diamondspark seamless cored wires for brilliant welding results

Benefits

High deposition rate.

Böhler Welding seamless cored wires carry all general productivity advantages brought along by the cored wire product design, when compared with solid wires. At equal wire diameters, the current conducting cross section of cored wires is smaller and, therefore, resistance heating in the sheath (I2R effect) is higher at the same welding current. This translates into a higher wire melt-off rate and – depending on cored wire type (flux- or metal-cored) – in higher deposition rates than with solid wires. 

Growing portfolio.

On top of this basic productivity advantage, diamondspark cored wires make use of the powerful option to very precisely influence welding characteristics with well-designed cored wire formulations.

Böhler Welding rutile cored wires with fast freezing slag, for instance, provide deposition rates in positional welding up to three times as high as obtainable with any conventional arc welding process. In the downhand position, Böhler Welding metal-cored wires are the fastest way to join steel plate. Arc stabilizers make favorable spray arc welding start at welding currents where solid wires of the same diameter operate in the short or globular arc mode, with associated superior productivity and virtual absence of spatter. In fillet welding, significantly higher travel speed can be applied than with solid wires, with excellent weld quality.

Easy parameter settings.

One of the features of diamondspark metal-cored wires is a wide envelope of applicable welding parameters, enabling easy setting and wider use of productive spray arc parameters.

Hermetically sealed & ultra-dry.

Within the field of flux-cored arc welding, the seamless design offers optimal protection against moisture reabsorption and thereby against hydrogen induced cracking / hydrogen assisted cracking (HIC, HAC, cold cracking). For the simple reason that there is no open seam running over the wire length, moisture cannot penetrate into the filling.

diamondspark tubular seamless cored wires are produced with very low levels of diffusible hydrogen – typically 2-3 ml / 100g weld metal for rutile types and even lower for metal-cored and basic wires and the diamondspark laser-sealed metal-cored wires are even ultra-dry with average initial hydrogen levels well below 2 ml / 100 g weld metal.

diamondspark wires maintain this property until the moment of welding, regardless of the duration of storage and time of exposure at the work site. Without increasing hydrogen level in weld metal even after long term exposure, these wires provide the very best low-hydrogen performance available in the market.

Problem-free feeding.

The seamless, copper coated wire design adds sufficient stiffness and glide to overcome friction in liners, welding guns and contact tips. The copper coating enhances current transfer between contact tip and wire – and together with arc stabilizers in the filling – promotes good arc ignition and a stable arc. Controlled wire cast and helix largely avoids “dog tailing”, giving, well positioned welds.

Customer statements

Franz Wirnsperger (Head of Welding Technology and Analyses PALFINGER AG):

“With the new laser-sealed cored wires from the diamondspark series, Böhler Welding is setting new milestones in welding consumables and support herewith PALFINGER with the continuous development to ensure the global quality benchmark in lifting solutions.”

Dipl.-HTL Ing. Horst Jöbstl (Managing Director Schwing GmbH):

“With the new laser-sealed cored wires of the diamondspark series, we have the ideal filler material at our disposal to satisfy future welding requirements of high performance concrete pumps. Böhler Welding underlines its leading position in this area as supplier of innovative products developed in co-operation with customers.”

Products

diamondspark products covers a full range of seamless cored wires from two different fabrication technologies tailored to match the needs of demanding applications.

Details of diamondspark products for normal strength steel

Details of diamondspark products for weather resistant steel

Details of diamondspark products for low-temperature steel

Details of diamondspark products for high strength steel

Details of diamondspark products for pipe steel

Details of diamondspark products for creep resistant steel

Packaging

diamondspark cored wires are available in spools of 16 kg and in octagonal drums with a filling content of 250 kg.

Use of the drum avoids 15 spool changes of roughly 10 minutes, compared with wire spools. The result is 150 more minutes of net arc time and a correspondingly higher duty cycle and production output. Use of the drums will thereby immediately lower welding costs and increase a company’s profit.

The implementation of our drum systems – with high quality welding wires and dedicated accessories – will streamline the entire cored wire welding operation and further lower welding costs. A range of accessories for efficient internal transport and installation of the drums is available, including a choice of four different “click and go” liner types to connect the drums with the wire feed unit.

Find more information in the Brochure:

Success Stories

BÖHLER alform 700 L-MC

In the development of the seamless cored wires, Böhler Welding closely liaised with its mother company voestalpine who produces advanced high strength steel grades. Together they share a long lasting technological partnership with a globally leading fabricator of truck-mounted loader cranes, marine cranes, wind cranes and container handling systems. This innovative multi-national company - whose metal forming and welding operations are extremely efficient and performed with advanced technologies - tested BÖHLER alform 700 L-MC. This eventually went as far as an interruption of regular robotic production welding to replace solid wire to verify the potential of the metal-cored wire.

The result was a 15% lower net welding time for a critical crane component enabling the production of 8 instead of 6 pieces in an eight hour shift. This was due to the higher applicable travel speed in producing undercut-free fillet welds.