Alles wat je moet weten over het lassen met ESAB's Aristorod lasdraden. Voordelen, tips & tricks, how-to, etc. Meer info: www.esab.com/aristorod

1. Welder Guide Book
OK AristoRod™
NON COPPER-COATED SOLID MAG WIRES
WITH ADVANCED SURFACE CHARACTERISTICS
STRENGTH THROUGH COOPERATION

2. Contents
Introduction3
Before you start welding - checklist
4
• Contact tip and gas nozzle
4
Contact tip size, liner size and wire diameter
•
4
• Liner
5
• Gas and water
5
• Wire feed unit
5
• ESAB Marathon Pac™ installation
6
• Drive rolls and wire feeding
8
• Shielding gas
9
Contact tip and gas nozzle
10
Welding parameter setting
12
14
OK AristoRodTM product range
SATTM process
15
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robotised, mechanised or manual operation supported by unique video
animation in 24 languages, scientific data and high speed arc recording.
It discusses quality and productivity benefits in detail and reviews the full
range of wire types for non- and low-alloyed steels.
www.esab.com/aristorod
2

3. Introduction
OK AristoRod™ is a family of non copper-coated MAG wires with
superior welding performance. OK AristoRod™ unique Advanced
Surface Characteristics (ASC) gives the user higher performance and
efficiency no matter if it is manual, mechanised or robotic MAG
welding. OK AristoRod™ therefore has a positive impact on reducing
overall welding costs. ESAB's unique ASC has enabled the creation of
a family of non-copper-coated wires which do not contaminate wire
feeders, liners, torches and contact tips with copper particles. This
results in trouble free feeding, a high process stability, reduced
consumption of wear parts and superior welding properties.
ESAB OK AristoRod™ has a number of unique features. These
translate into clear end user benefits which, together, add up to
increased productivity and lower welding costs.
Feature
Consistent welding
performance
Benefit
Consistent weld results
Stable arc with low feeding
force
Excellent arc ignition
High weld quality. Reduced
rework or post weld cleaning
High current operability
Higher productivity
Extremely low spatter level
Reduced post weld cleaning
Reduced post weld cleaning
Trouble-free feedability, even Higher productivity, reduced
at high wire feed speeds and equipment downtime
long feed distances
Low fume emission
Cleaner working environment
In order to benefit the most from using AristoRod™ MAG wires,
there are some important steps to keep in mind, in particular
compared to using copper-coated wires. This guide provides
practical step-by-step information on how to install and use of
AristoRod™ non copper-coated solid wires.
3

4. Before you start welding
To fully benefit from the excellent weldability of OK AristoRod™
MAG wires, the welding equipment needs to be maintained in
good condition. The following checklist serves as a guide.
CHECKLIST
Contact tips and gas nozzle
✓ Remove spatter and replace
worn or damaged contact tip.
✓ For the best welding
performance and longest tip
life, ESAB AristoTip contact
tips are recommended for use
with AristoRod™ wires.
✓ Grind the end of the liner
conical for optimal fitting of the
contact tip (ESAB M8).
✓ Ensure that the contact tip is
the correct size and fits tightly.
✓ nsure the gas nozzle is free
E
from spatter.
correct
incorrect
Wire diameter
(mm)
Description
ESAB item nr.
1.0
AristoTip 1.0M8/10/30mm
0700300301
200
1.2
AristoTip 1.2M8/10/30mm
0700300303
200
1.4
AristoTip 1.4M8/10/30mm
0700300305
200
For additional sizes, contact ESAB.
4
Pieces/box

5. Liner
✓ Spiral steel liners are
recommended.
✓ Never use liners which have
been used for copper-coated
wires. Copper residuals may
stick onto the AristoRod™
wire and deteriorate it is
excellent 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. Firstly
remove contact tip.
Gas and water
✓ Check gas and water
connections for leaks.
✓ Check if water cooler is filled
and pump operates
satisfactorily.
Wire feed unit
✓ Position wire guide tubes as
close as possible to the
rollers to prevent kinking of
the wire.
A substantial amount of fine
metallic shavings underneath
the drive rolls indicates
misalignment.
Correct
Incorrect
5

6. Before you start welding
ESAB Marathon Pac™
installation
ESAB Marathon Pac™ is the
most advanced bulk wire
packaging system available to
fabricators. The complete
Marathon Pac™ family consists
of (from left to right) :
• Endless Marathon Pac™
• Mini Marathon Pac™
• Standard Marathon Pac™
• Jumbo Marathon Pac™
ESAB MarathonPac™ is
completed by a full range of
accessories for efficient internal
transport and handling and for
easy installation.
Always make sure ESAB original
Marathon Pac™ accessories*
are used for best performance.
*For a complete list of Marathon Pac
accessories, contact ESAB.
Original lifting joke to handle the drum
safely and to not damage the drum or
wire.
6
Special cone for Jumbo Marathon
Pac™ with 475kg non- or lowalloyed wire.

7. Step 1. Remove the rubber strap
and VCI paper.
Step 2. Place the wire conduit
attachment or “spider” on top of the
Marathon Pac™.
Step 3. Feed the welding wire
through the centre of the spider.
Step 4. Place the carton or plastic lid
(Standard and Mini Marathon Pac™)
or cone (Jumbo Marathon Pac™).
Step 5. Attach the wire conduit to
the lid or cone with the quick
connector.
Step 6. Attach the wire conduit to the
wire feeder. Avoid liner bends or point
pressure on the liner.
7

8. Before you start welding
Check drive rolls and wire feeding
✓ Use drive rolls with smooth,
double V-grooves. U-shaped
grooves or knurled rolls may
damage the AristoRod™ 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
feedings 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 such that it is
possible to stop a bend wire at
the gas nozzle by applying a
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.
8
Smooth
Knurled

9. Shielding gas
✓ Check that the appropriate
gas is used. Adjust gas flow
rate to between 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 too.
9

10. Contact tip and gas nozzle
2 mm
Correct positioning of contact tip.
Incorrect. Contact tip too recessed.
Incorrect. Contact tip protruding
beyond gas nozzle.
12-
20
mm
Ideal stick-out for wire diameters
1.0 and 1.2 mm.
10
It is essential to fit the gas
nozzle and contact tip at the
right distance relative to each
other. The ideal distance of the
contact tip is 2 mm recessed.
A longer distance will force the
welder to use too long a stickout, resulting in poor weldability.
This may lead to lack of fusion,
particularly in narrow joints.
Contact tips protruding beyond
the gas nozzle can result in
insufficient gas shielding.
Correct stick-out length
The stick-out is the distance
between the contact tip and
workpiece and must be kept
between 12 and 20 mm
(ø1.0 and 1.2 mm). Excessive
stick-out results in a too short
arc length, larger droplets, an
unstable arc and spatter, so
poor weldability. Additionally, it
may reduce the gas protection
which can lead to porosity.
When welding in spray arc with
too short a stick-out, the arc
length can become too long.
The weldpool will get hotter and
more difficult to control.

11. When welding in short arc
transfer, the arc stability and
start properties will improve
when reducing the stick-out.
Gas nozzle diameter
Various nozzle diameters must
be available to allow satisfactory
access to the joint, to maintain
the above recommended stickout, and to ensure proper
shielding gas protection. Small
diameter gas nozzles are used
for the first layers only. Revert to
the standard gas nozzle
diameter when access to the
weld joint allows this, so full gas
protection can be assured.
12-
20
mm
Correct. Use a smaller diameter
nozzle or a conical nozzle for the
1st layers in the root area.
20
m
m
Incorrect. Use of standard gas
nozzle restricts access to narrow
joints, resulting in too long a
stick-out.
Correct. Use of standard gas nozzle
for completing the joint ensures
good gas protection and correct
stick-out.
11

12. Welding parameter setting
Use positive polarity for OK
AristoRodTM solid wires. A given
welding current requires a specific
arc voltage for optimum weldability.
The welding current is set by
adjusting the wire feed speed
control. The arc voltage is
regulated by the open circuit
voltage (OCV) setting of the power
source.
Correct. Correct arc length. Stable
and concentrated arc with a quiet
spray droplet transfer.
How to get an optimum setting?
For the following procedure, it is
vitally important to keep the stickout constant within the correct
range for each welding position.
• Select a welding current (I)
which suits your application
from the figure on page 13.
Incorrect. Arc length too short. Wire
dips into weld pool (stubbing) caused
by too low an arc voltage, too high a
wire speed or too long a stick-out.
• Start welding with the lowest
voltage value from the given
range. This may result in
stubbing, however wire
burnback 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.
12
Incorrect. Arc length too long. Arc
becomes too wide, giving insufficient
penetration. Also a risk of burnback to
the contact tip. This may be caused
by the arc voltage being too high, the
wire feed speed too low or the stickout being too short.

13. NOTE: As mentioned, stick-out
control is very important. If the
recommended stick-out length is
not maintained constant,
weldability will fluctuate.
Shortening the stick-out will
result in an increasing current
and a longer arc. Lengthening
the stick-out will result in a lower
current and the arc being too
short.
• Due to AristoRod’s advanced
surface characteristics 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.
OK AristoRod™
OK AristorodTM
1
Welding in short arc area. Use for thin plate, tack welding
or positional welding.
1.0 mm
2
Welding in globular area. Unstable arc and excessive spatter.
Try to avoid.
1.2 mm
3
Welding in spray arc transfer. High productivity,
thick plate, downhand welding, low spatter.
4
Excessive weld metal. Difficult to control.
38
4
36
3
34
32
30
Voltage
28
2
26
24
22
20
When arc length is too
short increase voltage.
1
18
When arc length is too
long decrease voltage.
16
14
12
50
100
150
200
250
300
350
400
Amperage
13

14. 14
ER80S-B2
ER90S-G
ER80S-G
ER100S-G
ER110S-G
ER120S-G
ER120S-G
13.16
13.22
13.26
55 (13.13)
69 (13.29)
79 (13.31)
89 (1B96)
G Z 3Ni1Cu
G2Mo
ER80S-G
G4Si1
ER80S-G
ER70S-6
12.65
G4Si1
13.12
ER70S-6
12.63
G2Ti
13.09
ER70S-2
12.62
G2Si
ER80S-D2 G4Mo
ER70S-3
12.57
G3Si1
13.08
ER70S-6
12.50
EN-ISO
14341-A
A5.18
A5.28
AWS
G Mn4Ni2CrMo
G Mn4Ni2CrMo
G Mn3Ni1CrMo
G Mn3NiCrMo
16834-A
G CrMo2Si / G 62M 2C1M3
Z CrMo1Si / G 55A 1CM
G CrMo1Si / G 55M 1CM3
G MoSi /G 1M3
21952-A /-B
OK AristoRod Classification wire Classification wire and weld metal
AWS and EN classifications
G 38 0
G 46 0
G 42 2
G 42 2
G 42 3
G 35 2
G 38 2
C1
G 89 4
G 79 4
G 69 4
G 55 4
G 46 4 G 42 0
G 46 2
G 50 4
G 46 4
G 46 4
G 46 4
G 38 3
G 42 4
M21
EN-ISO 14175
High strength
High strength
High strength
High strength
Weather resistant
Creep resistant
Creep resistant
Creep resistant
Creep resistant
Creep resistant
Normal strength
Normal strength
Normal strength
Normal strength
Normal strength
Shielding gas Steel type
OK AristoRod™ – the complete range

15. ESAB Swift Arc Transfer™
arc
Mixed
arc
Spray ar
c
ting
Rota
arc
Short
Arc voltage
The ultimate high productivity process.
Forced short arc
SAT
TM
Wire feed speed (m/min)
ESAB’s AristoTM U82 robot
package enables SATTM welding. it
is a complete set of welding
equipment and consumables,
based on ESAB’s latest digital
power source technology. The
package consists of:
• The Aristo™ Mig 5000iw
inverter or ESABMig 4002,
5002 or 6502 choppers.
• The AristoTM U82 control unit
ESAB Swift Arc Transfer™ is a
high productivity MAG process
that utilises AristoRod™ noncopper coated wires at very
high wire feed speeds . The
SAT™ process produces flat
welds with good penetration
and without undercut.
with SATTM synergic lines or
The Aristo W82 interface for
different robot brands.
• The Robofeed 3004w ELP
encapsulated wire feeder with
up to 30 m/min. wire feed
speed.
• Cable packages.
• The Marathon Pac bulk drum
with robot quality welding wire
and optional bobbin holder.
15

16. World leader in welding
and cutting technology
and systems.
Quality and environment
standards
Quality, the environment and
safety are three key areas of
focus. ESAB is one of few
international companies to have
achieved the ISO 14001 and
OHSAS 18001 standards in
Environmental, Health Safety
Management Systems across all
our global manufacturing
facilities.
16
At ESAB, quality is an ongoing
process that is at the heart of all
our production processes and
facilities worldwide.
Multinational manufacturing, local
representation and an
international
network of independent
distributors brings the benefits of
ESAB quality and unrivalled
expertise in materials and
processes within reach of all our
customers, wherever they are
located.
ESAB AB
Box 8004, SE-402 77 Gothenburg, Sweden.
Phone: +46 31 50 90 00. Fax: +46 31 50 93 90.
E-mail: info@esab.se
www.esab.com
Reg. No: XA00161520 06 2012 . Printed in the Netherlands.
ESAB operates at the forefront of
welding and cutting technology.
Over one hundred years of
continuous improvement in
products and processes enables
us to meet the challenges of
technological advance in every
sector in which ESAB operates.