|D/F MIG Automatic Water-Cooled-to-the-Tip Machine Torches|
D/F MIG Water-Cooled-to-the-Tip 5" & 8" Series-A High-Capacity Automated Machine Torches
Improve productivity with theses automated weld torches for automatic welding systems. These torches have been specially designed to deposit more weld metal at fast travel speeds which eliminates bottlenecks and cuts costs.
D/F Machine Specialties has been committed to producing the finest American made welding products available on the market today. Most recently, D/F Machine Specialties announced its NEW Automatic Water-Cooled to the Tip Torch. D/F's MIG (Gas Metal Arc Welding) & TIG (Gas Tungsten Arc Welding) torches have been used exclusively with welding automation equipment by Lincoln Electric, Miller Welding, Linde/ESAB, and Thermadyne for over 40 years. For automated welding systems, hard automation, high deposition, and large wire diameters that require preheat and high amperages, a D/F heavy duty water-cooled weld automation torch is ideal and has been used for metal build up, hardbanding, hardfacing, metal spray applications, and pipeline construction, or even retrofit with a flux delivery system for sub-arc applications, and applications where carbide is added like with the Welding Alloys Multi Surfacer: custom designed automated welding equipment. Our torches have been designed, tested, used and continuously upgraded for more than 40 years, in almost every type of environment. The flexibility of D/F Machine Specialties automatic welding torches makes them ideal for all fabrication applications. Our torches are suitable for GMAW, pulsed GMAW and FCAW processes. They provide a wide range of travel, wire feed, and oscillation parameters to accommodate various materials, thicknesses and joint designs.
The fully Water-Cooled-to-the-Tip direct mount Docking Spool® MIG (GMAW) automatic models NCM-W/C-T & HTM-W/C-T machine torches are for high current single arc welding. Very similar in design to the Linde ST-12, Guild ST-12 and Binzel AUT 750 but with improvements and new features, and proven to be a superior replacement alternative for the Lincoln Electric NA-5 & NA5R submerged arc wire feeders with K148A & K148B torches, or on Miller sub-arc machines with OBT 600 & OBT 1200 machines, the D/F Machine Automatic Water-Cooled-to-the-Tip positive contact assembly are designed to provide long trouble-free service. These Automatic Water-Cooled-to-the-Tip Torches are available in 5" and 8" lengths. Each length is available with our standard size nozzles (1.125"), and our high capacity (Series A) nozzles (1.445") for more gas coverage. You can switch between the standard nozzles and high capacity nozzles if you have the correct inner parts for each. With the use of the D/F sub-arc nozzle thread seals (14871 for Standard Size nozzles & 14872 for High Capacity size nozzles) these heavy duty MIG water-cooled torches can be converted and used as sub arc torches. Because of the robust design of the torch and the water-cooling on the body, nozzle and tip, downtime and consumable cost can be greatly reduced in the submerged arc process (SAW). With the various models available, an automated MIG torch selection may be made to suit individual automated welding system requirements.
Example: Require 40136 with 4 Ft. Water-In Hose Assembly - 40136-4
The direct mount fully Water-Cooled-to-the-Tip Docking Spool® accommodates two (2) water cooled nozzle assemblies. This arrangement is readily adaptable to dedicated or automatic welding applications such as the Lincoln Electric NA-3, NA-4, NA-5, NA5R, Power Feed 10, LF-72, LF-74 automatic wire feeders, Miller series power pins, ESAB, Euro and Tweco #4. The equipment consists of four (4) basic components: a Utility Station, an intermediate Utilities Combination assembly, a High Deposition Docking Spool®, and a Water Cooled Nozzle. The Docking Spool® is the principal component in this welding equipment arrangement. It accepts the utilities at the top end of the Docking Spool® and provides a means of accepting the water cooled nozzle at the lower end with superior water cooling. Several features important to a welding system are provided. Incorporated within the water channels of the Docking Spool® are check valves which provide a means of retaining residual water in the lines when the nozzle assembly is removed from the Docking Spool®. In addition a POSIT® Ring is provided at the upper end of the Docking Spool® which allows positive location in a mounting bracket to maintain dimensional stability.
The W/C Tip Torches can run the complete line of D/F standard size C122 DHP contact tips and the complete line of D/F standard size CrZr (chromium zirconium) long-life contact tips, as well as any custom current tip configuration you may need. .030" (.8mm), .035" (.9mm), .045" (1.2mm), .052" (1.4mm), 1/16" (1.6mm), 3/64" (1.2mm), 5/64" (2mm), 3/32" (2.4mm), 1/8" (3.2mm) and other diameters.
W/C Tip D/F Machine Specialties torches are standard equipped with 1 water/out & power cable are rated at 650 amps (continuous duty cycles). These ratings are, however, dictated by the contact tip. The NCM (slip-in) series of contact tips is rated up to 450 amps (continuous duty cycles). If your welding application requires amperages above 450, you must change to the heavy duty threaded CrZr (chromium zirconium) series of contact tips.
These automatic machine welding assemblies are designated by torch models. The model NCM (slip-in Contact Tip) has a current capacity 450 amps in argon shielding. Like the ESAB ST-12, these accommodate slip-in current tips fastened by a collet action nut. The wire diameter range with hard wire is .030"-1/16", cored wire .035"-1/8", and aluminum wire range of .035"-3/32".
The torch model HTM (Threaded Contact Tip) has a current capacity range of 650 amperes. Rating will be contingent on the combination of current tip and shielding gas to be used. The model HTM employs threaded CrZr (chromium zirconium copper) current tips and will accommodate .030" - 1/16" hard wire, .035" – 1/8" cored wire and 3/64" - 3/32" aluminum wires.
In some instances C122 DHP is adequate, but for stainless steel and stiff, high column strength or abrasive wires such as flux cored / metal cored, CrZr is the correct choice. D/F Machine Specialties can increase several key characteristics creating a higher-quality consumable with increased conductivity, even higher softening temperature and improved hardness. This means a reduction in "arc start failures" and increased tip life. Copper chromium zirconium (CuCrZr) contact tips increase productivity.
W/C Tip model torches can also be retrofit to have 2 water/out & power cables increasing the continuous duty cycle rating to 850 amps. These amperages require the use of the HTM or threaded series of chromium zirconium (CrZr) current tips.
Each D/F gun is fully assembled and ready to install. In order to make the installation complete, the code number, wire size, make/model (Lincoln wire feeders, Miller wire feeders, Tweco wire feeders, ESAB wire feeders, & EURO Quick-Disconnect wire feeders), and inlet as needed must be specified when ordering. If special welding tools or accessories other than those listed previously are required, please consult with the factory. Get the right feeder adapter connection to fit your MIG wire feeder.
D/F Water-Cooled-to-the-Tip 5" & 8" Automated Machine Torches
The fully Water-Cooled-to-the-Tip Models NCM-W/C-T & HTM-W/C-T Direct Mount Automatic Machine Torches offer the same features as those described for the machine barrels above. These torches feature the 1.125" smaller O.D. water-cooled nozzle for hard-to-reach, limited access areas. Very similar in design to the Union Carbide ESAB ST-12 and Guild ST-12 but with improvements and new features, and proven to be a superior replacement alternative for the Lincoln Electric K148A & K148B, the D/F Machine Automatic Water-Cooled-to-the-Tip positive contact assembly are designed to provide long trouble-free service. These D/F heavy duty water-cooled weld automation torches are ideal and have been used for metal build up, hard banding, hard facing, metal spray applications, and pipeline construction, or even retrofit with a flux delivery system for sub arc applications, and applications where carbide is added.
The direct mount fully Water-Cooled-to-the-Tip Docking Spool® accommodates two (2) water-cooled nozzle assemblies. This arrangement is readily adaptable to dedicated or automatic welding applications such as the Lincoln Electric NA3, NA4, NA5, NA5R, Power Feed 10, LF72, LF74 automatic wire feeders, Miller series power pins, ESAB, Euro and Tweco #4. The equipment consists of four (4) basic components: a Utility Station, an intermediate Utilities Combination assembly, a High Deposition Docking Spool®, and a Water Cooled Nozzle. The Docking Spool® is the principal component in this welding equipment arrangement. It accepts the utilities at the top end of the Docking Spool® and provides a means of accepting the water cooled nozzle at the lower end with superior water cooling. Several features important to a welding system are provided. Incorporated within the water channels of the Docking Spool® are check valves which provide a means of retaining residual water in the lines when the nozzle assembly is removed from the Docking Spool®. In addition a POSIT® Ring is provided at the upper end of the Docking Spool® which allows positive location in a mounting bracket to maintain dimensional stability.
Example: Require 40136 with 4 Ft. Water-In Hose Assembly - 40136-4
Fixed automation is a process that uses mechanized machinery to perform repetitive operations in order to produce a high volume of similar parts. In fixed automation, the sequence of processing operations is fixed by the equipment layout.
Programmable automation is an applied form of fixed automation that is capable of repeating motion, in a series of steps, for producing products in batches. Applied products in a programmable automation system are made in batch quantities ranging from several dozen to several thousand units at a time. For each new batch, the programmable automation equipment must be reprogrammed and changed over to accommodate the new product style. Programmable automation may commonly include one to three axes of torch motion and/or multiple welding arcs.
D/F Machine Specialties is the world leader in the manufacture of water-cooled torches for hard automation systems which encompasses fixed automation and programmable automation.
Each D/F automatic welding torch head is fully assembled and ready to install. In order to make the installation complete, the code number, wire size, make/model automated welding system (Thermadyne Thermal Arc Wire Feeders, Lincoln wire feeders, Miller wire feeders, Linde/ESAB wire feeders), and inlet as needed must be specified when ordering. If special welding tools or accessories other than those listed previously are required, please consult with the factory. Get the right feeder adapter connection to fit your MIG wire feeder.
Hardbanding is the process of depositing hardfacing alloys onto drill pipe tool joints, collars and heavy weight pipe in order to protect both the casing and drilling assets from wear associated with drilling practices. Hardbanding is most commonly applied to the box end of drill pipe tool joints using a MIG welding process, bonding the hardbanding alloy with the parent steel of the drill pipe. There are, however, other hardbanding application methods that are occasionally used including laser and plasma arc processes.
The need for hardbanding arose decades ago when drilling contractors and operators wanted a way to protect and extend the life of costly drill pipe and tool joint material from the wear associated with rotational and axial friction forces while drilling and tripping in and out of a well. Initially, tungsten-carbide particles were dropped into a mild-steel matrix, remaining the industry standard used for many years. However, well owners soon realized that while the tool joint was virtually free of wear, the tungsten-carbide based hardbanding was causing extreme rates of wear and occasional total failure of the well casing. The goal for the hardbanding industry became clear: create a hardbanding alloy that is casing-friendly while providing adequate protection of the tool joints.
Since that time, the market has become increasingly competitive and newer, more metallurgically advanced alloys have been introduced that protect casing and drill string assets better than ever. As wells are being drilled further, faster and more directionally, new challenges arise for hardbanding alloy producers. Competitive hardbanding products must now be able to protect drilling and casing components, but also withstand increasing extreme pressures and temperatures experienced in wells today. "Staying ahead of where drilling is going" is a mantra that every hardbanding producer will have to follow in order to stay competitive. Research is producing valuable and telling results that is enabling companies to improve their existing products, as well as, work towards introducing new and innovative hardfacing alloys to protect drill pipe and casing assets like never before.
As drills go deeper and the hardbanding industry stedily evolves, D/F Machine Specialties strives to meet the assocaited demands by selling quality MIG welding products for your hardbanding needs. Our Automatic MIG Water-Cooled-to-the-Tip Machine Torches and our Open-Arc Water-Cooled Gasless Overlay Machine Torches are ideal for steel wire, stainless steel, hard, cored, flux cored, or stellite, 1000 degree preheat, high deposition or continuous duty cycles - these are the torches used by:
Hardbanding solutions for your business - whether you are oil & gas operators, drilling contractors, pipe rental companies, pipe manufacturers, or hardband applicators, hardbanding will help you:
Companies that use Hardbanding Solutions:
Frequently Asked Questions:
What is hardbanding?
Hardbanding is the process of depositing a layer of super hard metal onto drill pipe tool joints, collars and heavy weight pipe in order to protect both the casing and drill string components from wear associated with drilling practices.
How is hardbanding applied?
Hardbanding is most commonly applied using a modified MIG welding apparatus designed specifically to apply hardbanding onto a tubular surface. With this process, a continuous consumable wire electrode and a shielding gas are fed through a welding torch. An electric arc transferred between the wire electrode and parent metal melts the hardbanding wire and forms a fully metallurgically bonded hardbanding overlay. There are, however, other hardbanding application methods that are occasionally used including laser and plasma arc processes.
How often does hardbanding have to be reapplied?
Depending on drilling conditions and hardbanding performance, hardbanding will have to be reapplied anywhere from several weeks to many months of service. Hardband re-application is a costly and time consuming process which usually involves transporting drill string components to inspection or other facilities that are capable of hardbanding operations. Mobile hardbanding units may also be deployed to or near drilling operations for on-site application. Use of these machines depends on the availability or supply of units offered in any given area.
What are the different types of hardbanding?
Hardband products can generally be divided up into two categories: Tungsten Carbide (non casing-friendly) and Casing Friendly hardband products. Casing friendly material can be metallurgically classified as “chromium-carbide”, “Titanium Carbide”, “Niobium Boride”, and other, based materials.
What is "cracking hardbanding", and why does it crack?
Cracking hardbanding describes a hardbanding product that exhibits what is referred to in the hardfacing world as “check relief cracking”. “Check relief cracking” occurs when low-melting phases form over grain boundaries as the molten weld puddle cools. In other words, a specific type of carbide forms on the grain boundaries of the microstructure that create stress as the material cools immediately after being deposited on the parent metal – as a result, fine cracks form. Hardfacing materials that exhibit cracking cannot be used for structural uses, though for abrasion or wear resistance they are widely acceptable, as in the case of hardbanding for tool joint and other drill string component applications.