Welding robots

[smithyboi32]

Hi all , new to the site.

i have 5 Fanuc Lincon welding robots.

at the moment they use 100%Co2 ( as its cheaper)
but we weld .8 -2.5mm thick and some 12mm round bar. They have been having problems with there migs , no penertraion and blow holes .

iv sorted the no penertraion as they was programed by people with no mig welding experiance (fools) .

but no matter what i do i cant seem to controle the blow holes , iv started to run trials with coogar5 ( 5%C02 2-3% O2 the rest Argon i belive).
only bad point is that i have to use 1.2mm welding wire

is this the right gas for what i need to weld ?

Regards
adam

 

[Robotstar5]

We use 12% CO2 with mainly 1.0mm wire to weld 1-3mm plates/tubes.
Got rid of CO2 only over 10 years ago! we use bulk gases and a mixing panel.

 

[smithyboi32]

never thurt of the mixing option , is the mix pre set or can it be changed ?

i belive we used to use it here and still have the second tank out the back.

do you have many problems using that ?
and i dont suppose you know the price you pay by anychance ?
have priced up argon but as a manifold pack and not bulk.

 

[Robotstar5]

The mixing panel allows you to vary the ratio of CO2 to Ar, we optimised ours a few years ago.

We also have a manifold pack for emergencies (only needed once in 10 years)

I will try and find out bulk gas prices

We run 14 robots (mostly Fanuc) and 15 manual welders, so bulk is the most cost effective, do you run marathon wire packs?

 

[smithyboi32]

yes we have marathon packs supplied by sfinx (something like that).

looking into converting 2 mig robots to gas less fulxcore as there so far away from the pipe work, but not sure of the ins and outs yet .

i agree bulk gas will be most cost effective , but BOC never got back to me on a price so only have manifold pack price.

trying to weld with 1.2mm wire is a pain with such this meterial never mind with 100% Co2 lol

 

[Robotstar5]

We use Midland Welding for most of our consumables, good service at competitive prices - no connection, just satisfied customer!

 

[matt1978]

Hi Smithy,

Do the machines have the possibility to run in Pulse mode?

If you don't have a Pulse facility, you will always struggle to weld at very low amps for thin material with 1.2 mm wire.

 

[smithyboi32]

i dont belive they can run in pulse mode, im not running in too low settings . around 20volts i think.

to make it worse its car parts and covered in the dreaed galv .

if anyones got a setup running around the same parts , would you mind me coming to have a look ?

near to coventry or walsall area.

 

[matt1978]

For a Argosheild light mix (5-7% C02)

1.2mm Steel wire, Material thickness of around 1.2mm'ish

16-17 Volts around 2.0m/m wire speed

Thats about the lowest setting that would be stable on that size wire. (approx 70-80 amps)

 

[smithyboi32]

ok thanks Matt , running trials on Monday night so il try those setting then .

cheers

 

[Robotstar5]

Do the machines have the possibility to run in Pulse mode?

What make/model weldset have you got connected to the robot?

 

[smithyboi32]

the setup we have here is ...

Fanuc ArcMate 120iB
Fanuc system R-J3iC
Lincoln PowerWave 455M