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Manufacturing and Repairing High-strength Structures in the Crane and Lifting Industry – When Safety Matters.

The need for high quality and consistent mechanical properties combined with high production rates is a major challenge for welding work in crane and lifting technology. The right synergic lines and innovative processes, such as Rapideep 2.0, guarantee optimal welding behavior and perfect joining properties together with our high strength consumables portfolio (diamondspark and Alform range from 690–1100 MPa yield strength). Among other things, the following advantages, developed specifically for the crane and lifting technology sector, were examined in detail.

 

 

Further convince yourself of the

  • unique matching solution for 1000Mpa yield strength grades
  • mechanical properties met, in high-strength thin-walled applications in both heat-affected zones and weld metals
  • turn-key package for repairing

Optimized Properties for Thin-walled Applications

In crane and lifting as well as automotive industry the ongoing trend is to use high strength material with low wall thickness to reduce weight and costs of welded components.

For very low wall thickness, in the range from 2 up to 5mm, HAZ (heat affected zone) softening (low hardness) or hardness peaks plays an important role. Hardness profile of the welded joint is mainly influenced by the heat input of the welding process.

Böhler Welding high productive low-heat input solutions offer excellent mechanical properties including a smooth hardness profile, combining the weldability of its high-strength diamondspark metal cored wires with the TERRA welding equipment and the dedicated Böhler Arc synergy system.

As an example, a low heat input process (0.4 kJ/mm) applied to a 3mm butt weld without preparation, made in one pass at 120 cm/min reaching, produces good bead shape, perfect and smooth penetration and a harmonized hardness profile. In this specific case wire is diamondspark 700 MC for welding S690 steel grades, either TMCP or Q+T.

Optimized Properties for the Perfect Shape High-speed Fillet

For fillet welds the reduction of lead times for fabrication of welding components means an increase in the welding speed. Technical limitations are given by producing undercuts and lack of fusions. Using Böhler Arc in combination with diamondspark metal cored wires, it is possible to fine tune mechanized welding procedures up to 120 cm/min welding speed for high strength materials. Speed is further increased by more than 10% when using the innovative Rapideep 2.0 process, providing  the additional advantages of:

  • “a crispy” arc with good wetting behavior; a better weld bead surface
  • more regular penetration
  • heat input similar to a standard spray arc
  • electric arcs that are more stable and more focused

Conventional spray arc at 120 cm/min travel speed: undercuts and convex bead shape.

Rapideep 2.0 with Böhler Arc at 120 cm/min travel speed: flat bead and smooth transition.

Optimized Welding Behavior of Lattice Boom

The quality of the high strength tube on tube weldments used for lattice boom cranes depends highly on the arc behavior. The key elements especially are gap bridging, penetration, undercuts, spatter formation and weld seam shape. Böhler Arc, combined with a double pulse mode, available with the URANOS welding equipment, with the diamondspark high-strength metal cored wire as a filler metal, was developed to cover all of the issues vital for this application:

  • Good penetration is achieved with current peak of pulse mode
  • Gap bridging can be done with a low current phase
  • Very good steering of weld pool viscosity can be carried out with a double pulse
  • Low spatter formation
  • Easy handling as the weld pool cools down in the low current phase
  • Good weld bead shape as the average current is in a safe range for this application.

Ultra high Strength 1100 MPA Yield Strength Matching Solution

Up to now, welding of 1100MPa Yield Strength steel plates was only possible with under-matching welding consumables, accepting weld metal strength properties below such strength value.

The new diamondspark 1100-MC is the only welding consumable, which can guarantee to meet the plate strength. 

The patented chemical composition of the metal cored wire safeguard, a matching solution for those ultra high strength base materials, is produced either as classical Q/T or alternatively fine-grained base material in line with TM rolling processes.

8 mm thickness welded joint filled with three passes 

As an example, this 8 mm thickness welded joint is filled with three passes. The base material is from voestalpine, Alform 1100 X-treme a TMCP produced base material from strip. diamondspark 1100-MC was used as a filler material for the full welding solution.

Welding Parameters:

  • I = 250 A
  • V = 25 V
  • Travel Speed: 52 cm/min root, 65 cm/min fills
  • Heat Input: 0.52-0.54 kJ/mm
  • Shielding gas: M20 type (92% Ar CO2 bal.)

Test Results:

  • Transversal tensile broken in the base material at high tensile stress > 1150 MPa
  • Max hardness: 430 HV10 in HAZ
  • Weld metal Charpy V impact toughness 40J average at -20°C
  • Side bend test: no defects detected

Repairing Line for Site and Shop Maintenance

Repairing existing structures during the scheduled safety inspections or in case of problems and accidents, is a crucial aspect. This is above all decisive because the welding of high strength material needs to be carried out with special care and  within restricted specifications in order to restore the structural integrity and preserve the mechanical properties.

Böhler Welding offers integrated solutions, with multi-process portable welding equipment, such as URANOS 2700 PMC, fine-tuned with excellent low diffusible hydrogen and high toughness welding consumables that have been conceived for repair, covering all the steel grades. The fine-tuning between the welding equipment and the filler metal is ensured thanks to Böhler Arc. Böhler Welding provides specific double coated basic stick electrodes and wires, either solid or, metal cored, available in portable 5 kg spools and small diameters (solid wires at 0.8 mm and metal cored wires at d. 1.0 mm).

TERRA & URANOS Welding Equipment

Depending upon the model, multi-process or GMAW/SMAW only high-technology inverters on a heavy-duty cycle that are equipped with an arc digital control and special arc processes such as various pulsed modes, high-speed as Rapideep and Quickpulse perform at their best in crane & lifting technology in combination with the diamondspark metal cored wires.

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URANOS NX 2700 PMC

Portable equipment for all welding processes, producing excellent repairing weldments with the double coated basic stick electrode and with cored and solid wires. Featuring a compact arrangement for the wire spool, long cables and hoses for welding at distant position, it is ideal for shop repairing and for being fitted into maintenance shop cars for site operations.

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Böhler Arc

The Perfect combination of process, filler metal and welding equipment is achieved thanks to Böhler Arc synergic lines, maximizing performance and arc stability, coupled with an outstanding ease of use, resulting in great advantages for the welder and efficiency for the industrial process.

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RapiDeep

An innovative welding process based on a highly concentrated arc, resulting in a consistent heat input reduction, higher precision, easier control, deeper penetration along with less risk of undercuts. It allows for a significant increase in the welding speed with a direct impact on cost savings (higher productivity, less welding time).

FWS Crane & Lifting Rapideep

RapiDeep shows better penetration and smoother transition with base materials when operating at the same wire speed and travel speed. It can produce higher penetration still with a very well-shaped good bead when increasing to more than 60 % the travel speed.

Crane and lifting performance is further enhanced when using diamondspark metal-cored wires, reaching a considerable welding speed above 100 cm/min in various applications.

QuickPulse

As the alter-ego of RapiDeep in the pulsed world, QuickPulse couples the benefits of the concentrated arc with the greater stability offered by the pulsed arc for the best penetration at a low heat input and a high welding speed. In crane and lifting technology, whereas RapiDeep is the perfect solution when using diamondspark metal cored wires, QuickPulse enhances the performance when the filler metals are solid wires.

Double Pulse

It features two different waveforms. The first at a higher intensity ensures the melting of the base material, while the second is characterized by a wider arc opening at lower parameters. The second waveform takes benefit from the fluidity and the heating generated by the first waveform in order to efficiently deposit material filling bevel and gaps without a further over-heating. In the case of assembly with gaps or non-regular geometry as there is in lattice boom cranes, it is a key factor in achieving the perfect weld.

diamondspark Metal cored Wires for Joint Welding of High-strength Structures

diamondspark is an entire portfolio of seamless cored wires. They are characterized by a large parameter window suitable for all welding processes, low diffusible hydrogen and outstanding mechanical properties, for Full Welding Solutions in the crane and lifting technology, the metal cored wires selection below covers all the high strength grades, including a unique offer for the 1100 MPa yield strength.

diamondspark Metal Cored Wires Portfolio

PRODUCT NAME EN/ISO AWS/SFA BASE MATERIAL STEEL GRADE Product Data Sheet - DE Product Data Sheet - EN Safety Data Sheet - DE Safety Data Sheet - EN
diamondspark 700 MC 18276-A: T69 6 Mn2NiCrMo M M21 1 H5 A5.36 / SFA-5.36: E110T15-M21A8-K4-H4 S690, S700
diamondspark 900 MC 18276-A: T89 5 ZMn2NiCrMo M M21 1 H5 A5.36 / SFA-5.36: E131T15-M21A6-K4-H4 S890, S900
diamondspark 960 MC 18276-A: T89 4 ZMn2NiCrMo M M21 1 H5 - S960
diamondspark 1100 MC 18276-A: T89 2 ZMn2NiCrMo M M21 1 H5 - S1100
diamondspark 700 MC 18276-A: T69 6 Mn2NiCrMo M M21 1 H5 A5.36 / SFA-5.36: E110T15-M21A8-K4-H4 S690, S700
diamondspark 900 MC 18276-A: T89 5 ZMn2NiCrMo M M21 1 H5 A5.36 / SFA-5.36: E131T15-M21A6-K4-H4 S890, S900
diamondspark 960 MC 18276-A: T89 4 ZMn2NiCrMo M M21 1 H5 - S960
diamondspark 1100 MC 18276-A: T89 2 ZMn2NiCrMo M M21 1 H5 - S1100

Solid Wires for Joint Welding of High-strength Structures

The solid wires used for the construction of high-strength structures are supposed to have a high-quality standard, excellent welding behavior and constant mechanical properties. Böhler Welding offers these wires in different diameters and packaging solutions. Drum solutions up to 400 kg each provide good availability for mechanized welding processes Guided by good feeding properties, these products support the increase of efficiency of welding stations. Strict quality measures in manufacturing and ongoing development work ensure the highest quality for customers.

Solid Wires Portfolio

PRODUCT NAME EN/ISO AWS/SFA BASE MATERIAL STEEL GRADE Product Data Sheet - DE Product Data Sheet - EN Safety Data Sheet - DE Safety Data Sheet - EN
Böhler X70-IG 16834-A: G 69 5 M Mn3Ni1CrMo A5.28 / SFA5.28: ER110S-G S690/S700
Union NiMoCr 16834-A: G 69 6 M21 Mn4Ni1,5CrMo A5.28 / SFA5.28: ER100S-G / [ER100S-1(mod.)] S690/S700
Union X90 16834-A: G 89 6 M21 Mn4Ni2CrMo A5.28 / SFA5.28: ER120S-G S890/S900
Union X85 16834-A: G 79 5 M21 Mn4Ni1,5CrMo A5.28 / SFA5.28: ER110S-G S890/S900
Union X96 16834-A: G 89 5 M21 Mn4Ni2,5CrMo A5.28 / SFA5.28: ER120S-G S960
Böhler X70-IG 16834-A: G 69 5 M Mn3Ni1CrMo A5.28 / SFA5.28: ER110S-G S690/S700
Union NiMoCr 16834-A: G 69 6 M21 Mn4Ni1,5CrMo A5.28 / SFA5.28: ER100S-G / [ER100S-1(mod.)] S690/S700
Union X90 16834-A: G 89 6 M21 Mn4Ni2CrMo A5.28 / SFA5.28: ER120S-G S890/S900
Union X85 16834-A: G 79 5 M21 Mn4Ni1,5CrMo A5.28 / SFA5.28: ER110S-G S890/S900
Union X96 16834-A: G 89 5 M21 Mn4Ni2,5CrMo A5.28 / SFA5.28: ER120S-G S960

Welding Consumables for Repairs

From stick electrodes to cored and solid wires, the welding consumables portfolio listed below, also available in smaller diameters, is proven and balanced for working with URANOS 2700 PMC and Böhler Arc. Particularly noteworthy is the availability of small diameter wires and small coils, as well as special double coated stick electrodes that combine excellent mechanical properties with the best operability.

Welding Consumables repairing Line

PRODUCT NAME BASE MATERIAL STEEL GRADE PROCESS DIAMETER Product Data Sheet - DE Product Data Sheet - EN Safety Data Sheet - DE Safety Data Sheet - EN
Union NiMoCr S690/S700 GMAW 0,8mm & 1,0mm & 1,2mm
BÖHLER X70-IG S690/S700 GMAW 0,8mm & 1,0mm & 1,2mm
Union X85 S690/S700 GMAW 1,0mm & 1,2mm
diamondspark 700 MC S690/S700 MCAW 1,0mm & 1,2mm
Union X90 S890/S900 GMAW 0,8mm & 1,0mm & 1,2mm
Union NiMoCr S690/S700 GMAW 0,8mm & 1,0mm & 1,2mm
BÖHLER X70-IG S690/S700 GMAW 0,8mm & 1,0mm & 1,2mm
Union X85 S690/S700 GMAW 1,0mm & 1,2mm
diamondspark 700 MC S690/S700 MCAW 1,0mm & 1,2mm
Union X90 S890/S900 GMAW 0,8mm & 1,0mm & 1,2mm
diamondspark 900 MC S890/S900 MCAW 1,0mm & 1,2mm
Union X96 S960 GMAW 0,8mm & 1,0mm & 1,2mm
diamondspark 960 MC S960 MCAW 1,0mm & 1,2mm
diamondspark 1100 MC S1100 MCAW 1,0mm & 1,2mm
UTP 890 KB S960 SMAW 2,5x350mm & 3,2x350mm

Personal Protection & Accessories

One of the most important aspects in the welding process is the protection of the welder. Which is why voestalpine Böhler Welding created the new personal protection and accessories line.

The products reflect our high-quality demands and give welders the protection and the tools they need. Helmets such as Guardian 62 Complete and the Guardian 62F Air Complete, gloves, glasses and clothes are ideal for the pipeline jobsite. Additionally, we provide a full range of electrode holders and ground clamps.

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weldTECH Application Services

For voestalpine Böhler Welding, being a Full Welding Solutions provider means acting as a partner for pipeline contractors through the weldTECH Application Services, which include a team of welding engineers experienced in pipeline construction.

weldTECH Application Services

Calculation Tools

weldNet® Material Manager

weldNet® Material Manager - the digital material and filler metal database from voestalpine Böhler Welding

Have access to the consistently up-to-date material database and the welding consumables portfolio of Böhler Welding, with more than 35,000 base materials; over 24,000 of which include a chemical analysis and more than 2,200 DIN, EN ISO and AWS standard titles along with their validity and issue dates.

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weldNet® Material Manager

weldNet® Equipment Configurator

With the weldNet® Equipment Configurator, you now have the possibility to assemble your welding machine with all the components required individually and at any time.

In addition to the suitable power source, the complete package consists of welding torch, cooling, wire feed, carriage and other accessories, up to the correct welding programs.

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weldNet® Equipment Configurator

Welding Calculator

The Welding Calculator App supports the planning and optimization of welding tasks such as the calculation of cooling time, preheating temperatures or the calculation of the required filler metal quantities. As a joint development between the voestalpine Steel Division and voestalpine Böhler Welding, the app is currently available for Android in the Google Play Store and for iOS in the App Store.

Download the voestalpine welding calculator app on your smart phone, tablet or laptop here:

Download for iOS
Download for Android
Desktop Version