MAGNATECH 427A, Operating & Maintenance Instruction Manual

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OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
44
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
12.8.2 Fit-up Requirements Maximum Wall Mismatch
Every procedure should be developed to accommodate reasonable fit-up and bevel variations that will be
seen in the job. Mismatch on the job should not exceed this predetermined maximum value unless the weld
procedure is modified or adjustments are made during the weld cycle. Making adjustments during the weld
is most difficult and can only be helpful if excessive mismatch location is known. During the weld
development stage the procedure should be done allowing for .062" (1.5mm) of overall mismatch or less.
This is the recommended total mismatch. During the PQR the prep geometry should be the same as field
welds, eliminating the requirement for further weld development in the field.
Root Pass Refinement (5G Position)
Problem Possible Solution
Excessive reinforcement from 2 o’clock to 11
o’clock
 Increase travel speed 0.125ipm (3mmpm) max increment at a time.
 Decrease High Pulse Current if pulse technique is used alternately.
 Decrease Low Pulse Current (% of High Pulse Current) or increase Low
Pulse time to 0.2 seconds max.

Increase wire speed 2ipm maximum increments at a time.
OD of root pass bead excessively convex

Decrease wire speed 2ipm (50mmpm) maximum increments at a time.
 Decrease travel speed 0.125ipm (3mmpm) increment at a time.
 Increase current. If pulse mode is used increase Low Pulse Current (% of
weld current) or decrease Low Pulse time .2 seconds max per change.
ID penetration is insufficient

Decrease wire speed 2ipm (50mmpm) maximum increments at a time.

Decrease travel speed 0.125ipm (3mmpm) increment at a time.

Increase current

Change Prep Geometry : As a last increase land extension length for J-
Prep. Increase bevel geometry included angle for standard V-bevel
(Increase 37.5
°
sidewall angle to 45
°
).
 Change Tungsten Geometry : Use a greater included angle tip
geometry.
ID bead concave 360º around pipe

Decrease current

Increase wire speed

Increase travel speed

Change prep geometry
 Change tungsten geometry
ID bead uniform except concavity at 5 o’clock to 7
o’clock

Decrease arc length

Increase wire speed

Increase travel speed
Consumable insert not completely consumed
 Increase current or High Pulse Current if pulsing used.
 Decrease travel speed
 Increase Low Pulse Current (increase % of High Pulse Current)
 Increase High Pulse time
 Decrease Low Pulse time
Consumable insert ID bead not uniform

Decrease current

Increase travel speed

Change tungsten geometry
 Change insert fit-up if possible