Production Process

and Benefits of Seamless Flux- and Metal-cored wires

particularly for offshore / oil & gas

GCC Orbitalum Meeting

Singen, June 30, 2014

Summary

• Introduction of ITW Welding GmbH / Germany

(formerly STEIN wire & welding)

• Production process of seamless flux- and metal

cored wires including quality control

• Advantages of seamless cored wires

• Application examples

ITW Welding - Your Route to Full

Performance in Welding

ITW Welding location Germany

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Since 1964 seamless flux- and metal

cored wires are produced at the

location in Altleiningen / STEIN held

the patent on the system for the

production

Development of the patented

wire basket spool for welding

wire in 1975

Independent marketing and

sales of welding consumables

in 1997

Company‘s Welding History

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Became part of ITW Welding - 1st March 2013

STEIN name changed to ITW Welding GmbH – Sep. 13

•Production process of Seamless

Flux- and Metal-cored wires

and quality control

Divers cross sections of flux-cored wires

Seamless flux-cored wires

Folded flux-cored wires

MEGAFIL - Seamless Cored Wire Production

Technology

Production process seamless cored wires

High frequency welded tube

Initial annealing

and calibration to filling diameter

Uniform agglomerated flux core

densely filled by vibration

Drawing to final size, copper coating and spooling

Approvals and Management Systems

We are certified by these

approval bodies for:

- Flux- and Metal Cored Wires

- The Production and

Quality Management

ISO 9001 and ISO 14001

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Technical Center

The Technical Center is equipped with all necessary

Testing Equipment for:

• 3.1 Certifications (100 % made in-house)

• Approvals for International Approval Bodies (TÜV, LR,

DNV, ...)

– Determination of all mechanical properties

– Chemical Analysis including N2, O2 and H

measuring

• Technical Equipment

– Spectrometer

– Scanning electron microscope (SEM)

– X-Ray fluorescence analyzer (RFA)

– Universal drawing machine, CHARPY-V,

hardness test equipment

•Advantages of

Seamless FCAW/MCW

•Application examples for offshore /

oil & gas

Characteristics of MEGAFIL

Seamless Flux- and Metal-Cored Wires

• Hydrogen content HD < 4 ml/100 g Weld

• Real value < 3 ml/100 g WM

• Absolute resistance to moisture pickup

during the entire usage/welding time

• Superior mechanical properties (than wire with seam) that stand up to extreme environments

• No particular storage necessary and longer shelf life! We tested after 10 years of production, wire showed same chemical/mechanical/hydrogen properties

• No need of baking / holding / quiver treatments even in humid conditions

• Reduced risk of Hydrogen related issues

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No Moisture Pick Up – Even Under Extreme Conditions

Advantages of MEGAFIL seamless cored wires

• Copper-coating to improve current carrying capabilities

• Uniform shape (perfectly round) results in smoother wire feeding

• No torsion / tension / no twist, so stable process for robotic welding

• Low wear on feed rolls / liner / contact tip, … lesser maintanance

• Easy handling with stickout of 15 – 18 mm; no problems with Nitrogen /

Hydrogen (embrittlement). Lesser interpass cleaning

• Large range of approvals (DNV, ABS, LR, TÜV, BV, CWB, GL …)

• All certificates are with 3.1 chemical and mechanical values

• All certificates are batch certificates

• No flux filling gaps – 100 % control by flux filling check device

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Product Range

Product Range

Steel grade FCW

mixed Gas Co2 typical Ar / Co2 80/20 %

SAW

S355

( X42-X52)

(AH36-EH36)

(AH40-EH40)

yield ReH 355 Mpa

tensile Rm 470-630 Mpa

elogation 22 A [%]

S420

(AH420-FH420)

yield ReH 420 Mpa

tensile Rm 550-720 Mpa

elogation 20 A [%]

S460

(X60-X70)

(AH460-FH460)

yield ReH 460 Mpa

tensile Rm 500-640 Mpa

elogation 20 A [%]

S500

(AH500-FH500)

yield ReH 500 Mpa

tensile Rm 560-720 Mpa

elogation 18 A [%]

S550

( X80)

(AH550-FH550)

yield ReH 550 Mpa

tensile Rm 640 - 820 Mpa

elogation 18 A [%]

S620

(~X90 )

(AH620-FH620) (ABS EQ63)

yield ReH 620 Mpa

tensile Rm 710 - 880 Mpa

elogation 18 A [%]

S690

(X100)

(AH690-FH690) (ABS EQ70)

yield ReH 690 Mpa

tensile Rm 770 - 940 Mpa

elogation 17 A [%]

S890

( X120)

yield ReH 890 Mpa

tensile Rm 940 - 1100 Mpa

elogation 10 A [%]

S960 -

1100 -1300

yield ReH 960 Mpa

tensile Rm 980-1150 Mpa

elogation 10 A [%]

PWT test welding for pipe with MEGAFIL 710 M

MF 710 M

CTOD test results

MF 240 M

Mechanical properties with and without PWHT

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with PWHT

without PWHT

Typical Applications – Rig Fabrication

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Resume: We are Passionate about Welding

I want us all to walk away knowing and understanding that:

• ITW Welding GmbH has a know-how in the production of high quality seamless cored wires for 50 years.

• ITW Welding is a total solution provider for welding prosesses.

• Partnering with ITW Welding, you will have the deep knowledge and experience of engineers at your side.

Thank you very much for your attention!

ITW Welding GmbH

Spechttal 1a

67317 Altleiningen

Germany

Phone: +49 (0) 6356 / 966-119

E-Mail: Martin.Schnirch@drahtzug.com

Homepage: www.itw-welding.com