Melt Off Rates

Power Wave AC/DC 1000™
Solid Electrode Melt-off Rates –

TE CHNIC AL 602200001
REP ORT
No. 602200001
FROM
ABSTRACT
Application With the ability to deliver square wave AC or DC power
Engineering and to modify the power by use of AC frequency, offset
and balance, it is possible to configure the arc to best
David C. Lincoln suite specific welding conditions. In theory, it is
Technology Center possible to develop an infinite number of different melt-
off rate curves for any given electrode size and
The Lincoln Electric electrical stickout. The intent of this document is to
Company provide specific information relative to frequently used
arc configurations and to provide accurate melt-off
February, 2005 data for these configurations. A method is also
presented to establish similar data for any specific arc
configuration.
Lee Allgood
Technical Consultant Accurate melt-off data provides key useful information
& for comparing alternative welding procedures and for
Greg McCall establishing the cost of specific procedures. The
Technical Support Power Wave AC/DC 1000 makes it possible to easily
obtain accurate information.
Call us at 1-866-635-4709 for:

Welding applications support
Information on distributor training
Welding School information
Seminar information
PROPRIETARY & CONFIDENTIAL: This document contains information owned by Lincoln Global, Inc. and may not be
duplicated, communicated to other parties or used for any purpose without the written permission of Lincoln Global, Inc.
Note: Because many variables in design, fabrication, and service conditions affect the results obtained in applying this
type of information, the testing and serviceability of a product or structure are the responsibility of the builder.
THE WELDING EXPERTS lincolnelectric.com
BACKGROUND
The introduction of the Power Wave AC/DC 1000™ and the Power Feed 10A Controller
has added increased versatility and reliability to the submerged arc welding process.
While this added capability may at first seem to complicate using the process, the exact
opposite is the case. The output stability of the Power Wave AC/DC 1000™ coupled
with the "turn of a knob" ability to totally reconfigure the Power Wave AC/DC 1000™
can tailor the arc to suit the job at hand. This makes it a simple matter to select the
optimum arc conditions for a particular weld. The following is a review of the primary
mode settings and how they affect the output.
Square Wave Balance
This is always expressed as a percentage of the DC + component. (i.e., 25%Balance

means 25% of the cycle will be positive while 75% of the cycle will be negative, etc.).
Square wave balance less than 50% allows the arc to act more like DC negative polarity
thus increasing electrode melt-off but without incurring the disadvantages of
conventional DC negative welding. Figure-1 schematically illustrates negative
unbalance. Note that only 25% of the time is the arc positive while 75% of the time it is
negative. This ability can be used to tailor the arc to achieve increased deposition and
decreased penetration. For some butt weld types where penetration is important and
where it might be desirable to decrease deposition, positive unbalance may be
preferred.1 Any unbalance percentage greater than 50% will result in positive
unbalance. This is shown schematically in Figure-2.
Figure-1 Figure-2
Square Wave Offset
Offset is expressed as a percentage between –25% and +25% of the rms value that is
kept positive or negative. In other words –25% means the normal positive component of
each cycle is held to 25% of the normal root mean square (rms) value and the negative
1
For a detailed discussion of basic butt welds, see Technical Report No. 808230004
A Technical Report by Application Engineering, Copyright The Lincoln Electric Company, Cleveland OH, USA
REF: Submerged Arc Melt-off Data Page 2 of 16 February, 2005
component becomes 75%. In some respects when offset is adjusted to maximum

values the arc action is somewhat analogous to that of a pulsed arc. Negative values
contribute to increasing deposition levels toward the values obtainable with DC negative
welding yet without the problems frequently encountered with the later. This is
schematically shown in Figure-3. Positive values will decrease deposition rates and may
be helpful in producing butt welds that require good penetration but not a lot of fill; AWS
B-U3c-S welds could be of this type. 2
Square Wave - Normal Curve

Square Wave - Negative Offset
50% Positive
Amps
Total
Amps
50% Negative
Total
1 CYCLE
1/60 SECOND
Square Wave - Current Offset
Figure-3
Square Wave Frequency
While frequency is historically accepted to be fifty or sixty hertz, the Power Wave
AC/DC-1000 can function at any chosen frequency between zero (DC) and 100 hertz.
Frequency can play an important role in a specific welding procedure. Relative to a
"normal" sixty hertz, deposition rates can be slightly increased or decreased as can
penetration.
Frequency alters the total time for the arc to be at peak values. As the frequency
decreases, more time is available at peak value and ----- more importantly ----- less time
is spent in the transition region. The converse occurs as frequency is increased. The
below figure illustrates this by showing what occurs during one complete cycle.
This can be of help in shaping and controlling the thickness of the reinforcement on
penetration type butt welds as well as reducing bead-edge undercut.
Figure-4
2
See footnote-1.
Frequency also plays a roll in total deposition rate. Deposition rates may increase as
much as 6% as the frequency is lowered.
GENERAL DISCUSSION
Throughout this document the term electrical stickout (ESO) is used rather than contact
tip to work distance. Older Lincoln publications frequently refer to the later as visible
stickout. Under optimum conditions, and with larger diameter electrodes, all three terms
mean essentially the same thing. ESO, however, specifically means the electrode to
work distance from the point in the contact tip where current transfer to the electrode
occurs. A worn contact tip or an incorrectly sized contact tip can alter the ESO. This can
cause a significant change in current, especially with smaller sized electrodes, which
can result in major changes in amperage/wire feed speed relationships.3
A K-148 contact nozzle assembly has been used for all welding referred to in this
document in a conscientious effort to eliminate any ESO issues. ESO is here defined as
specific contact tip to work surface distance along the axis of the electrode.
All welding is done using the constant current mode of the Power Wave AC/DC 1000™.
One of the main reasons for this is that, in general, submerged arc can be very
successfully used at high currents with large weld puddle volumes. Under these
conditions surface appearance is significantly improved when welding is done using
constant current (variable voltage).4 The ability of the Power Wave AC/DC 1000™ and
PF-10A to regulate and deliver constant power greatly enhances the advantages of
using high deposition submerged arc procedures with larger diameter electrodes.
About the term "melt-off rate": If one ignores electrode lost at the start of a coil and the
bit of electrode lost at the end of a coil, then melt-off rate and deposition rate may be
considered the same. This is not true when certain welding fluxes that actively contribute
alloying materials to the weld puddle are employed. In these cases, considering melt-off
rate to be the same as deposition rate results in understating the actual deposition rate.
All data used to develop the melt-off rate curves in this document was acquired using
Observer and/or Command Center software. Both of these produce accurate results.
The beauty of Command Center is that it can be easily used in the field to verify actual
results.
The data for each curve consists of at least five data points spanning the recommended
current range for the particular sized electrode. The actual procedure involved making a
bead-on-plate weld of sufficient length to assure reaching a stable welding condition.
Travel speed was set to assure proper location of the arc relative to the weld puddle and
the base plate. Voltage, while not specifically recorded, was set to result in a quiet arc
and a well shaped weld bead.
3
This is the basis for extended stickout welding with semi-automatic squirt welding and innershield welding.
4
Reference is made to Bulletin C5.50, Submerged Arc Welding Guide.
Data Evaluation
Each data set was rationalized to eliminate arc starting and arc stopping data points.
The data was then statistically evaluated using Microsoft Excel. Each data set
containing well in excess of one hundred data points was tested to a 95% confidence
level. This typically reported a wire feed speed (wfs) value with a ± value significantly
less than one inch per minute. Similarly, amperage yielded values in the range of ± 1.5
to 0.25 amperes. Not surprising, the higher values were always associated with
amperages run at the lowest end of the data set.
The data group for electrode size was then rationalized, again using Excel, to determine
the equation for best curve fit. The form of the equation is wfs (Y) equal function of
amperes (X) and includes the intercept point (0,0). Typically, the best fit curve yielded
an equation of the form;
Y = aX n where n > 0
This usually resulted in an equation with an R2 value greater than 0.96. There are a few
exceptions usually for DC+ curves where an equation of the form;
Y = aX 2 + bX
better fits the data. This usually occurs with the larger sized electrodes and the resultant
curve almost becomes linear in nature.
The equations are presented in a graphical format using software that accurately draws
graphs. For reference purposes, the equations are shown on the graphs.
Incidentally, the Power Wave AC/DC 1000™ in conjunction with Command Center
software makes it very easy to establish a wfs/amperes curve right in the field for any
specific operating mode.
Using the Data
For any given sized solid electrode and specific ESO, while an infinite number of
relationships can be developed, it should be kept in mind that there is an upper and
lower boundary. This boundary is represented by the DC- and DC+ curves. The graph
on page 9 clearly illustrates this.
The graphs are presented as WFS vs. Amperes since these are the variables that can
be set using the PF-10A controller. Therefore, a multiplying factor must be applied to
the WFS to obtain actual melt-off. This factor is shown on each graph and in table-1.
Page 7 is a similar graph but for 3/32 diameter electrode with the curves for two
additional modes added. It is used to illustrate some of the ways for which this data can
be used.
1. Accurate melt-off values can be determined for any current relationship for which
a curve has been developed.
2. As a simple cost reduction tool, assuming a present procedure using 500
amperes DC +, the deposition rate is 13.4 lbs/hr. Staying at 500 amperes but
switching to AC Square Wave Balanced, a deposit rate of 17.2 lbs/hr is realized.
This is an increase in deposition rate of 28.4 percent without increasing current.
Further, if the weld bead size is kept the same as would be the case of a fillet
weld, there would be a decrease in heat input of about the same magnitude
which could be beneficial.
3. Some upper edge scalloping is being experienced with a lapweld procedure
based on 450 amperes, DC+. A possible solution might be to reduce the current
but keep the melt-off rate of 11.6 lbs/hr the same. Using the ACSW75%BAL
curve indicates a current just slightly over 400 amperes (calculating it from the
equation gives 407 amperes). This represents about a 10% reduction in amperes
without a reduction in melt-off rate.
Table-1 WFS to LBS/HR Conversion

Solid Electrode Diameter- Multiplying Factor to Obtain
Inches Lbs/Hour
3/32 0.115
1/8 0.210
5/32 0.325
3/16 0.470
Pages 7 through 16 contain a collection of graphs containing curves for some

commonly used modes. For clarity of presentation, each size electrode is represented
by more than one graph.
TM
POWER WAVE AC/DC 1000
2.4 mm
MELT-OFF RATE (WFS vs AMPERES)
3/32” DIAMETER SOLID ELECTRODE @ 1.00” ELECTRICAL STICKOUT
300
EQUATIONS
2
DC+ : WFS=0.0294 x AMPS^1.3333 R =0.9874
DC- : WFS=0.0272 x AMPS^1.4170 R2=0.9884
2
ACSWBAL: WFS=0.0137 x AMPS^1.4962 R =0.9857
ACSW 25%BAL: WFS=0.0175 x AMPS^1.4728 R2=0.9951
2
ACSW 75%BAL: WFS=0.0311 x AMPS^1.3453 R =0.9974
6.35 m/mn 250
EG
-N
DC
L
BA
%
25
5.08 m/mn 200
WIRE FEED SPEED - IN\MIN
SW
L
BA
AC
SW
AC
L
BA
%
75
3.81 m/mn 150 SW
AC OS
-P
DC
2.54 m/mn 100
1.27 m/mn 50
Lbs/hr-melt-off = 0.115 x (WFS)

0.0522 kg/hr * wfs
0
100 200 300 400 500 600 700
Drawn: Jan,2006 AMPERES
TM
2.4 mm MELT-OFF RATE (WFS vs AMPERES)
300
EQUATIONS
2
DC+ : WFS=0.0294 x AMPS^1.3333 R =0.9874
2
DC- : WFS=0.0272 x AMPS^1.4170 R =0.9884
2
ACSWBAL: WFS=0.0137 x AMPS^1.4962 R =0.9857
ACSW 25%BAL: WFS=0.0175 x AMPS^1.4728 R2=0.9951
ACSW 25%BAL (-)10% OFF 40 HZ:
6.35 m/mn WFS=0.0146 x AMPS^1.507 R2=0.9948
250
-
DC
ACSW 75%BAL (-)10% OFF; 40 HZ
L
BA
5.08 m/mn
%
200
25
SW
AC
L
BA
SW
AC
3.81 m/mn 150 +
DC
2.54 m/mn 100
1.27 m/mn 50

0.0522 kg/hr * wfs
0
100 200 300 400 500 600 700
AMPERES
Drawn: Jan,2006
TM
3.2 mm
180
EQUATIONS
2
DC+ : WFS=0.0218 x AMPS^1.2914 R =0.9836
DC- : WFS=0.0457 x AMPS^1.2301 R2=0.9891
-
C
D
2
ACSW-BAL: WFS=0.0154 x AMPS^1.3739 R =0.9897
4.064 m/mn 160
AL
-B
SW
3.556 m/mn 140 AC
+
3.048 m/mn 120
DC
2.54 m/mn 100
2.032 m/mn 80
1.524 m/mn 60
1.016 m/mn 40
0.508 m/mn 20
0.0953 kg/hr * wfs
0
300 400 500 600 700 800 900
Drawn: January, 2006 AMPERES
TM
180
EQUATIONS
2
DC+ : WFS=0.0218 x AMPS^1.2914 R =0.9836
EG
DC- : WFS=0.0457 x AMPS^1.2301 R2=0.9891 -N
DC
2
4.064 m/mn ACSWBAL: WFS=0.0154 x AMPS^1.3739 R =0.9897
L
160
BA
ACSW 25% BAL: WFS=0.0115 x AMPS^1.4306 R2=0.9908
%
25
SW
L
BA
AC
3.556 m/mn SW
140 AC
3.048 m/mn 120 OS

C-P
D
2.54 m/mn 100
2.032 m/mn 80
1.524 m/mn 60
1.016 m/mn 40
0.508 m/mn 20
0.0953 kg/hr * wfs
0
300 400 500 600 700 800 900
POWER WAVE AC/DC 1000TM

180
EQUATIONS
DC+ : WFS=0.0218 x AMPS^1.2914 R2=0.9836 C-
D
DC- : WFS=0.0457 x AMPS^1.2301 R2=0.9891
4.064 m/mn 160 ACSW 25% BAL: WFS=0.0115 x AMPS^1.4306 R2=0.9908
R2=0.9964
L
ACSW (-)20% OFF: WFS=0.0227 x AMPS^1.3145
BA
ACSW (+)20% OFF: WFS=0.0149 x AMPS^1.3687 R2=0.9932
%
25
FF
SW
O
AC
%
3.556 m/mn 20
140 (-) FF
W O
S 0%
AC +)2
(
SW
AC +
3.048 m/mn 120 DC
2.54 m/mn 100
2.032 m/mn 80
1.524 m/mn
60
1.016 m/mn 40
0.508 m/mn 20
0.0953 kg/hr * wfs
0
300 400 500 600 700 800 900
TM
4 mm
140
3.048 m/mn 120

EG
-N
DC
AL
2.54 m/mn -B
100 W
-S
AC
2.032 m/mn 80
OS
C-P
D
1.524 m/mn 60
1.016 m/mn 40
0.508 m/mn 20
0.1474 kg/hr * wfs
0
300 400 500 600 700 800 900 1000
TM
4 mm POWER WAVE AC/DC 1000
140
3.048 m/mn 120 EG

C-N
D
ACSW 25% BAL ACSW

(-)25% OFF, 40HZ 25% BAL
2.54 m/mn AC-SW-BAL
100
ACSW 25%
BAL(+) 20% OFF
2.032 m/mn 80 S
C-PO
D
1.524 m/mn 60
1.016 m/mn 40
0.508 m/mn 20

0.1474 kg/hr * wfs
0
300 400 500 600 700 800 900 1000
TM
120
EQUATIONS
2
DC +: WFS=0.0809 x AMPS^0.9283 R =0.9862
DC - : WFS=0.0247 x AMPS^1.1853 R2=0.9920 -
2 DC
ACSWBAL : WFS=0.0074 x AMPS^1.3323 R =0.9929
2.54 m/mn 100
L
BA
SW
AC
2.032 m/mn 80
1.524 m/mn 60 +
DC
1.016 m/mn 40
0.508 m/mn 20

0.2132 kg/hr * wfs
0
400 500 600 700 800 900 1000 1100 1200 1300
DRAWN: JANUARY, 2006 AMPERES
TM
120
EQUATIONS 2
DC +: WFS=0.0809 x AMPS^0.9283 R2=0.9862
110 DC - : WFS=0.0247 x AMPS^1.1853 R =0.9920 -
ACSWBAL : WFS=0.0074 x AMPS^1.3323 R2=0.9929 DC
ACSW 25%BAL (-) 20% OFF : WFS=0.0235 x AMPS ^ 1.1775 R2=0.9914
ACSW 25%BAL (+) 20% OFF : WFS=0.0078 x AMPS ^ 1.2941 R2=0.9870
100 ACSW 25%BAL : : WFS=0.0101 x AMPS ^ 1.2947 R2=0.9940 F
OF
0% L
(-)2 BA
L %
90 BA 25 AL
% B
25 CSW SW
W A
S AC
AC
80
F
OF
%
70 )20
(+
AL
5%B
2
SW
60 AC
DC+
50
40
30
20

10
0
400 500 600 700 800 900 1000 1100 1200 1300
POWER WAVE AC/DC 1000TM

120
EQUATIONS
DC +: WFS=0.0809 x AMPS^0.9283 R2=0.9862
110 DC - : WFS=0.0247 x AMPS^1.1853 R2=0.9920 -
ACSWBAL : WFS=0.0074 x AMPS^1.3323 R2=0.9929 DC
ACSW 25%BAL : WFS=0.0101 x AMPS^1.2947 R2=0.9940
ACSW 75%BAL : WFS=0.0069 x AMPS ^1..3 1 94 R2=0.9980
100
Z
0H
L -6
BA
%
90 25 HZ
W 60
S L -
AC BA
SW
80 AC
HZ
- 60
L
BA
5%
7
70 SW
AC
60
DC+
50
40
30
20
10 Lbs/hr-melt-off = 0.470 x (WFS)
0
400 500 600 700 800 900 1000 1100 1200 1300

Melt Off Rates

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Melt Off Rates

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Power Wave AC/DC 1000™

Solid Electrode Melt-off Rates –

Call us at 1-866-635-4709 for:

Square Wave Balance

This is always expressed as a percentage of the DC + component. (i.e., 25%Balance

Square Wave Offset

component becomes 75%. In some respects when offset is adjusted to maximum

Square Wave - Normal Curve

Square Wave Frequency

Using the Data

Table-1 WFS to LBS/HR Conversion

Pages 7 through 16 contain a collection of graphs containing curves for some

2.54 m/mn 100

Lbs/hr-melt-off = 0.115 x (WFS)

2.54 m/mn 100

Lbs/hr-melt-off = 0.115 x (WFS)

2.54 m/mn 100

3.048 m/mn 120 OS

2.54 m/mn 100

Drawn: January, 2006 AMPERES

POWER WAVE AC/DC 1000TM

2.54 m/mn 100

Drawn: January, 2006 AMPERES

3.048 m/mn 120

Lbs/hr-melt-off = 0.325 x (WFS)

0.1474 kg/hr * wfs

3.048 m/mn 120 EG

ACSW 25% BAL ACSW

BAL(+) 20% OFF

Lbs/hr-melt-off = 0.325 x (WFS)

2.54 m/mn 100

Lbs/hr-melt-off = 0.470 x (WFS)

DRAWN: JANUARY, 2006 AMPERES

Lbs/hr-melt-off = 0.470 x (WFS)

DRAWN: JANUARY, 2006 AMPERES

POWER WAVE AC/DC 1000TM

10 Lbs/hr-melt-off = 0.470 x (WFS)

DRAWN: JANUARY, 2006 AMPERES

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