, wire size, welding procedure,service requirements and the environment. The User should conrm by qualication testing,
or other appropriate means, the suitability o any welding consumable and procedure beore
use in the intended application.
CAUTION:
Users should be thoroughly amiliar with the saety precautions reerenced in the product label
or the relevant product and the Saety Data Sheet or the product. Saety Data Sheets are
available at www.esabna.com or by calling 1-800-ESAB-123.