SAW MACHINE RANGE

The SAW equipments are used in various segments from the simple
head for any autonomous installation to complete welding systems
for infrastructure, energy and piping industries.
Lincoln Electric developed turnkey solutions for the main applications
we can found in these sectors of activity.

2013-464

2011-396
The H beams can be weld with
the Lincoln Electric dedicated solution:
BEAM-MATIC.

CRUISER SAW carriage offers the

possibility to weld in restricted area and
on large pieces. It is the ideal economical
solution for welding on site or in workshop
(single arc or tandem arc version).
2004-926_ret

2011-324

Some dedicated
platforms exists as
The Autonomous SAW
the wagon wheels
head can be combined cladding applications.
2011-270

with all external support.

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 Weld the I-beams in vertical positions,
without tacking thanks to the
T-MASTER solution.

2015-370
2012-582

Internal welding
boom allowing
the longitudinal
and circumferential
welding of pipes.

2014-137
Multiple arc heads allowing to increase
productivity in the longitudinal, helical and
circumferential of pipes.
2010-311

2356-053

Lincoln Electric has solutions

for Windmills
applications thanks
The Lamp
to the heavy duty
2011-245

SAW Column post machine

and booms allows to increase
and rotators. of productivity
in this very
competitive
segment.
2013-484

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 SAW SUBMERGED ARC WELDING INSTALLATION
Applications
Process for welding and hard surfacing of
low alloyed carbon steel, stainless steel and
refractory steel.
It combines productivity, quality and operator
comfort.
It is used in thicknesses from 3 to 300 mm
and provides a high welding speed and high
deposition rates.
With one or more wires, it is found in many
industries: infrastructure, shipbuilding,
offshore pipe mill, heavy duty pressure
vessels, energy...

SAW process and performances

Multi Arc
POWER SOURCES

Tandem Twin
MULTIPLE

Tandem Arc
LSO Multi-arc (x5)
Investment

LSO Multi-arc (x4)

LSO Multi-arc (x3)
POWER SOURCE

Tiny Twin Arc Tandem twin wire

SINGLE

Tandem single wire

Long Stick Out (LSO)
Long Stick Out Twin wire
Single Wire
Single wire
150 200 250 300 350 400 10 20 30 40 50 60 70 80 90 100 110
100
Deposition Rate (%) vs Single Electrode Deposition Rate (Kg/h)
(Values are indicative and depend on the material and the quality required)

AC current management
Complete management of the AC wave form with the control of the
frequency, balance and offset for a maximum flexibility of production.
Control the penetration and geometry of the weld bead. Eliminate the
effect of magnetic arc blow. Positive Current Level = Penetration
AC Frequency

DC+ AC DC-
Current, Voltage or Power

Cycle balance = Penetration/Deposition

Penetration
Deposition rate Negative Current Level = Deposition

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 TANDEM ARC

SINGLE ARC

PERFORMANCES

SAW equipments: inverter technology

Power Wave AC/DC 1000SD
The Power Wave AC/DC 1000 SD proposes a complete range of equipment combining performance,
flexibility of use and ensuring high reliability in welding cycle management.

MAXsa 10: D2C SAW:

Mobile Console Digital Cycle Control
The MAXsa 10 associated to Power Wave AC/DC 1000 SD can be
the Power Wave AC/DC 1000 SD associated to PLC controller D2C SAW
allows to manage the main via analog interface (MAXsa 10) or
welding parameters for a total via fieldbus protocol (MAXsa 19) for
control of the Submerged a complete management of the machine
Arc process. with the submerged Arc process.
● Selection of the polarity (DC+, AC, DC-).
The D2C SAW thanks a large color touch screen friendly to use is able
● Selection of the mode (CV or CC).
to control all the devices linked to the welding as:
● Selection of the wire material and diameter.
● All welding and positioning axes (Column & Boom, Rotator, Positioner, …).
● Management of programs and memorization.
● Crossed slides of the head.
● Manual control of wire and flux feeding.
● Seam tracking, laser spot…
● Power Manager software to configure the installation.
● Production monitoring and CheckPoint software
for a full traceability ot the welding data. The welding monitoring during the cycle is facilated thanks direct manual
controls (joystick and encoder buttons…)
D2C SAW is easy to adapt for a particular request or specific cycle needed
for the final customer application.
Remote control RC-MATIC
For immediate action throw push buttons,
a remote control can be added to the
D2C SAW welding system. Connected
at the welding head throw a cable of 5 m,
the operator can get the useful basic
function of SAW head management.
Fixation of the remote control is secured
by a magnet.

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 SAW INVERTER POWER SOURCES
Lincoln Electric offers inverter technology for DC and AC SAW applications:
● Efficient power consumption reducing operating costs,

● High duty cycle: 1 000 A at 100% (40 °c),

● Easy to integrate from conventional interface to digital unit, POWER WAVE

● Multi-purpose installation:

- CV: Constant Voltage,

AC/DC 1000 SD
- CC: Constant Current.
A second model of DC power source can be associated with MAXsa 10: FLEXTEC 650X.

POWER WAVE AC/DC 1000 SD FLEXTEC 650X

Power supply (3x 50-60Hz) 380-400-460-500-575 V 380-460-575 V
Effective power at 100% 55 kVA 46 kVA
Current range
Duty cycle at 100%
100-1 000 A
1 000 A / 44 V
40-650 A
650 A / 44 V
FLEXTEC
Weight 363 Kg 75 Kg
650X
Dimensions L x l x H 1 248 x 501 x 1 184 mm 745 x 410 x 554 mm
Protection index IP 23S IP 23

Power Wave® Software Solutions

Power Wave Manager
● Check the status of every component in your welding system.
● View and easily adjust the information associated with your welding operation.
● Setup the configuration of the differents components of the welding installation.
● Display of all real-time measurement values like voltage, ampere, wire feed speed, torque.

CheckPoint™: Welding Production Monitoring

CheckPoint’s secure, cloud-based access allows key stakeholders
to view and track welding operations anywhere in the world,
on any device:
● Track real-time weld production data 24/7.

● Create custom custom alerts and notifications.

● Operator Arc on Time.

● Material Consumption.

● Weld and Assembly Information.

Production monitoring™ Weldscore™

Production monitoring monitors a lot of Allows you to score each weld based on a trained
information for the management of the sample of acceptable welds.
customer production. Great for:
● Current status and shift analysis. ● Expanding quality control capabilities,

● Weld listing and downtime analysis. ● Training school monitoring, grading and

● Monitoring by Weld ID, Employee ID final examinations,

or Consumable Lot ID. ● Critical welds with specific quality control

requirements,
● Operator testing and certification programs

or Consumable Lot ID.

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SAW DC MULTI-PROCESS INSTALLATIONS
If an application requires pure welding power combined with multi-process power, then the IDEALARC range
with smooth DC output is your best investment. Designed for Semi-automatic and automatic welding,
the precise control of the IDEALARC® DC 1000 provides superior MIG, flux-cored, submerged-arc welding
and excellent air carbon arc gouging with up to 16.0 mm diameter carbons.
The IDEALARC® DC 1500 is a multi-process DC arc welding power source for automatic welding
applications. It produces outstanding arc characteristics on both constant voltage and
constant current processes for great welding versatility from a single power source.

IDEALARC® DC 600 IDEALARC® DC 1000 IDEALARC® DC 1500

IDEALARC® DC 600 IDEALARC® DC 1000 IDEALARC® DC 1500

Power supply (3x 50-60Hz) 220-380-440 V 380-440 V
Effective power at 100% 44 kVA 74 kVA 121 kVA
Duty cycle at 100% 600 A / 44 V 1 000 A / 44 V 1 500 A / 44 V
Weight 237 Kg 372 Kg 644 Kg
Dimensions L x l x H 988 x 567 x 781 mm 991 x 567 x 781 mm 965 x 566 x 1 453 mm

NA-3 & NA-5 Control & Heads

Improve productivity with the NA-3S or NA-5 automatic
wire feeders. These systems have been specially designed
to deposit more weld metal at faster travel speeds which
eliminates bottlenecks and cuts costs.
NA-3S
Features
● Solid state controls allow precise control
of welding procedures, striking characteristics,
as well as bead size and shape.
● Easily adjusted for a wide range of processes,
feed speeds and wire sizes.
● Compact units with excellent flexibility
to fit into simple fixtures or the most complex
automated production lines. NA-5F head
● Rugged construction minimizes downtime NA-5
and maintenance costs.

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 SAW EQUIPMENT
SAW welding head Lincoln electric offers a large range of welding heads from

2012-641
standard to special models for a perfect
adaptation to the customer application.

Standard Compact
tubular head tubular head Internal head Narrow gap head

Seam tracking
TRACKMATIC device guarantees the good positioning of the torch in the joints
to be welded without operator intervention.
A sensing probe finger or an inductive or laser sensor allows joint tracking
(height or alignment) and commands the necessary corrections required to the
torch trajectory thanks to motorised slides travel 100 - 200 or 500 mm.
Whilst increasing productivity, it ensures a constant weld quality,
a reduction in repair operation and easier use for the operator.

Regulation
on crossed
slides

Seam detection

Seam tracking with sensing probe Seam tracking with inductive sensor

Video camera Laser spot

Combined with a laser spot, the video camera unit allows to view To show the wire point
the welding area and can remotely control the positioning of the of impact relative to the joint
torch in the joint. on the workpiece. The spot
This is an essential tool for welding in difficult acces area like projects an illuminated
inside a tank of small diameter. point in front of the electrode
The equipment is supplied with a spot light to Illuminate over wire for guiding. One spot is
viewed area, and a color LCD industrial screen high definition 15”. used for horizontal alignment
and the association of two
spots make it possible to
monitor the horizontal
and vertical position.
2003-035
2008-312

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Flux management
Equipment to improve productivity and ensure operator safety.

Flux recovery equipment Flux supply equipment Centralised recovery

A compact unit to significantly Pushed flux supply Centralised flux recovery system
reduce manual refilling system providing a greater through pushed flux device and
of the flux feed hopper welding autonomy due electrical turbine with filtration
10 liters. Powered by to the flux tank capacity of flux dust. Ideal system for
compressed air. Pressure of 70l. heavy duty application with

2356-031
4 to 6 bar. Venturi reduced flux consumption and
device completed minimum flux handling. The
with tank and filter system can be equipped with a
cartridge for recovery device to keep the temperature
and dust filtration. of the flux up to 120 or 200 °C.

Dust recovery Dust recovery Flux recovery

tank with filter tank with filter tank

Flux recovery hopper Flux recovery hopper Flux recovery hopper

Pushed
Flux recovering Flux recovering Vaccum
Flux recovering flux
Recovery and dust filtration Flux feeding under pressure unit
Recovery and dust filtration device
Flux feeding under pressure Air recovering
Pushed flux
device

Wire management
Lincoln electric proposes optimized packaging solutons for submerged arc welding.
All wires are free from any organic component limiting the
diffusible hydrogen contribution to the weld metal.

25 kg spool 100 kg coil 300 kg spool 1000 kg coil Drums from 350 to 1000 kg

Drum accessories:
Turn table designed to dispense
all sizes and grades of wire.
4-axis adjustable arm with ceramic
inlet guide prevents wire shaving.
Quick disconnect allows for easy
conduit connections.
The pneumatic Feed Assist
provides an economical method to assist
your wire feeder in moving wire through
the conduit in applications where long
conduit runs are necessary.

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 SAW NARROW GAP

2012-641LE
Applications
Narrow Gap process used for welding thick plates,
mainly for the following industrial applications:
Power Generation, Nuclear, Pressure Tanks, Windmill, Petrochemical.

2014-242
Process
It is a Submerged Arc process with single or tandem narrow gap torch, designed to
weld thick plate (generally over 50 mm) using practically parallel sides and narrow
gap preparation.
Narrow gap process allows to increase productivity and to result in lower cost
welding by decreasing the volume of metal needed and the welding time compared
to conventional preparation with bevel.
The process is adapted for both longitudinal and circumferential welding.

Equipment: LINCOLN ELECTRIC provides a full range of equipment for every application
Example of modular tandem welding head proposed.

Flux recovery system

Wire feeder
2012-641LE

Single wire AC

Single wire DC

Automatic seam tracking

Flux supply
Video camera

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SAW MULTIPLE WIRES

3arc welding
head

Helical or
Longitudinal welding
circumferential
welding

PERFORMANCES

SAW MULTI-ARCS SYSTEM (heads and controllers)

The Lincoln Electric Automation proposes to integrate multiple wires head from Uhrhan & Schwill Gmbh
company world-renowned specialist for Pipe Mills segment.

E5 system Z5 system
The E5 system manages all the parameters of the multi-arcs The Z5 system manages the complete machine components
welding and it can be associated to D2C controller for a complete and all the parameters of the multi-arcs welding:
management of the machine: ● From single arc to multiple arc (x6),

● Single arc, Tandem arc or triple arc, ● Long stick out process,

● Long Stick Out process, ● Large touchscreen,

● Touchscreen based remote control, ● Full control of wire and flux feeding system,

● Management of programs and memorization, ● Display and recording of all real-time measurement values like

● Manual control of wire and flux feeding, voltage, ampere, wire feed speed, torque, movement speed…
● Display of all real-time measurement values like voltage, ● Seam tracking by laser scanner.

ampere, wire feed speed, torque.

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 STRIP CLADDING PROCESSES
Cladding is a fundamental process
in the pressure vessel industry and
is applied across whole spectrum of
applications, from Nuclear, Oil and
Gas industries to Chemical Processing
equipment and steelmaking.
Cladding is required on the process side
of high pressure critical process plant
equipment to provide corrosion resistance
against highly severe corrosive service
fluid or to increase wear resistance of
a component being subjected to heavy
wear and tear applications e.g. continuous
casting rollers in steel mills.

Submerged arc strip cladding

● The arc causes more
penetration into the base
material, resulting
in dilution levels of ~20%.
● Deposition rate : 12-14 kg/h
for 60 x 0,5 mm strip.
● Current range restricted
to limit dilution.

Electro slag strip cladding

Conventional Hybrid Technique*
● Arc-less process, use conductive flux and works on Joule’s ● Hot metal cored wires added to the molten pool as 3rd
resistance heating principle. constituent.
● The strip current passes through the molten slag. The resulting ● Always in single layer, coupled with high welding speed.
resistance heating effect melts the strip and deposits the molten ● Lowest dilution level coupled with the highest deposition
weld pool onto the base material. and faster surface coverage rates.
● Low dilution level (9 to 12%). Process has significant advantages
over SAW.

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Comparison:
● Submerged arc (SAW).
● Electro slag conventional (ESW 2D).
● Electro slag hybrid* (ESW 3D).

Electro slag
Submerged Arc
Conventional Hybrid*

Strip + Metal Cored Wire

Consumables Strip + SAW Flux Strip + ESW Flux + ESW Flux

Deposition rate (Kg/h) 60 x 0.5 mm strip 12-14 22-30 28-42

Normal speed: 15-18

Welding speed (cm/min) 10-14 High speed: 24-35 1

Minimum number of layer in Ni-625 2 2 1

to achieve <5% Fe chemistry
Flux type for high speed cladding in single layer NA Alloyed Neutral

* Patent Pending

Welding heads E5 controller

● In-house designed heads for strip widths 15 to 120 mm. ● Management of the welding process
● Water cooled and robust modular design. with the E5 system and its mobile console.
● Power cables can be added as required.
● Easily oriented for desired welding direction.

Standard head

Internal head

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 SAW TRACTORS LT-7 Tractor
Single or twin wire
LT-7 Tractor
The LT-7 Tractor is a self-propelled mechanized wire feeder,
designed for submerged arc process with track system capabilities.
It is self-guiding and easy to operate. For welds butts,
horizontal fillet and lap joints to the left or right side
of the tractor frame.

Features
● Travel speed from 0,12 to 1,8 m/min
● Wire diameters from 2,4 to 4,8 mm
● Wire speed from 2,5 to 10,2 m/min

Cruiser Tractors
The self-propelled modular Cruiser and Tandem Cruiser travel
carriages can deliver deposition rates up to 13kg per arc per hour
for butt and fillet joints on lengthy plate welding applications
common in bridge or barge decking, large tank fabrication
or shipbuilding. It is suitable for all those positions below.

Features
● Advanced control pendant.
● 3 or 4 wheels guiding.
● Travel speed from 0,25 to 2,5 m/min. Cruiser
Wire diameters from 2,4 to 5,6 mm.
●

● Wire speed from 0,4 to 12,7 m/min.

Single or
twin wire

Flat butt welding

Fillet welding

Circular welding of large vessels with ø over 1 600 mm

Tandem Cruiser
Single wire

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 SAW INTERNAL BOOM
Lincoln Electric can propose several solutions
of internal boom welding.

The main processes are:

● Pipe manufacturing by internal longitudinal welding,

● Assembling of 2 pipes by circular welding.

Once the internal weld is done, the outside weld is performed

by an other equipment.
The structure and configuration of the internal boom
depends of the length of the pipes.
Pipes from 4 m to 12 m long.

2013-485LE
2013-485LE

Internal welding head with single wire,

video and seam tracking.
2012-582LE

2012-327LE

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 BEAM-MATIC
The automation of long workpieces welding (beams, wagons, box section

2013-464
constructions) requires sophisticated machines which move on rails.
The BEAM-MATIC system is used to weld beams
of constant or varying cross-section in widths between
220 and 2 000 mm *.

* Other dimensions on request.

1589-03
2 types of BEAM-MATIC are available:
● Cantilever: CT,

● On base column and boom: LM.

The BEAM-MATIC allows to weld in MIG-MAG

or SAW (single or twin wire) process.
In standard, the machine is equipped with
a flux recovery device and a pushed flux supply.
Possibility to use wire spools or wire drums on the 2 BEAM-MATIC.
The torch level is fix on the BEAM-MATIC CT and it’s possible to lift the torch
level on the BEAM-MATIC LM.

BEAM-MATIC CT
BEAM-MATIC LM
2008-414
2011-396

Clamping bench:
The clamping bench allows the positioning of the web and the
flanges before the welding, with an additional clamping bench it’s
possible to save time and increase productivity.

Standard / Dimensions for clamping bench

A
C
2009-524

A = 12 000 to 24 000 mm *
B B = 220 to 2 000 mm *
C = 120 to 500 mm *

Web thickness: 4 to 20 mm
Flange thickness: 10 to 30 mm
* Other dimensions on request.

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T-MASTER
The T-MASTER “Big size beam welding line” is designed to weld with Submerged arc

2008-180
process the T and I beams with the web in vertical position without need of continuous
tack-welding of beam. A short tack is only needed at the beam leading edge.

A
B
2013-493

10°
D C

SUPER LIGHT LIGHT MEDIUM HEAVY

H 1 500 - 600 kg/m H 2 000 - 1 000 kg/m H 3 000 - 2 000 kg/m H 4 000 - 3 000 kg/m
mini maxi mini maxi mini maxi mini maxi
A: Flange length mm 150 800 150 1 000 200 1 250 200 1 500
B: Flanges thickness mm 5 30 6 40 8 65 8 80
C: Web length mm 200 1 500 200 2 000 250 3 000 300 4 000
D: Web thickness mm 5 15 6 25 8 30 8 40
L: Beam length mm 6 000 12 000 * 6 000 12 000 * 6 000 12 000* 6 000 12 000 *
Weight / meter kg / m 600 1 000 2 000 3 000
Taper angle ° 10 10 10 10
* additional length by 3 m

* Other dimensions on request.

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 WINDMILL SOLUTIONS

2010-311
Working closely with engineering departments and major manufacturers
in this sector, Lincoln Electric is constantly working to develop processes,
equipments and consumables meeting the ever more demanding requirements
of increasingly hostile environments.
This constant innovation has resulted in a complete range of equipment and
consumable solutions specially designed for wind-power industries.

Example of layout for windmill towers fabrication.

2012-641LE

Heavy duty welding heads:

Narrow gap or SAW tandem head.

Large column and booms, rotators and positioners

are proposed in this windmills solution.

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LAMP-POST SOLUTIONS
High productivity performance machine equipped with SAW or Plasma
welding process. No tacking of parts is required.
A dedicated software manages the lamp post production including automatic
positioning of the pole edges before welding according to the various shapes
and conicity of each product.
A burner ramp under the lamp-post reduces the welding distortions.

Several options are available on request.

2013-484
2356-053
A
WELDING PROCESSES
ØB

C ● SAW single wire diameter from 1.6 to 5.0 mm

● Plasma welding 3 or 4 heads

MACHINE CYCLE
A: 3 to 17 m ● SIEMENS controller
B: 60 mm mini - 600 mm maxi
Overview and control in real time of the machine,
C: 3 to 6 mm ●

parameters recording, remote connection

Round conical, polygonal
(32, 16 and 8 sides) A PERFORMANCES / OUTSTANDING POINTS
Conicity maxi: 50% ● Joint tracking with camera and operator joystick
ØB

C ● Only 1 operator

● Machine availability: 95%

● Fix machine / Movable piece

● Speed range: 1 m/min to 3 m/min according

to process and thickness

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