Accessories; Porosity - Abicor Binzel ABIROB A360 Instruction Manual

ABIROB INSTRUCTION MANUAL

ACCESSORIES

To get the best possible service from your ABIROB torch and insure proper servicing, the following peripher-
al equipment will be needed.
Alignment Jig for ABIROB Necks
Along with the advantages which the design
of the ABIROB brings, the Alignment Jig is
used to check the geometry of the neck outside
the welding booth and make slight adjustments
where necessary.
It is recommended that all new swanneck are
checked and aligned before installation. This
will eliminate any alignment problems which
may have occurred during shipping.
CAT Torch Mount
This provides a secure link between robot and
tool. The CAT robot mount is a 3-dimensional
safety coupling to protect the tool on the robot
or on the handling equipment. Any collision
automatically activates the safety switch built
into the robots emergency stop circuit. The
CAT's accessory program offers a wide range
of mounts and extensions to reach the neces-
sary TCP.
Cleaning Stations
Spatter from welding process lodges inside the
gas nozzles and this leads to insufficient gas
coverage, and in time, to spatter bridging and
eventually to a short circuit. The result can be a
damaged torch. The cleaning station prevents
this from happening and operates with speed
and precision to reduce manual intervention,
increase the service life of the wear parts
and cut robot downtimes.
837.0500 (A360/A500 standard length necks)
837.0510(A360/A500 long "L" necks)
8
ABIROB INSTRUCTION MANUAL
TROUBLESHOOTING: POROSITY (SUMMARY)
NOTE: Most POROSITY is caused by gas problems, followed by base metal contamination.
Causes of Porosity
BASE METAL CONTAMINATION
Impurities on base metal.
FILLER METAL CONTAMINATION
Impurities on filler metal (wire).
ATMOSPHERIC CONTAMINATION
Drafts, wind, fans, etc.
GAS MIXING APPARATUS
1. Too high a gas flow, causing turbulence,
and/or sucking air at hose connections;
creating venturi effect at end of gas nozzle.
2. Too low a gas flow, causing insufficient gas coverage.
3. Damaged or kinked gas lines.
4. Too high an oxygen content.
5. Leaks in gas distribution system.
6. Other impurities in gas – moisture, etc.
7. Inconsistent gas flow (cfh) at the torch connection.
GAS TURBULENCE
1. Excessive spatter build-up in gas nozzle and
on contact tip.
2. Nozzle damage, causing uneven gas coverage.
3. Torch gas ports clogged or deformed.
4. Super-heated nozzle, causing shielding gas to expand
rapidly and create return effect at end of nozzle.
Results in contamination of gas by atmosphere.
5. Gas diffuser/nozzle insulator missing.
6. Too high a gas flow causing venturi effect.
WELDING PARAMETERS, ETC.
1. Too long a wire stick-out; gas nozzle too far
from weld puddle.
2. Bad torch position – too sharp a torch incline
causing venturi effect at the end of the nozzle
leading to atmospheric contamination.
3. Excessively wide weld pool for nozzle I.D.
4. Arc voltage too high.
5. Too high a travel speed.
Possible Solutions
a. Remove contamination; clean surfaces
b. Use of specific wire/gas mix for specific
types of impurities.
a. Replace wire.
b. Install wire-cleaning system.
c. Prevent industrial dust/dirt/grit from
contaminating wire during storage or use.
d. Prevent build-up of aluminum oxide on
exposed aluminum wire surface by using up
quickly.
e. Remove wire from wire drive unit and store
in a sealed plastic bag when not in use for
long periods.
a. Protect weld from drafts (curtains/screens).
b. Use tapered or bottleneck gas nozzles when
drafts cannot be avoided.
1a. Reduce gas flow.
1b. Tighten all hose connection points.
2. Increase gas flow.
3. Repair or replace
4. Adjust mixer.
5. Repair leaks.
6. Overhaul system; fit filters and/or dryers.
7. Regulate pressure into flow meter for
consistent cfh delivery of gas.
1. Clean nozzle and tip regularly; spray with
anti-spatter fluid.
2. Replace nozzle.
3. Clean or replace.
4. Check duty cycle rating of torch.
5. Replace.
6. Reduce gas flow.
1. Use longer nozzle or adjust stick-out (3/8"
minimum or 15 times wire diameter).
2. Correct torch angle.
3. Width of the weld pool should be 1.3 times
nozzle I.D.; use suitable wider gas nozzle.
4. Reduce voltage.
5. Reduce speed.
9