Technology Gets to the Root of Pipe Welding

Open root welds on pipes can be made three to four times faster than GTAW by using the
Surface Tension Transfer process. When integrated with an internal spacer clamp into a new
automatic orbital pipe welding system, even faster production is possible, with no lack of fusion.
Pipe welding codes, whether for applications in the field or in the plant, require high-quality root
pass welding. To ensure that the joints will not leak, especially for steam or pressurized applications,
a weld must penetrate completely through the pipe.
In the past, pipe welding was done by one of three methods, each of which has its advantages and
disadvantages. These are the methods that have been used.
Gas tungsten arc welding (GTAW) is popularly known as TIG. Travel speeds are slow, heat input is
usually high, and it requires high operator skill level.
Gas metal arc welding (GMAW) - also known as MIG - is a much faster process than GTAW. However,
because operator skill level is hight and heat input difficult to control, fusion may not always be 100
percent.
Shielded metal arc welding (SMAW), also known as stick, can be cost effective in terms of
equipment but requires high operator skill. Frequent starts and stops are another potential problem.

Smoke and Spatter are reduced when pipe

joints are welded by means of the Surface
Tension Transfer (STT) process.

By contrast, the Surface Tension Transfer (STT) process

makes it possible to complete open root welds three or four
times faster than GTAW, with low heat input and no lack of
fusion. The STT process uses high frequency inverter
technology with advanced waveform control to produce a highquality weld with less spatter and smoke. For pipe welding, the
process also makes it easier to perform open gap root pass
welding, with better back beads and edge fusion. It is easier to
operate than other processes, yet produces consistent, X-ray
quality welds. The STT process results in a complete back
bead without shrinkage from the 12 to 6 o'clock weld
positions. Also, because current control is independent of wire
feed speed, the process allows greater flexibility under all
conditions.

Controlling Spatter and Smoke

STT is a proprietary Lincoln Electric process that makes use of Wave Form Control Technology to
control current precisely and rapidly during the entire welding cycle. It is unique in that it is neither
constant current (CC) nor constant voltage (CV). Instead, the power source adjusts current
automatically to the instantaneous heat requirements
of the arc.
Spatter and smoke are reduced with this process,
whether the arc shielding gas is 100 percent CO2,
blends of argon and CO2 or helium mixtures for use
with stainless steel. Reducing spatter minimizes final
weld surface preparation and allows the operator more
welding time before the gun nozzle must be cleaned of
accumulated spatter.
Reduced spatter also translates into significant cost
savings because more of the electrode is applied to
the weld joint, not as spatter on the pipe and
surrounding fixtures. Further cost savings are realized
because larger diameter wire can be used.

In open root pass pipe welding, the STT

process controls the wave form of the
welidng current for excellent penetration
control, fusion, and back bead.

At the start of the cycle, when the electrode shorts, the current is reduced immediately, eliminating
the incipient short. This low-level current is maintained for a short time so that the surface tension
forces can begin transferring the drop to the puddle, forming a solid mechanical bridge. A high level
of pinch current is then applied to accelerate the transfer of the drop. The necking down or
squeezing of the shorted electrode is monitored. When a specific value is reached, the pinch current
is reduced quickly to a low value before the fuse separates. When a short breaks, it does so at a low
current, which produces very little spatter.
Next, the arc is reestablished and a high current known as peak current is applied. This momentary
pulse of current establishes the arc length and causes the arc to broaden and melt a wide surface
area, which eliminates cold lapping and promotes good fusion.
Better Pipe Welding Results
The constant voltage GMAW process normally used for pipe welding does not control the current
directly. Instead it controls the average voltage. This can cause the weld puddle temperature or
fluidity to be too high, and the internal bead may be flat or shrink back into the root. This is known
as "suck back." Also, when using conventional short arc GMAW, the operator must concentrate the
arc on the lip or leading edge of the puddle to ensure proper penetration and fusion. If the arc is too
far back on the puddle, penetration will be incomplete. If the arc is too far ahead, the electrode
shoots through the gap and causes whiskers to form inside the pipe.
Because Surface Tension Transfer controls the welding current independently of wire feed speed, the
process makes it easy to control the temperature or fluidity of the puddle to ensure proper
penetration and fusion. This is what makes it so attractive for open root pipe welding applications. In
the 5G position, the operator simply has to stay in the puddle. Experienced pipe welders almost
always find the process a welcome improvement, both in ease of welding and comfort. They
particularly appreciate the reduction in spatter when welding in the 6 o'clock position.
As the decision process evolves, the vendor and the fabricator will continue working together to
determine the appropriate system accessories, including safety devices, the optimal layout for the
robotic cell, manpower and training requirements, and service and maintenance requirements
(internal vs. outside vendor support).
The STT process is gaining acceptance in pipe welding and similar applications, which require precise
control of heat input as well as smoke and spatter reduction. Since the heat is controlled directly, the
internal backbead profile is also controlled. Welders find that not only are open root welds easier to
make, but their mechanical and metallurgical properties are excellent. Superior welding bead profiles
can be attained with improved properties in the heat affected zone. Moreover, open root welds are
made without the use of ceramic or copper internal backup. In the case of copper, corrosion is thus
eliminated by avoiding the possibility of copper inclusions.
The process is effective for welding mild and high-strength steels, as well as stainless steel and
related alloys. On steel, it offers the advantages of low hydrogen and 100 percent CO2 shielding
with low spatter. When welding duplex stainless, critical pitting temperature is significantly better
with STT than with GTAW, and travel speeds three or four times that of GTAW can be obtained, with
much less skill.