ESAB Welding and Cutting Products‘s ICE technology is a submerged arc welding technology that enhances productivity by using an Integrated Cold Electrode, which yields higher deposition rates without increasing heat input.
Instead of adding more energy, ICE utilizes the excess heat already available to melt an additional non-powered welding electrode. This results in up to 50 per cent higher deposition rates and up to 100 per cent more productivity in root welds. ICE works with tandem welding application in root passes for superior penetration and high productivity.
Submerged arc welding is already the most productive welding process. However, productivity during sub arc welding can be inhibited by the need to limit heat input. With ICE, there is no additional heat input; the processes uses the heat already generated. This boosts productivity by up to 50 per cent, depending on the application.
The increased deposition rate means higher welding speeds for greater productivity in a range of different applications. This productivity gain allows many applications to be completed with fewer runs. At a 50 per cent higher deposition rate, this can reduce flux consumption by as much as 20 per cent.
The increased deposition rate can also be used to increase welding speed. This increase in speed can significantly improve productivity in applications where welding speed is the key to maximizing productivity.
ICE technology enables the use of tandem welding in root passes, which results in improved penetration and high productivity. The need for back gouging is eliminated. This increases productivity up to 100 per cent in root welding, depending on the application.
There are plenty of other savings too. Welding is highly energy-intensive. Any reduction in energy consumption offers significant environmental and financial benefits. The ability to achieve a dramatic increase in deposition rate with no additional energy input ensures an inevitable and substantial reduction in energy consumption.
Another productivity booster is the innovative Flat Cap Control feature. Fine adjustment to the ratio of ‘cold wire’ used for cap runs makes it possible to produce a flatter cap to the weld. The result: improved fatigue resistance and a reduction in the amount of post-weld treatment required.
ICE improves productivity, which enables many applications to be completed with fewer runs. In this way, flux consumption can be reduced by up to 20 per cent when welding with a 50 per cent higher deposition rate.
The technology allows the user to boost output significantly without the investment in new welding systems, extra capacity, or additional skilled welding labor. It also reduces energy requirements, which ensures a smaller carbon footprint, resulting in more environmentally friendly and lower-cost production.