The Ebflow system enables very high joint completion rates in thick section steels. It has the capability to carry out linear and circumferential welds in thick steel up to 50m long in a single pass. This achievement comes following 10 years of research and development. It is the most advanced, high speed and cost effective welding system built for thick section steel large work pieces. Ebflow has a achieved a weld rate of 200mm per minute in 150mm thick steel & the fastest thick section joint completion rate outside of a full vacuum chamber ever.
The local vacuum nature of Ebflow is particularly suitable for large tubulars in thick section material. Welds can be made in a fraction of the time - over 20 times quicker is not unusual.
| S355 Grade Steel |
Ebflow |
Saw |
FCAW |
"Stick" |
| Linear Seam - 1.3m x 60mm WT |
6.0 mins |
8.3 hrs |
31 hrs |
41 hrs |
| Circ Seam - 711mm Ø x 40mm WT |
3.5 mins |
5.0 hrs |
47 hrs |
63 hrs |
Benefits
- Facilitating very high joint completion rates in thick section steels
- 20 to 30 times faster than traditional methods.
- 200mm per minute in 150mm thick steel have been achieved.
- Using a system of sliding seals and precision handling enables fast longitudinal and circumferential welds on large work pieces
- A coarse vacuum is established and maintained only where it is needed, no vacuum chamber required.
- Pre-heating is not necessary and consumables are not required during the weld.
- Minimal distortion.
- Quality and reliability are improved with immediate post weld inspection possible.
- Achieving the fastest thick section welding rates ever.
EBFLOW system
The Local Vacuum nature of EBFLOW is particularly suitable for large tubular thick section material. Welds can be made in a fraction of the time - over 20 times quicker than conventional arc welding methods is not unusual.
Tubulars - Wind Farms and Oil/Gas exploration
Technological innovation in this sector is being driven by the desire to reduce the costs and increase the manufacturing rate of large tubular structures used in tower foundations and offshore rigs of all types.
Specifications
EBFLOW process particularly suited for wall thickness above 40mm and up to 200mm
3,300 hrs Sub Arc Weld: 60 meters long x 6 meters diameter, 80mm thick section
110 hrs EBFLOW system: 60 meters long x 6 meters diameter, 80mm thick section
Wind Tower flanges
EBFLOW Technology is being deployed to manufacture flanges from sections rather than forging the whole flange in one piece.
Flanges added to the ends of the tubulars are used to join them together
Forgings can be welded and, because there’s no filler wire, the autogenous weld can be heat treated and the weld rendered invisible. It cannot be found using most methods of QC.
Nuclear - Power Generation and Waste Containment
Modern nuclear power plants rely on the use of large tubular structures to contain high pressure water for cooling and for long term storage of waste.
These forgings can also be welded with no filler wire, the autogenous weld can be heat treated and the weld rendered invisible. It cannot be found using most methods of QC.
High integrity autogonus welds and near parent metal strength
Production is quicker, more cost effective and less reliant on a small number of manufacturers so easing a production bottleneck
EBFLOW Vs Submerged Arc
Multiple Submerged Arc Welds (SAW) Vs a single pass EBFLOW
No joint "V" preparation required just clean metal to metal
Wide range of materials can be successfully welded
Single pass weld compared to a multi pass conventional arc weld