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WELDING
GLOBAL MANUFACTURING BASES
AND OFFICES
ASIA
JAPAN:
KOBE STEEL, LTD., Welding Business
Global Operations and Marketing Department
TODAY
Marketing Center
Tel. (81) 3 5739 6331 Fax. (81) 3 5739 6960
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KOREA:
KOBE WELDING OF KOREA CO., LTD.
Tel. (82) 55 292 6886 Fax. (82) 55 292 7786
CHINA:
Vol..
KOBE WELDING OF SHANGHAI CO., LTD.
Tel. (86) 21 6191 7850 Fax. (86) 21 6191 7851
SINGAPORE:
KOBELCO WELDING ASIA PACIFIC PTE. LTD.
Tel. (65) 6268 2711 Fax. (65) 6264 1751
THAILAND:
THAI-KOBE WELDING CO., LTD.
Tel. (66) 2 636 8650 to 8652 Fax. (66) 2 636 8653
KOBE MIG WIRE (THAILAND) CO., LTD.
Tel. (66) 2 324 0588 to 0591 Fax. (66) 2 324 0797
VIETNAM:
REP. OFFICE of THAI-KOBE WELDING in DONG NAI
Tel. (84) 61 395 5218
MALAYSIA:
KOBE WELDING (MALAYSIA) SDN. BHD.
Tel. (60) 4 3905792 Fax. (60) 4 3905827
INDONESIA:
P.T. INTAN PERTIWI INDUSTRI
(Technically Collaborated Company)
Tel. (62) 21 639 2608 Fax. (62) 21 649 6081
INDIA:
KOBELCO WELDING INDIA PVT. LTD.
Tel. (91) 124 4010063 Fax. (91) 124 4010068
EUROPE
NETHERLANDS:
KOBELCO WELDING OF EUROPE B.V.
Tel. (31) 45 547 1111 Fax. (31) 45 547 1100
SWEDEN:
KOBELCO WELDING OF EUROPE AB
Tel. (46) 31 767 55 91
AMERICA
USA:
KOBELCO WELDING OF AMERICA INC.
Tel. (1) 281 240 5600 Fax. (1) 281 240 5625
Products Spotlight ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Preface ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
A method that controls wire feeding in high-speed Figure 2 compares the amount of wear at the Dear KWT readers! I’d like to express my sincere gratitude for your kind and C 21 NTENTS
Vol.
welding of thin steel plates is being applied mainly contact tips after one-hour continuous welding continuous patronage of KOBELCO products. page
by car manufacturers as a new technology that
greatly reduces spatter generation even at the
between a conventional wire and MG-1T(F). The
amount of wear at the MG-1T(F) contact tip is one
The year 2018 is a profoundly memorable year for our global business.
THAI-KOBE WELDING CO., LTD. (TKW) has celebrated the 50th anniversary
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globular transfer area in high current welding. With half that of the conventional wire s. The surface since it was established. As the first overseas production operation of the entire
this method of welding, wire feeding is controlled treatment has also improved wire feedability and arc KOBE STEEL group, the establishment of TKW was an important turning point in
so as to alternately change the wire-feed direction stability in addition to reducing wear at the contact tip. the KOBELCO group’s long-lasting history over 110 years.
from forward and backward, as shown in Figure 1.
The time variation of welding current, arc As a member of the overseas business, I was honored to be present on such a MG-1T(F) controls wire feeding
voltage and wire feed resistance between a memorable day after half a century and felt very proud. I would like to pay my in high speed welding of thin
steel plates
conventional wire and MG-1T(F) were measured respects to our senior members as well as everybody who was involved. Looking
as shown in Figure 3, and the result is shown in back over the last 50 years, I understand both the difficulties the company has faced page
is that it causes heavy wear in the contact tip, leader among the 13 overseas bases, becoming the largest production base in the
Welding Business group as well as a base of research and development that
resulting in the deterioration of welding quality Figure 4: Time variation of welding current, arc voltage and wire feed responds to the needs of local customers.
caused by an unstable arc. resistance between a conventional wire and MG-1T(F)
Over the next 50 years, it will be important for TKW to have energy and
MG-1T(F), one of the new F Series solid wires, Tables 1, 2 and 3 show the typical wire chemical
contribute to the development of the welding industry in order to support not only
can minimize rapid wear of contact tips by compositions, mechanical properties of the Thailand’s but also the Southeast Asian region's industrial advancement.
reducing physical friction-resistance as well as all-deposited metals and chemical compositions of
improving electricity supply by means of its the all-deposited metals of MG-1T(F), respectively. Maintaining the Thai business and strengthening the ties between TKW and the
special wire-surface treatment. Table 1: Typical chemical compositions of MG-1T(F) wire
KOBELCO group in other Southeast Asia countries is the way to achieve our
Welding Business slogan: Take the overwhelming No. 1 position in Asia. I promise
Before welding After welding Wire C Si Mn P S Cu *1
Conventional wire MG-1T(F) MG-1T(F) 0.05 0.89 1.40 0.006 0.015 0.24
that we, in the Global Operations and
JIS Z 3312
Marketing Department, will mobilize
0.02-0.15 0.55-1.00 1.25-2.00 ≤0.030 ≤0.030 ≤0.50
YGW12 all of our available resources and Note:
Note: *1: Cu value contains Cu coating.
tightly cooperate with overseas , , in trade names indicate
Table 2: Typical mechanical properties of all-deposited metal companies. It is, therefore, highly FAMILIARCTM, TRUSTARCTM,
appreciated if you could extend your
300
Absorbed PREMIARCTM.
Wire 0.2%OS (MPa) TS (MPa) El (%)
contact tip [μm]
energy at 0℃(J)
Wear amount of
250
50
YGW12
≥390 490-670 ≥18 ≥27 Koichi (Jay) Sugiyama is published by
0 General Manager Marketing Center
Conventional wire MG-1T(F) Table 3: Typical chemical compositions of all-deposited metal Global Operations & Marketing
Welding Business,
C Si Mn P S Cu Department, Marketing Center
Figure 2: Comparison of wear amounts of contact tips Welding Business KOBE STEEL, LTD.
Note: One hour continuous welding at 200A-25V, 100% CO2 gas 0.06 0.60 1.00 0.012 0.013 0.24 KOBE STEEL, LTD. URL: http//www.kobelco.co.jp/english
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Technical Highlight ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ KOBELCO
WELDING
TODAY
“1Z Series” welding consumables Vol.21 No.3 2018
for galvanized steel sheets 3 Porosity defects on defects and reduced productivity due to repairs, all of
which are problems linking quality and cost.
galvanized steel sheets
Furthermore, the vaporized Zn gas prevents stable
The biggest problem in welding galvanized steel sheets droplet transfer. The gas disturbs the arc as it ejects
is the generation of porosity defects such as blow holes, underneath, causing the droplets to become larger and
pits and spatter. The welding usability of galvanized steel unable to transfer smoothly to the molten pool; instead,
sheets varies depending on the weight per unit area of Zn they are short-circuited by the molten pool, generating a
film coating (hereinafter referred to as Zn coating mass) large amount of spatter.
on the steel sheets. Where the Zn coating mass is higher,
the occurrence of porosity defects and/or spatter
increases. Figure 1 is a schematic drawing that shows the 4 Welding consumables for
galvanized steel sheets
mechanism of porosity generation in lap fillet welding of
galvanized steel sheets.
The Zn coating mass is so influential in welding
When Zn, which has a boiling point of about 900°C, is galvanized steel sheets that the selection of welding
heated by the arc and decomposes pyrolytically, it methods and consumables is extremely important. Table
vaporizes and generates a large amount of gas. Porosity 2 shows the features of the newly-developed 1Z Series
forms from the vaporized Zn gas that remains in the welding consumables for galvanized steel sheets while
molten pool. The effects of porosity include poor bead Table 3 shows the chemical compositions and
appearance, low tensile strength caused by cross-sectional mechanical properties of their deposited metals.
2 The features of different kinds of with organic resin Steel sheet 60-300
They are galvanized steel sheets on which the Zn Prepainted
galvanized steel sheets coating is coated with an additional layer of organic steel sheets
Prepainted Organic film
resin or film. This provides better corrosion resistance electrogalvanized
Zn+Ni alloy 1μm/20-30
steel sheets Figure1: The mechanism of porosity
A wide range of galvanized steel sheets are available and looks attractive, too. with organic film Steel sheet
generation in lap fillet welding
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Technical Highlight ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ KOBELCO
WELDING
TODAY
Vol.21 No.3 2018
4-1. Solid wires copper coating. Due to the non-Cu coating, Cu flaking, the viewpoint of porosity resistance.
MG-1Z, a solid wire exclusively developed for which is usually caused by the pressure of a pressing
Sheet thicknesses of between 1.6 and 6.0 mm and the
welding galvanized steel sheets, is designed to produce roller or by contact with the liner inside a conduit cable, 5.0
horizontal and flat welding positions are recommended.
feedability and electric conductivity even without a gas nor the pulsed MAG process are recommended from Welding current (A)
SE-1Z
Solid wire 0.10 0.49 1.10 0.009 0.009 - 430 540 30 110
MG-1Z
Lap fillet weld: 240A-30V-450mm/min; Sheet thickness: 3.2mm; Zn coating mass: 135g/m2
MX-1Z 0.05 0.50 1.52 0.011 0.010 - 480 570 26 83
Gas-shielded
MX-100Z 0.10 0.40 1.55 0.011 0.012 - 480 590 27 100
FCW
DW-1SZ 0.12 0.15 1.48 0.010 0.005 - 420 560 26 60
Covered
Z-1Z 0.09 0.15 0.48 0.015 0.005 - 380 450 26 100
electrode
Bead appearance Macrostructure
Self-shielded
OW-1Z 0.25 0.23 0.91 0.008 0.002 2.38 --- --- --- ---
FCW
Figure 4: Bead appearance and cross-sectional macrostructure of MX-1Z (1.2mm dia.) weld
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Technical Highlight ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ KOBELCO
WELDING
TODAY
Vol.21 No.3 2018
welding current of not less than 200A while 4-3. Covered electrode Figure 7 shows the bead appearances, cross-sectional
MX-100Z does so in the low current zone equal to or Z-1Z is another newly-developed covered electrode macrostructures in both horizontal fillet welding and lap 5 Postscript
less than 200A. for welding galvanized steel sheets. Its special features fillet welding and the fractured surface of horizontal
include strong arc blow and an excellent arc fillet welding of a Z-1Z (4.0mm dia.) weld. In welding hot-dip galvanized steel sheets, welding
By contrast, when the Zn coating mass is equal to or efficiency can be improved by selecting the most
more than 150g/m2, DW-1SZ is suitable. concentration. As it provides good arc stability,
spattering is reduced. 4-4. Self-shielded flux cored wire suitable combinations of welding method and
DW-1SZ features excellent porosity resistance, OW-1Z is a self-shielded flux cored wire (FCW) consumable and taking into consideration the type of
small-sized spatter and a stable arc; in addition, it is Z-1Z’s recommendable Zn coating mass is equal to galvanized steel sheet as well as its Zn coating mass.
that does not require shielding gas and is suited to
suitable for all position welding. However, it can only or less than 550 g/m 2 , and it is suitable for welding
outdoor welding. Its high porosity resistance minimizes The 1Z Series welding consumables for galvanized
be utilized with direct current electrode negative hot-dip galvanized steel sheets as well as normal steel
porosity defects even in welding galvanized steel sheets steel sheets are suitable for sheets with a wide range of
(DCEN). plates.
with rather high Zn coating mass of up to 550 g/m2. Zn coating mass and can be utilized under a range of
However, sufficient care must be paid during use, welding procedures. They are also designed to reduce
because it has to be utilized with DCEN polarity only, it porosity defects and spatter generation.
is limited to sheets with plate thickness from 1.0 to 6.0 Note: Welding galvanized steel sheets generates more
Lap fillet weld: 140A-19V-300mm/min; Sheet thickness: 2.3mm; Zn coating mass: 135g/m2 mm and it should not be applied to weld joints requiring fumes than does welding normal steels. Please pay
high notch toughness. special attention, therefore, to environmental safety and
Figure 8 shows the bead appearances and hygiene by ensuring appropriate ventilation as well as
cross-sectional macrostructures of OW-1Z (1.2mm by using respiratory protection devices.
dia.) in horizontal fillet welding and lap fillet welding.
Bead appearance Macrostructure [References]
The photos in Figures 9 and 10 show the welding of a K. Yamazaki: Gas shielded arc welding of galvanized steel sheets ‒
Figure 5: Bead appearance and cross-sectional macrostructure of MX-100Z (1.2mm dia.) weld frame structure for a bus with SE-1Z and of a water problems and solutions - : The Japan Welding and Engineering
pipe with Z-1Z. Society, WE-COM Magazine Vol. 11 (Jan. 2014)
Horizontal fillet weld: 240A-22V-250mm/min; Sheet thickness: 6.0mm; Zn coating mass: 550g/m2
Horizontal fillet weld: 230A-22V-300mm/min; Sheet thickness: 6.0mm; Zn coating mass: 550g/m2
Figure 6: Bead appearance and cross-sectional macrostructure of DW-1SZ (1.4mm dia.) weld
Lap fillet weld: 280A-25V-300mm/min; Sheet thickness: 6.0mm; Zn coating mass: 550g/m2
Horizontal fillet weld: 130A; Sheet thickness: 6.0mm; Zn coating mass: 450g/m2
Figure 8: Bead appearance and cross-sectional macrostructure of OW-1Z (1.2mm dia.) weld
Lap fillet weld: 130A; Sheet thickness: 6.0mm; Zn coating mass: 450g/m2
Fractured surface
Figure 7: Bead appearance, cross-sectional macrostructure and fractured surface of Z-1Z (4.0mm dia.) weld Figure 9: Welding a frame structure for a bus with SE-1Z Figure 10: Welding a water pipe with Z-1Z
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Bulletin ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ KOBELCO
WELDING
TODAY
Vol.21 No.3 2018
Entertainment featuring a mix of Thai Presentation of the memorial gift A famous Thai singer (center) and her fans,
and Japanese cultures from KOBE STEEL, LTD. posing at the dinner show
Ceremony of monks walking for alms The memorial plate was presented by Thai Shin-Yo-Kai All the participants including employees of TKW and KMWT are posing in front of the office.
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