The Ultimate Solution for MAG Orbital Welding (Pipe welding)

In the realm of Orbital Welding, precision and efficiency are paramount. When it comes to welding applications demanding high heat input, the CEWELD® AA R500 PIPE stands out as a reliable and versatile solution. This seamless rutile cored wire is specifically designed for MAG orbital welding, offering exceptional performance and durability.

Standard classification depending on the heat input
EN ISO
EN -ISO 17632-A: T 50 4 Mn1Ni P M21 1 H5 > 1,5 kJ/mm
EN -ISO 18276-A: T 55 4 Mn1Ni P M21 1 H5 < 1,5 kJ/mm

 

AWS
ASME -AWS A 5.36: E81T1-M21A4-Ni1-H4 > 1,5 kJ/mm
ASME -AWS A 5.36: E91T1-M21A4-Ni1-H4 < 1,5 kJ/mm

 

Applications for AA R500 PIPE

CEWELD® AA R500 PIPE is a seamless rutile cored wire with very good modeling properties, therefore excellent constraint welding with higher amperages is possible. Suitable for use down to -40°C depending on requirements down to -60°C. Especially well suited for orbital welding and basically welding on weld pool backing in all positions, even with high heat input. The CEWELD® AA R500 PIPE is suitable for Pipeline and tank construction, steel construction and shipbuilding as well as in offshore or onshore applications.

Features
  • Extremely low diffusible hydrogen contents HD < 3 ml/100g are measured on average.
  • HD < 4ml/100g is guaranteed according to AWS.
  • No re-drying necessary resp. is not allowed because of the copper plating.
  • Reduces costs compared to stick electrodes and many folded flux cored wires.
  • Ni < 1 % ( suitable for sour gas projects ).
  • NACE requirements are met.
  • Easy slag removal. (Partially self-dissolving).
  • Very good notch impact values even in forced positions down to - 40°C, conditionally also down to -60°C possible.
  • Orbital welding with bath backing or a root seam with high performance possible.
  • High productivity due to alloying optimally adapted to orbital welding.
  • Crack-proof even in constrained positions. Reduces reworking and thus costs.

All these points make the CEWELD® AA R500 PIPE a very economical solution for welding in constrained positions
with high heat input, especially in MAG orbital welding by machine.

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copper welding wire copper spool
Suitable products for weld pool backing or root welding from CEWELD

Visit Ceramic backing U shaped, Ceramic backing Ø shaped or read our brochure about Cermic backing for more information.

 

Filler metals for root welding

We offer a wide selection of welding wires including; Stick electrodes, metal cored wires, solid wires and tig wires. Al suitable for root welding. Down below you find some of them.

Stick Electrodes

CEWELD® AA M400

without Ni
17632-A: T 42 4 M M21 1 H5
A 5.18: E70C-6M H4

CEWELD® AA M460

without Ni
17632-A: T 46 6 M M21 1 H5
A 5.18: E70C-6M H4

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T 50-6 seamless metalcored welding wire for 500 MPa X70 steels

CEWELD® AA M500

< 1,0 % Ni
17632-A: T 50 6 Ni1 M M21 1 H5
A 5.28: E80C-Ni1 M H4

CEWELD® AA M550

~ 1,5 % Ni
18276-A: T 55 6 Mn2,5Ni M M21 1 H5
A 5.28: E80C-Ni2 M H4

Metal Powder Cored Wires

CEWELD® SG Ni1

14341-A: G 50 6 M21 3Ni1
A 5.28: ER80S-Ni1

CEWELD® SG Ni2,5

14341-A: G 46 7 M21 2Ni2
A 5.28: ER80S-Ni2

CEWELD® SG NiMo1

16834-A: G 505 M21 Z3Ni1
A 5.28: ER80S-Ni1

Solid Wires

CEWELD® SG Ni1 Tig

636-A: W 46 6 3Ni1
A 5.28: ER80S-N

CEWELD® SG Ni2,5 Tig

636-A: W 42 9 2Ni2
A 5.28: ER80S-Ni2

Tig rods

CEWELD® SG Ni1 Tig

636-A: W 46 6 3Ni1
A 5.28: ER80S-N

CEWELD® SG Ni2,5 Tig

636-A: W 42 9 2Ni2
A 5.28: ER80S-Ni2

The latest production technology in combination with a special selection of raw materials ensures excellent mechanical properties.

Quality values of the weld metal according to ISO for the CEWELD® AA R500 PIPE 

Mechanical  Rm Rp0,2 A5 Charpy V (J)
[MPa] [MPa] [%] - 20° - 40° - 60°
680 590 23 100 90 70
Chemical (%) C Si Mn P / S Ni Mo
0,06 0,5 1,6 0,01 / 0,003 0,9 0,01
Hydrogen (H2) Guaranteed HD < 4 ml/100g according to AWS A 4. 3
Typical values are between 1.5 - 3 ml/100g

 

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Seam preparation of the standard weld metal according to ISO

Seam preparation of the standard weld metal according to ISO 

Welded with high heat input. With approximately 12 welding beads

Typical layer structure for orbital welding
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from 6 to 12 o clock welding

Welding direction from 6 to 12 o'clock position on both sides of the pipe.

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Seamless fluxcored welding wire thick

It is usually welded in a pendulum mode over the entire width of the seam. 

General advantages of our full closed cored wires, the so called seamless cored wire.

•    Hydrogen contents HD < 4 ml/100g weld metal according to AWS A4.3 are maintained.
On average, HD < 3 ml/100g weld metal is measured for the entire processing and storage time.
•    No special storage conditions required, analogous to those for solid wire. ( Dew point must be observed)
•    No re-drying required or is prohibited for copper plated types. Reduces costs.
•    Very easy handling for the welder. Reduces the risk of defects. ( e.g. bonding defects )
•    Excellent welding properties in constrained positions due to supporting effect of slag, for rutile types.
•    Good conveying properties therefore very suitable especially for machine welding.
•    Reduced nozzle wear compared to cored flux cored wire.
•    Many types available for high heat input welding.
•    Very crack-resistant weld metal, even in constrained positions.
•    Stable arc.
•    Low smoke generation
•    Very low spatter formation and thus lower weld metal losses.
•    Reduced rework costs

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Seamless fluxcored welding wire thick

Want to know more about Flux cored wires? Read the blog: "The best welding wire; Rutile flux cored, Metal Cored or Solid welding wire?" for more information!

The CEWELD® AA R500 PIPE was evaluated by means of practical tests. It was tested with different heat applications and layer buildups.

For all tests, the seam preparation with 30°C flank angle was selected. The air gap was set 3-4 mm. The root was prepared with a metal powder filler wire in the short arc in the PF position. All filler layers were also welded in the PF position with a shielding gas of group M21. The layer structure and thus also the heat input during welding were varied.

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widely waved

Widely oscillated
With high heat input

Quality values
Rm 610 Mpa
Rp0,2 540 Mpa
A5 27 %
AV 80 J(-40°C)

 

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narrow waved

Slightly oscillated
Reduced heat input

Quality values
Rm 680 Mpa
Rp0,2 590 Mpa
A5 25 %
AV 90 J(-40°C)

 

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non waving

Not oscillated
Lowest heat input

Quality values
Rm 720 Mpa
Rp0,2 610 Mpa
A5 23 %
AV 100 J(-40°C)

 

These results show very clearly that the quality values can be strongly influenced by the welding parameters and thus the heat input and the layer structure. Of course, this can also be used for oneself if the boundary conditions are varied or adapted to

In summary, the following influences should be noted:
• Heat input (Q = [ k* U *I *60] / [ v*1000 ] kJ/ mm).
• Carbon equivalent Cev. for some base materials
• Preheating temperature (°C)
• Interpass / working temperature (°C)
• Cooling time (s)
• Layer structure (beads per layer) ( ideally always from the flanks to the center)

These points can be summarized under the heading T 8/5 Time Concept. You can find more information about the t 8/5  concept in the blog: "Strong Steel, Robust Connections: Welding Fine-Grain Structural Steel".

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Seam structure welding

You can find more information about the influence of layer structure in the blog: "Strong Steel, Robust Connections: Welding Fine-Grain Structural Steel".

plate thickness Current [A] Voltage [V]
15mm 4 Layer
160 - 180
220 - 240		 22 - 24
20mm 5 Layer
160 - 180
220 - 240		 22 - 24
25mm 6 Layer
160 - 180
220 - 240		 22 - 24
30mm 9 Layer
160 - 180
220 - 240		 22 - 24