THE GAME CHANGER

IN PIPE MILLS

www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 1

 FOR OVER 120 YEARS, KNOWN WORLDWIDE
FOR RELIABILITY AND PERFORMANCE

NETHERLANDS
UNITED KINGDOM
POLAND
CANADA FRANCE RUSSIA
GERMANY
UNITED STATES SPAIN
JAPAN
ITALY
CHINA
UAE
MEXICO

VENEZUELA INDIA
LOCATIONS
COLUMBIA SINGAPORE

Global Headquarters
PERU
Solution Centers
BRAZIL
SOUTH AFRICA
CHILE AUSTRALIA
ARGENTINA

11 000 Employees worldwide

160 Active in 160 countries
48 Manufacturing locations for consumables and equipment
325 R&D engineers worldwide
42 Solution Centers
2.7 Billion USD Revenue

THE GAME CHANGER

IN PIPE MILLS
By providing a full solution including equipment, consumables, integration and expertise
we are the GAME CHANGER IN PIPE MILLS.

FULL EQUIPMENT RANGE FULL TECHNICAL SERVICE TO CUSTOMER FULL CONSUMABLE PACKAGES
•T  urn-key welding equipment packages •A  ssistance with to WPS development •W
 ire & Flux specially
• S tate-of-the-Art Digital Welding to Customer designed for Pipe Mill
system Z5 with Real Time Data • L ab equipment for trial purposes requirements
Logging & Traceability available

2 THE GAME CHANGER IN PIPE MILLS www.lincolnelectric.eu www.uhrhan-schwill.de

Industry Challenges Solutions and Training
We understand the critical nature of welding requirements in To make a quality pipe every time, you need the right
the pipe mill industry. From stringent requirements on extreme resources. We offer a complete solution to support your mill:
wall thicknesses to consumables for pipe used in highly corrosive integrated equipment solutions that are reliable and cutting-
environments, consistency and reliability are key to delivering a edge, consumables to weld everything from mild steel up to
project on time and under budget. X100 paired with welding support. We believe every production
campaign is unique and we have a team of technologists,
Typical Pipe Mill Applications engineers, metallurgists, programmers and specialists to
Whether the pipe you’re making is destined for an oil field or support your mill.
a stadium, you’re likely to encounter demanding customers, We also offer a variety of on-site, regional and global training
exacting line specifications and unforgiving delivery schedules. programs specifically designed to address the welding and
We understand the necessity of welding that is done right the cutting challenges you face every day.
first time. Online SAW-H, offline SAW-H or SAW-L, no matter the
Today, we are setting new standards in the art of multiple arc
pipe-making process, we have the equipment, consumables and
welding technology and automation. Thanks to continuous
technical know-how to ensure that you will be able to deliver
research, further development and combined efforts, large
the highest-quality pipe on time. With manufacturing locations
diameter pipe mills worldwide trust our technology and
around the globe, we’re able to quickly and efficiently provide
integrated our systems into their production processes very
the products you need when you need them.
successfully.
Uhrhan & Schwill, a Lincoln Electric company, is the recognized
industry leader with decades of experience in the development of
integrated systems for pipe mills. The unique welding expertise allows
us to provide unmatched technical support in application, procedure
and product development tailored specifically to pipe-making.
Our progress is our customers advantage

Uhrhan-Schwill
Essen
DE

Lincoln Electric
Cleveland
USA
TABLE OF CONTENTS
THE PIPE MILL INDUSTRY 3
EQUIPMENT 4
CONSUMABLES 10
EMERGENCE™ 18
PACKING & STORAGE 19
AUTOTAB WELDING & CUTTING PROCESS 21
GAME CHANGING SOLUTIONS FROM A SINGLE SOURCE 22
www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 3
 EQUIPMENT

EQUIPMENT
MACHINERY
Tack Welding Machines
Tack welding in pipe production is utilized to hold
the pipe form and is fully consumed during the
SAW process. Our tack welding solutions achieve
the highest productivity in the industry and are
fully customizable enabling integration into new or
already existing tacking stations.
Uhrhan & Schwill tack welding systems are designed
to meet the most demanding requirements:
yours! We will customize a solution to fulfill your
requirements as well as meeting all applicable
industry standards.
Our service is not limited to development, assembly
and commissioning of the tack welding machine.
It also includes the supply of appropriate welding
consumables.

Internal & External Welding Systems

In the process of welding longitudinal or spiral pipes,
SAW welding systems serve to weld a pipe from the
inside and outside.
This is done after the pipe has been tack welded.
All Uhrhan & Schwill welding systems, internal or
external, are available in different versions. These
versions are specially designed to fulfill the unique
requirements of every single customer. Our solutions
are making use of 1 to 6 electrodes, depending on the
application.
Further advanced welding solutions like cold wire or
Extended – ESO can be integrated on request.

4 THE GAME CHANGER IN PIPE MILLS www.lincolnelectric.eu www.uhrhan-schwill.de

EQUIPMENT

MOVING YOUR WELDING SOLUTION TO THE NEXT LEVEL

WIRE DEPOSITION RATES FOR MULTIPLE POWER SOURCES
SUBMERGED ARC WELDING POWER SOURCES
( MILD STEEL & LOW ALLOY)

GO FOR
Average Deposition Rate in (kg/h)
Improvement versus standard 3-Arc in [ %]

DC+/AC/AC

THE
Standard Stick Out 1 x Long Stick Out
3-Arc 40 kg/h
36 kg/h
3 x 4.0 mm +11%

NEXT
3 x Tandem Twin 48 kg/h
–
2 x 2.4 mm +33%

DC+/AC/AC/AC
Standard Stick Out 2 x Long Stick Out

STEP
4-Arc 70 kg/h 76 kg/h
1 x 4.8mm + 3 x 4.0mm +94% +111%

DC+/AC/AC/AC/AC
Standard Stick Out 3 x Long Stick Out
5-Arc 85 kg/h 100 kg/h
2 x 4.8mm + 3 x 4.0mm +136% +178% We support you to select:
● Optimum process
DC+/AC/AC/AC/AC/DC-AC ● Ideal parameters
Standard Stick Out 4 x Long Stick Out ● Consumables that guarantee the required
mechanical properties customized to your
6-Arc 105 kg/h 120 kg/h
2 x 4.8mm + 4 x 4.0mm +192% +233% application

www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 5

 EQUIPMENT

AUTOMATIC WELDING
CONTROL & DATA LOGGING
SYSTEM Z5
Digital Welding System Z5
READY FOR INDUSTRY 4.0
The Uhrhan & Schwill welding solutions are equipped
with a digital control system named Z5. This software has
been programed and designed by our programmers and
welding engineers. The user interface is controlling and
monitoring the entire welding process and is available is
multiple languages on request.
The user interface itself is consistent through every
possible application and uses modern touch screen
technology combined with real time controls for tack
welding, inside welding and outside welding applications.
The human machine interface guaranties efficiency to our
customers and a user-friendly work environment.
Pre-selection of all relevant welding parameters in
combination with closed loop real time control enables
our customers to weld a complete pipe in automatic mode.
Of cause all periphery equipment, such as flux handling,
seam tracking or pipe transport systems are 100%
implemented on request into the user interface of the
control software.
The integrated quality control system allows to recall all
specific mechanical and electrical welding parameters
for different pipe diameters, wall thicknesses and base
materials.
This will create a procedure database for different
production ranges and will help to fulfill the required
documentation during the end customer inspection.
Additionally, a fault indication system in real text mode
enables the operator to detect any fault and the exact
position on the pipe. These features are reducing repair
and maintenance time significantly.

6 THE GAME CHANGER IN PIPE MILLS www.lincolnelectric.eu www.uhrhan-schwill.de

EQUIPMENT

WELDING POWER SOURCES

Uhrhan & Schwill welding systems are based on power
sources from Lincoln Electric. All power sources are
optimized for dependability in demanding pipe mill
environments.
Lincoln Electric offers the newest Waveform Control
Technology® in the Power Wave® AC/DC 1000® SD.

The following power sources are available:

• US-DC-1000
• US-AC-1500
• US-Power Wave® AC/DC 1000® SD

Idealarc® US-DC-1000
The US-DC-1000 is a high-performance DC
power source and perfect for submerged
arc welding when high output power is
required. Four power sources are switched
in parallel to achieve a power range of
up to 4000 A.
Idealarc® US-AC-1500 US-Power Wave®
• high process safety The US-AC-1500 are electronically-
AC/DC 1000® SD
• outstanding arc characteristics on
 controlled AC power sources with The Power Wave® AC/DC 1000® SD
constant voltage and constant current transductor and perfect for submerged delivers Waveform Control Technology®
processes arc welding when high output power is to submerged arc welding.
• high efficiency and lasting welding required.
• 380-575 VAC, 50/60 Hz Voltage Input
quality • outstanding arc characteristics
– can be connected anywhere in the
• data consistency for repetitive welding • Scott connection for two AC welding
world
applications due to stable control design heads operated in tandem
• consistent operation, even with line
 • adjustment of output settings through • No hardware reconfiguration
voltage changes of up to ± 10% due to required with easy polarity
Rheostat while welding or at idle
switching – eliminates downtime.
built-in line voltage compensation
• three output studs with overlapping
•
• easy access for maintenance activities ranges ArcLink®, ethernet and DeviceNet™
due to removable side panels
• consistent operation, even with line
 communication
• manufactured according to DIN EN
 voltage changes of up to ± 10% due to
60974-1 built-in line voltage compensation
• three-year manufacturer warranty on • extra long life for repetitive welding

parts and labour applications through solid state circuitry
• seven-year manufacturer warranty on • easy access for maintenance activities
the power rectifier due to removable side panels
• many years of practical experience,
 • UL listed
even in rough operating environment

TECHNICAL SPECIFICATIONS
Dimensions
Output Range Weight W x D x H [mm]

Idealarc® US-DC-1000 150 – 1300 A 372 kg 560 x 1000 x 780

Idealarc® US-AC-1500 240 – 1500 A 820 kg 580 x 1210 x 1460
Power Wave® AC/DC 1000® SD 100 – 1000 A 368 kg 488 x 1174 x 1250

www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 7

 EQUIPMENT

POWER WAVE TECHNOLOGY

In most of the submerged arc applications it is possible to work in DC current with the electrode
being either positive or negative.

Thanks to Lincoln Electric Waveform Control Technology® embedded in the new

Power Wave® AC/DC 1000® SD power source, we can now take over the full area between
DC+ and DC-.

DC + DC- AC
● Most common mode ● Improves deposition ● A compromise between
● Deep penetration and rate (25%) the two DC modes
stable arc ● Limits penetration ● The optimum choice with
● Limited arc stability Power Wave® AC/DC 1000® SD

Waveform Control Technology® capability provides precise control over:

● Frequency ● Balance ● Offset

(Number of switch per (Percentage of time in (Positive/Negative
second from positive the positive polarity Amplitude)
to negative polarity) portion of one cycle)

Offset : Positive Current Level = Penetration

AC Frequency
Current, Voltage, or Power

Cycle Balance = Penetration/Deposition

Offset : Negative Current Level = Deposition

Stick-out: 32mm
15
DC-
13
Deposition Rate (kg/h)

AC Square wave
25% balance, -20 offset
11
AC Square wave
25% balance
9
AC Square wave
50% balance
7
DC+
5

3
200 400 600 800 Current (A) 1000

8 THE GAME CHANGER IN PIPE MILLS www.lincolnelectric.eu www.uhrhan-schwill.de

 EQUIPMENT

FLUX HANDLING SYSTEM

Independent to the number of electrodes, the Undersize, oversize and slag sieving, descaling or
flux used in Uhrhan and Schwill submerged arc heated flux storage containers - the flux supply
welding systems has to be supplied, vacuumed systems integrated into our welding systems
and recycled. This cycle is established by flux allow a smooth production process that can only
supply systems offered in the most diverse be ensured through continuous flux supply of the
designs. The product package includes the flux welding system. For maximum user friendliness,
vacuum device and the fully automatic suction the flux supply system control is integrated into
and recovery system. the welding system control.

. Our engineered solutions are available in

heated versions to fulfill the most stringent flux
moisture requirements.

Flux handling system

FILLING TANK 1 FILLING TANK 1

X
ING CLOSE discharge charge CLOSE discharge
OFF FILLING TANK
FILLING
1 TANK 1 FILLING TANK 1 TANK 1charge
FILLING
FLUX FLUX
HEATING HEATING CLOSE CLOSE
discharge discharge
charge charge CLOSE CLOSE
discharge discharge
charge charge
ON/OFF ON/OFF
FILLING TANK 1 FILLING TANK 1
X
TO FLUXCLOSE FLUXdischarge charge CLOSE discharge charge
AUTO AUTO
e
size sieve sieve
oversize oversize
CLOSE
CLOSE PIPE CLOSE
d CLOSE
CLOSE CLOSE PIPE PIPE
feed feed FLUX
yor conveyor conveyor
FLUX
CONTAINER
CONTAINER
FLUX
CONTAINER

CLOSE FILTER FILTER

FILTER CLEANING
magnetic magnetic PIPE CLEANING
etic separator separator
CLOSE
FLUX
CLEANING
ator CONTAINER

FILTER
sieve sieve CLEANING
e undersize undersize SUCTION SUCTION

size SUCTION

SUCTION

FLUX FLUX

FLUX
FLUX

flux system
flux system emergency
overview
fault
emergency
list
overview
f1fault
mainlist
f2 f1
machine
main
f5 f2
v/a
machine
f6 f5
wfs v/a
f7 f6
datawfs
f8 f7
tolerance
data
f9 f
flux
toler
id

flux system emergency fault f1 f2 f5 f6 f7 f8 f9 f11 f12

flux system
overview list main machine v/a wfs data tolerance flux id boom carriage
emergency fault f1 f2 f5 f6 f7
overview list main machine v/a wfs data tol

www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 9

 CONSUMABLES

CONSUMABLES PORTFOLIO
1
Lincoln Electric’s consumables are possible for the pipe mill industry. In order
0 engineered products that meet all industry to increase customer efficiency, Lincoln
S 140A and regulatory standards. Lincoln Electric Electric sells consumables in different
S 133TB operates the industry’s most advanced packaging sizes.
S 140TB
research center and are continuously
100 striving to provide the best products

CONSUMABLES
PORTFOLIO
8N (P)
Spiral or Longitudinal
Spiral
Longitudinal

50

45

40
WALL THICKNESS (mm)

35

30

25

20

15

10

0
SPX80
FLUX 780 761 (P) P223 SPX80N LPX80N 995N 998N (P)

STEEL GRADE X70 X80 X90

10 THE GAME CHANGER IN PIPE MILLS www.lincolnelectric.eu www.uhrhan-schwill.de

 CONSUMABLES

O SPIRAL PIPE WELDING (SAW-H)

GUARANTEED
WELDING Welding is a fundamental process in the pipe then shortened to the appropriate length.
SPEEDS mill industry. Modern spiral mills produce The subsequent submerged arc inside and
pipes with diameters from 300 to 3556 mm outside welding is carried out in a two-run
and wall thicknesses ranging from 6.4 to technique.
30mm. Within the online process the final
Whether welding online or off-line SAW-H,
internal and external SAW process are
we provide industry-leading solutions for
carried out while the steel strip is formed
every aspect of the pipe welding process,,
into a pipe. The Hybrid online process includes
including consumables specifically
an upstream GMAW tack welding process.
engineered for spiral welding applications.
In the off-line process, the pipe is tack welded
during forming in the spiral machine and

ONLINE OFFLINE HYBRID

● Coil Splice ● Coil Splice ● Coil Splice
● ID/OD: ~2.3m/min ● Tack weld: Up to 15m/min ● Tack weld: ~2.5m/min
● OD Cross weld ● AutoTab Weld ● ID/OD: ~2.4m/min
● ID/OD: ~2.4m/min ● OD Cross weld
● AutoTab Cut ● Production mix
● OD Cross weld

www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 11

 CONSUMABLES

LONGITUDINAL PIPE WELDING (SAW-L)

To a large extent welding processes influence welding machine can provide pipes for up to
GUARANTEED the productivity and quality within a longitudinal four submerged arc welding lines.
WELDING pipe making process. In a longitudinal pipe
Several decades of experience allow us to
SPEEDS mill, pipes with diameters from 406 to
provide reliable, highly productive and cost-
1625 mm and with wall thicknesses ranging
saving solutions for all welding applications
from 6.4 to 45 mm are produced. Pipe
within the mill. Our unmatched ability as
lengths vary between 12 and 18 meter. For
a machine supplier allows us to engineer
special applications, the pipe diameters even
custom-made solutions for all applications
go below 254 mm.
and to implement various innovative welding
Rolled plates are used as base material applications into our equipment design.
within a longitudinal pipe production.
Based on our knowledge in the pipe making
Different forming process like UOE, C-ing
industry, we can offer a full spectrum of
and 3-roll-bending are available on the
equipment, a wide variety of consumables,
market. While the continuous GMAW
and the corresponding welding support
tack welding process is performed, the
developed for the pipe mill industry.
subsequent inside and outside submerged
arc welding processes will be carried out
on separate welding stands. Thus, a tack-

OUTPUT U-O-E J-C-O 3-ROLL

Tack welding Up to 4-8m/min Output + – 0
Tab welding AutoTab Flexibility – 0 +
Inside welding Up to 5 arcs Bevel Quality 0 + –
zOutside welding Up to 6 arcs Roundness 0 – +
Tab removal AutoTab Heavy WT +
+ + 0
Small Diameter
● Each forming process has advantages and Investment – 0 +
disadvantages – but we weld them all
● Relationships with all major mainline suppliers

12 THE GAME CHANGER IN PIPE MILLS www.lincolnelectric.eu www.uhrhan-schwill.de

CONSUMABLES

RECOMMENDED FLUXES FOR SPIRAL AND LONGITUDINAL

APPLICATIONS - SPX80TM/SPX80NTM & LPX80NTM
● S traight to Coat ● L imitation in ●M
 aximize ●H
 assle-Free
The industry leading SPX80 TM
/ Nitrogen Productivity and Detectability
SPX80NTM flux is designed for LPX80N TM
are nitrogen Quality, Minimize Producing pipe with SPX80TM/
fast welding speeds, excellent limiting fluxes designed for Obstacles SPX80NTM not only produces
wetting, excellent bead shape seam welding of pipe. Used consistent and quality welds,
and a “straight to coat” finish. While productivity is critical,
with copper coated and non it does so hassle-free. With
With most welding fluxes, quality and appearance are excellent slag detectability,
copper coated Emergence™ also high priorities with pipe
pipes sit for hours or even pipes move easier through
wire, diffusible hydrogen in welding. SPX80 TM/SPX80N TM
days to properly out-gas your mill and eliminate the
the weld deposit is less than and LPX80NTM fluxes ensure
prior to coating. But with need for any post-weld
SPX80TM/SPX80NTM, your pipe 5ml/100g. a combination of consistent operations prior to inspection,
is ready to “straight to coat”, mechanical properties and a testing and coating.
eliminating WIP and more smooth bead appearance.
efficiently moving pipe to
ship.

SPX80™: Moisture Pickup Over Time

Competition SPX80TM
0.1

0.08

0.06

0.04

0.02

0
0 hours 24 hours 72 hours 96 hours

SPX80™: Diffusible Hydrogen

3
5.4

2
3.0
1

0
COMPETITION SPX80TM COMPETITION SPX80TM

www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 13

 CONSUMABLES

FLUX BREAKDOWN
FLUX TO WIRE RATIO IDENTIFIED AS KEY COST CONSUMPTION LINKED TO TWO MAJOR FACTORS
DRIVER FOR SAW ● Melting rate found to be nearly consistent
● Numerous variables influence this value ● Particle breakdown found
● Target project to eliminate variables to be critical component
● Evaluate independent
of flux delivery&recovery systems

SAMPLING METHOD CRITICAL FOR REPEATABILITY

Trials include only agglomerated fluxes as fused fluxes are not prevalent in Pipe Mills
Fluxes have best-in-class particle strength
Trends expected to be exacerbated in mill environments (ID and OD)

Pipe Mills can expect significant cost-savings when using fluxes

100.00%
90.00%
80.00%
70.00% 1st run
60.00%
2nd run
FLUX BREAK DOWN

50.00%
40.00%
30.00% 3rd run
20.00%
10.00%
0.00%
Competition Lincoln Electric

COSTS TO PRODUCE PIPE

LABOR & OVERHEAD
STEEL
ELECTRICITY
WELDING CONSUMABLES <3%
●
WIRE PRICE
● FLUX PRICE
-FLUX CONSUMPTION
● MELTING
●
WASTE
●
BREAKDOWN

CONTACT US ! WE WILL HELP YOU TO SET UP YOUR PARAMETERS

14 THE GAME CHANGER IN PIPE MILLS www.lincolnelectric.eu www.uhrhan-schwill.de

CONSUMABLES

SPX80TM ● Designed to meet the specific requirements ● S mooth bead profile achieves optimal appearance
of spiral pipe seam welding of up to API X80 on both inner and outer diameter welds
SPX80NTM grade pipe ● Self-peeling slag allows for clean and easy
● High speed welding capability for increased slag removal for reliable non-destructive
productivity testing results
MECHANICAL PROPERTIES
Impact ISO
Flux/Wire Combination Yield Strength (N/mm2) Tensile Strength (N/mm2) Elongation (%)
V(J) @°C
L-61 510 620 30 57 -18
L-70 570 660 26 76 -40
LNS140TB 550 640 28 40 -40

761 ● Active flux for limited pass welding ●A  pplicable for low quality steels
● High current capacity ● Coarse grain flux more suitable with the most rusty
● High restraint cracking resistant and dirty plates
● Suitable for rusty/dirty plates (at high current)

MECHANICAL PROPERTIES
Flux/Wire Yield Strength Tensile Strength Impact ISO AWS Classification
Condition Elongation (%)
Combination (N/mm2) (N/mm2) V(J) @°C (A5.23/A5.17)
L-60 Multirun 380 500 28 50 -20 F7A2-EL12
L-61 Multirun 440 530 28 100 -20 F7A2-EM12K
LNS 140A/L-70 Multirun 480 600 80 -40 F9A0-EA2-G

780 ● Active flux for limited pass welding

● Good general purpose flux, including semi-automatic
●G  ood slag removal, good bead shape
● Product also available in a fine grain and coarse formula
● High speed on dirty plate ● Good on circumferential welds on small diameters
● Good resistance to porosity on rust and primer with low voltage

MECHANICAL PROPERTIES
Flux/Wire Yield Strength Tensile Strength Impact ISO AWS Classification
Condition Elongation (%)
Combination (N/mm2) (N/mm2) V(J) @°C (A5.23/A5.17)
L-60 Multirun >420 510 28 50 0 F7A0-EL12
L-61 Two-run >420 >540 28 50 -20 F7A2-EM12K
LNS 140A/L-70 Two-run >420 >550 25 60 -20 F8A2-EA2-G

All these fluxes are available in 25kg standard plastic and SRB bags as well as 500kg/1000 bulk bags

P223® ● Aluminate basic agglomerated flux ●U  sable up to 3 wire systems

●G  ood impact values in two-run and multi-run technique ● Fine grain version available for the thinest
● Low hydrogen content wall and fastest welding speed
● Very suitable for longitudinal and spiral pipe welding
MECHANICAL PROPERTIES
Flux/Wire Yield Strength Tensile Strength (N/ Impact ISO AWS Classification
Condition
Combination (N/mm2) mm2) V(J) @°C (A5.23/A5.17)
L-61 Two-run 450 550 60 -20 F7A4-EM12K
L-50M (LNS 133U) Two-run 470 570 80 -20 F7A5-EH12K
LNS 140A (L-70) Two-run 500 600 50 -40 F8A4-EA2-A2
LNS 133TB Two-run 510 610 60 -40 F8TA4-G-EG

www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 15

 CONSUMABLES

LPX80NTM ● A nitrogen limiting flux designed for seam ● Less than 5ml/100g of diffusible hydrogen
welding of pipe in the weld deposit with both copper
● Recommended for longitudinal seam coated and non‑copper coated
welding on a range of pipe steels (Emergence™) welding wire

MECHANICAL PROPERTIES
Flux/Wire Yield Strength Tensile Strength Impact ISO AWS Classification
Condition Elongation (%)
Combination (N/mm2) (N/mm2) V(J) @°C (A5.23/A5.17)
Competition SPX80TM

L-61 As welded 540(78) 630(92) 28 35(26) -29 F6TA2-EM12K-H8

L-70 As welded 510(74) 620(90) 26 61(45) -29 F8TA2-EA1-H8

LA-81 As welded 560(82) 650(94) 25 50(37) -51 F8TA6-EA2TiB-H8

24 hours 72 hours
LNS 140A
96 hours
As welded 510(74) 620(90) 25 40(29) -29 F8TA2-EA2-H8

998N
● F lux designed for longitudinal multi-arc welding ● Nitrogen controlled weld metal providing good
pipe mill station also suitable for spiral welds impact toughness on arctic grade pipes
● High end pipe mill applications up to X80 ● Superior resistance to surface defects
● Superior resistance to undercuts on thin metal ● Very low diffusible hydrogen level in the weld
sheet work at high speed deposit
● Designed to operate on all the range of pipe ● 9 98N-P is a coarser size distribution of 998N for flux
thickness (6 to 50 mm) consumption reduction
Competition SPX80TM

MECHANICAL PROPERTIES
Flux/Wire Yield Strength Tensile Strength Elongation Impact ISO AWS Classification
Condition
Combination (N/mm2) (N/mm2) (%) V(J) @°C (A5.23)
24 hours 72 hours 96 hours

LNS140A As welded 570 680 27 75 -40

LNS140TB As welded 610 700 27 50 -50 F9TA6-G-EA2TiB

LNS 133TB Two-run 610 730 26 120 -50 F9TA6-G-EG

995N® ● A nitrogen limiting flux designed for seam ● Produces welds with minimal buildup
welding of pipe and good penetration
● Recommended for automatic single pass ● C apable of producing Charpy V-Notch test results
welding with up to five arcs required for arctic grade service

MECHANICAL PROPERTIES
Flux/Wire Yield Strength Tensile Strength Elongation Impact ISO AWS Classification
Combination (N/mm2) (N/mm2) (%) V(J) @°C (A5.23)

LNS140A 580 680 30 65 -40

LNS140TB 630 700 27 75 -50 F9TA6-G-EA2TiB

16 THE GAME CHANGER IN PIPE MILLS www.lincolnelectric.eu www.uhrhan-schwill.de

CONSUMABLES

RECOMMENDED WIRES FOR PIPE MILL APPLICATIONS

● A low carbon, high manganese, low silicon general purpose submerged arc wire
L-50M ● S uitable for both single and multiarc subarc applications
(LNS 133-U) ●P  rovides extra mechanical properties compared to an EM12K wire grade
AW S A 5.17 : EH12K

● Industry standard for submerged arc welding applications

L-61 ● A low carbon, medium manganese, low silicon general purpose submerged arc wire
AW S A 5.17 : EM12K ●A  good choice for a wide range of applications with single or multiple pass
subarc welding
Exists in non-copper coated version : EMERGENCE™ 61

● Titanium and boron micro alloy wire to achieve optimum impact properties
LNS 133TB with the 2-run technique, especially with pipe mill fluxes
AW S A 5.13 : EG ● Exclusively for as-welded applications

Exists in non-copper coated version : EMERGENCE™ 83

● A 0,5% Mo wire to be used on steel grades such as 16Mo3 or on non alloy

LNS 140A steels to improve impact properties when welding in 2-run technique
(L-70)
AW S A 5.23 : EA2
Exists in non-copper coated version : EMERGENCE™ 70 and 74

● Titanium and boron micro alloy wire to achieve optimum impact properties
LNS 140TB with the 2-run technique, especially with pipe mill fluxes
AW S A 5.13 : EA2TIB ● Exclusively for as-welded applications

Exists in non-copper coated version : EMERGENCE™ 81

● A low carbon, high manganese, high silicon, 1/2% molybdenum special purpose wire
LA 90 ● Recommended for seam welding of pipe and for the general welding
AW S A 5.23 : EA3K of high strength plate

Exists in non-copper coated version : EMERGENCE™ 90

www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 17

 EMERGENCE ™

EMERGENCE™
NON-COPPER COATED SUBMERGED ARC WIRE FOR PIPE SEAM APPLICATIONS

Copper is not normally a problem in welding, however in the Liquid Metal Embrittlement
right situation it can cause Liquid Metal Embrittlement (LME),
leading to costly downtime and repairs. Caused by molten copper wetting the steel grain
boundaries at elevated temperatures.
Traditional Bare Wires are Not the answer
Traditional bare wires suffer from severe tip wear, high
diffusible hydrogen, pockmarking and decreased corrosion
resistance.

Beyond the Surface

Emergence™ submerged arc wires feature a patented surface
coating to address these issues.

Proprietary Surface Treatment

• Elimination of copper in the coating decreases the risk
of copper contamination in the weld
•P roprietary surface treatment offers comparable Energy Dispersive X-Ray Spectroscopy (EDS) map showing copper
corrosion resistance to copper coated wires, without (red) present along grain boundaries. Also shown is slag (green) which
adding hydrocarbons that could increase diffusable followed copper during the wetting process.
hydrogen levels
• More than double the contact tip life when compared Diffusible Hydrogen
to competitive non-copper coated wire alternatives
Competitive
Copper
Non-Copper Emergence™
Wire Conversions Coated
Coated
AWS ISO Equivalent Copper
Product Name Classification Classification Coated Product (s) Typical Diffusible
Hydrogen - mL/100g
3.5 5.0 3.6
L-60
Emergence™ 60 EL12 S1
LNS 143 Represents average diffusible hydrogen values from testing with
Emergence™ 61 EM12K S2Si L-61 multiple Lincoln Electric Fluxes
Emergence™ 70 EA1 S2Mo L-70
L-S3
Emergence™ 73 EG (EH12K)* S3Si
LNS 133-U
Emergence™ 74 EA2 S2Mo LNS 140-A Contact Tip Life (1)
Emergence™ 81 EA2TiB SZ
LA-81 Less Than Half the Tip Wear of Competitive Non-Copper
LNS 140-TB
Emergence™ 83 EG SZ LNS 133-TB Coated Wire
Emergence™ 90 EA3K SZ LA-90 30
* Emergence™ 73 uses the same green rod as L-S3 and LNS 133-U, and has an AWS
Classification of EG. Please call for additional information.
25

20 23%
% Change in Diameter

Recommended Flux Package Options

15
Product Name Package Type
10
• 998N • Drum
• 995N® • Stem 5 7%
• 761-Pipe™ • Spider Stem
• 761 • Reel 0
• P223® Emergence™ Competitive
• SPX80™ Non-Copper Coated

(1) Contact tips from welding with 900A DC+.

18 THE GAME CHANGER IN PIPE MILLS www.lincolnelectric.eu www.uhrhan-schwill.de

PACKING & STORAGE

PACKING & STORAGE

STANDARD INDUSTRY PRACTICES

SAW Pipe Mill Consumables Usage – Standard Industry Practices for Consumables Manufactured by Lincoln Electric.

Both SAW-H and SAW-L pipe mills must take care in the handling, storage and usage of both flux and wire for quality pipe production.
While there are numerous options for guaranteeing optimal welding performance, this document is intended to outline standard
industry practices and Lincoln Electric’s position:

Fluxes
1. Lincoln Electric selects raw materials and manufacturing practices to
ensure low moisture in the finished flux. The flux is tested at point of
manufacture and this value is reported on the 3.1 lot certification for each
lot of flux. Moisture testing is done at 980°C (1800°F) in an oxygen carrier
gas to determine total water in the flux, with a maximum specification
limit of 0.05% by weight. Further, the pipe mill fluxes are formulated to
limit the diffusible hydrogen transferred to the weld metal.

2. Hermetically sealed packages, such as metal drums, plastic pails or the

Sahara Ready Bag (SRB), when undamaged, will ensure the moisture levels
of the flux do not change from the time of manufacture. Lincoln Electric
fluxes can be used directly from these packages with the assurance that
the flux will deliver the diffusible hydrogen level to which it is certified.

3. When flux is purchased in a hermetically sealed package, storing it in a climate-controlled environment is not required. However,
to eliminate contamination concerns during filling of an Uhrhan & Schwill flux container, it is standard industry practice to store
both flux and wire in a climate controlled storage facility. Further details can be found in the enclosed document, Storage &
Handling C5.660.pdf. The driving force for moisture pickup is relative humidity, rather than absolute humidity. Either heating the
air or dehumidifying the air will provide a low relative humidity. Once a package has been opened it is most important to protect
the flux from condensation since direct contact of the flux with moisture can lead to rapid moisture pickup. In some cases, it is
easier to do so with hot flux rather than cold flux from an air-conditioned room. A psychometric chart can be referenced to ensure
that the dew point of the air is always above the temperature of the flux.

4. Upon opening the flux, it should be directly transferred to a heated, covered flux storage container. These containers are
generally kept at 100-120°C to eliminate concerns of condensation. They also protect the flux from contamination.

5. The flux must be protected from high humidity and contamination during use. Any conveyance air must be of low moisture. Any
compressed air should be filtered to remove water, and special emphasis should be placed on the maintenance of the filters.
Further, the air must not contain oils or other sources of moisture and/or hydrogen. The flux should also be protected from and
cleaned of contamination during recovery and reuse. A well-designed and maintained magnetic separator will remove magnetic
mill scale, grinding debris, electrode stubs, etc. from the flux. For optimal performance, it is also important to maintain the
particle size integrity of the flux. Coarse “top” screens are important to remove large contaminants such as pieces of slag and
fine “bottom” screens are important to remove fines from the system. Neither will fully clean the flux of all contaminants, so it
is important to keep nonmagnetic contamination such as copper and general dirt from entering the flux at any point of its use
or conveyance to and from the pipe. In addition to appropriate screens, new flux should be added to the flux hopper at regular
intervals to maintain a consistent particle size distribution.

6. Maintaining the flux integrity from package to use and reuse can be accomplished by using a Uhrhan & Schwill flux system.
This system extends the ability to use Lincoln Electric’s fluxes without conditioning by further guaranteeing that flux within
the system and used in continuous production will retain similar characteristics for both moisture content and grain size
distribution thus having no adverse effects on welding performance.

www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 19

 PACKING & STORAGE

Wires
1.  T
 o eliminate contamination concerns it is standard industry practice to store both flux and wire in a climate controlled
storage facility.

2. Submerged arc wires are designed and manufactured to provide optimum performance in the as manufactured condition. No
attempt should be made to clean the electrode surface or add any type of surface material to the electrode.

3. The wire delivery systems should be designed and maintained to provide smooth feeding of the wire. Moving parts such as
directional rolls should be used to ensure that the wire is not damaged by dragging or scraping across any surface. The drive
rolls and wire straightener should not be excessively tight, again to avoid damaging the wire. It is helpful to monitor the current
draw of the wire feed motors to detect when there is excessive drag placed on the electrode.

4. Wires should be stored as shown on the attached document. Again, great care must be taken if removing wire from a cold
storage area into a warmer area to avoid condensation.

5. SAW wire with any visible signs of rust or discoloration should be set aside and held in climate controlled storage until
investigation has been made between the mill and Lincoln Electric.

Lincoln Electric has a long history of selling pipe mill consumables to mills around the world with a very successful track record.
Combining these products with integrated welding solutions from U&S, including flux storage, handling, delivery and recovery,
provides mills with the confidence and support required for successful daily production.

PACKAGING

25 kg Spool 100 kg Coil 300 kg Spool 1000 kg Coil

VCI packaging for optimum corrosion High capacity packaging for column/boom wooden reel liftable
protection during transportation and storage applications, optimum for multi-wire
applications (tandem/triple arc)

SPEED-FEED® Drum ACCUTRAK® / SPEED-FEED® Drums 25 KG BAG BULK BAG 1000 kg SPECIAL BULK BAG 1000KG
350 kg/600 kg 600 kg/1000 kg - Standard plastic - Standard bulk bag -Bulk bag with special bucked
- Moisture resistant - Moisture resistant lid closure
Sahara ReadyBag™ aluminium lined bulk bag - Moisture resistant aluminum
bulk bag

20 THE GAME CHANGER IN PIPE MILLS www.lincolnelectric.eu www.uhrhan-schwill.de

AUTOTAB WELDING & CUTTING PROCESS

AUTOTAB WELDING & CUTTING PROCESS

The AutoTab system is intended for automated
welding and cutting of run on/off tabs for pipe
fabrication inline with a mill’s exisiting production
flow. System solutions exist for both the attachment
of tabs to formed pipe or flat plate intended to be
formed after the tab attachment process as well as
the tab removal process.

AutoTab – Welding on Formed

Pipe (Spiral or Longitudinal)

www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 21

 GAME CHANGING SOLUTIONS FROM A SINGLE SOURCE

GAME CHANGING
SOLUTIONS FROM ONE
SOURCE
WELDING
WELDING SOLUTIONS
CONSUMABLES FOR THE
PIPE-MAKING
AUTOMATIC INDUSTRY
CONTROLLER
AND DATA
LOGGING UNIT

MACHINERY AUTOMATION
AND
FLUX
HEATING
FILLING TANK 1
FLUX
FILLING TANK 1

ON/OFF
CLOSE discharge charge
HANDLINGCLOSE discharge charge

SOLUTIONS
POWER FLUX
AUTO
SOURCES sieve
oversize
CLOSE
CLOSE PIPE
feed FLUX
conveyor CONTAINER

FILTER
magnetic CLEANING
separator

sieve
undersize SUCTION

FLUX

flux system emergency

overview
fault
list
f1
main
f2
machine
f5
v/a
f6
wfs
f7
data
f8
tolerance
f9
flux id
f11
boom

Critical Process
Pipemills Equipment
Multi Arc, Sub Arc
Technology Strip Cladding Narrow Gap Welding
solution solution
Global Leader
in Longitudinal Pipe Welding
and Leading Position
in Spiral Pipe Welding

22 THE GAME CHANGER IN PIPE MILLS www.lincolnelectric.eu www.uhrhan-schwill.de

YOUR NEXT POWER WAVE® DIGITAL APPLICATION

THE NEW DIMENSION

IN STRIP CLADDING
70% Time and 40% Cost Saving
− Always Single Layer Solution
− High Speed Cladding Process
Homogeneous and Cleaner Chemistry
− < 5% Fe in Ni-625
− Improved Quality

Full Process Control

− State-of-the-Art Digital Hybrid 3D Z5 Controller
− Real Time Data Logging and Traceability
First Proven Single Layer High Speed Solution with Neutral Flux
− < 5% Fe in Ni-625
− Required Undiluted AWS Chemistry for Stainless Steel
Reduction in Working Capital
− Single Stainless Steel Strip for All Austenitic SS Grades
− Faster Delivery of MCW and Full Control of Delivery Time
Instant Technical Service to Customer

 DOWNLOAD BROCHURE

www.lincolnelectric.eu www.uhrhan-schwill.de THE GAME CHANGER IN PIPE MILLS 23

 CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company® is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our
challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for information or advice
about their use of our products. Our employees respond to inquiries to the best of their ability based on information provided to them by the customers and
the knowledge they may have concerning the application. Our employees, however, are not in a position to verify the information provided or to evaluate
the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume any liability with respect to
such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express
or implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of fitness for any
customers’ particular purpose is specifically disclaimed.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains
the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication
methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
24www.lincolnelectric.eu
THE GAME CHANGER IN PIPE MILLS www.uhrhan-schwill.de www.lincolnelectric.eu www.uhrhan-schwill.de09/17