FAQ #1: Why is spatter common with Arnco wires and can it be controlled?

Spatter is common with the Arnco wires because of the open arc method of application as opposed to a wire that is applied while submerged in a flux (SAW). It can be controlled to a minimum depending upon several factors. Arnco personnel have witnessed the operation of many different configurations of hardbanding equipment that utilize all makes of welding equipment (Lincoln, ESAB, Miller, Safmig, etc.) What has been most readily noticed is that newer welding equipment usually produces less weld spatter. We realize that as welding equipment becomes aged, more maintenance is required. In doing so, there are some basic items that can be checked periodically to reduce spatter as well as other welding imperfections.

• Make sure that the electrical connections of the welding cables are kept clean to ensure a good contact is made.
• The length of the welding cables should be kept to a minimum so to not cause increased resistance and decreased current flow.
• Make sure that the contact of the drill pipe tool joints to the chuck assembly is clean to ensure a good electrical connection.

If these above items are assured and spatter still persists, there are other causes to investigate. These are listed on the Arnco Hardband Troubleshooting Chart.

No! The two wires are not compatible to be applied one over the other.

100XT™ can be applied ONLY on top of a chromium hardbanding that does NOT crack!

100XT™ has been applied successfully over Tungsten Carbide. Users should be made aware that the application of different hardbandings one over another is dependent upon the integrity of the initial hardband layer and the compatibility of the two hardbandings.

200XT™ has been applied successfully over Tungsten Carbide. As for 100XT™, users should be made aware that the application of different hardbandings one over another is dependent upon the integrity of the initial hardband layer and the compatibility of the two hardbandings.

The casing wear and tool joint wear characteristics of 100XT™ exceed those of 200XT™ and is crack-free when applied properly.

Contact tips should be changed on an “as needed” basis. Arnco personnel have observed that it is not uncommon for tips to be changed on a daily basis; sometimes twice a day. It depends on how fast the tip wears during welding. Some tips are better than others. All equipment components that contribute to good wire feed have to operate at optimum in order for the wire to exit the tip perpendicular to the welding surface. For example, if the equipment does not have a wire straightening component or the straightening unit is not adjusted properly, the wire will have a tendency to “walk” from left to right as the torch is oscillated. In doing so, the exit opening (ID) of the contact tip will become elliptical in shape. This could cause excessive spatter and distort the form of the weld bead. In addition, excessive tension applied to the wire feed rollers will cause the wire to flatten. If the wire can then be fed through the cable and contact tip, chances are the flattened wire will immediately cause the tip to wear and form an elliptical hole at its opening. The key is to inspect tips frequently.

When the 100XT™ is applied over a Tungsten hardbanding it is possible, on occasion, that small micro-cracking may be seen. As explained in the 100XT™ Recommended Procedures Manual, this micro-cracking has not been found to be detrimental to the application of 100XT™ nor during actual down-hole use. Arnco has observed these cracks to be very shallow in depth and short in length. When the cracks are observed they must be investigated by probe-grinding to ensure they do not extend into the parent metal. Nearly all of this type cracking has been found to extend into the weld for no more than 1/32”; most have been found to extend 1/64” or less. The usual cause for this type cracking has been due to low preheat temperatures. Review the Recommended Procedures Manual for the correct Preheat Temperature Range for the corresponding tool joint OD size.