The cleanest weld seam ever: CEWELD Ultra Clean III sets new standards
Have you compared multiple welding wires and brands? Have there been any (major) differences? Indeed, welding wire from 30 years ago is still produced in the same way and, in addition, the standards for its chemical composition have not changed. Is there anything left to improve? Ceweld Ultra Clean III is an innovation in the welding wire world that breaks all records, read all about it in our blog.
A groundbreaking innovation that prioritizes welder well-being and boosts welding output! Welding fumes have been something that concerns us all for many years and requirements regarding MAC values are tightened year after year.
We have acknowledged the critical role of welding fume extraction in safeguarding welder health. Through the implementation of diverse extraction methods, we have made substantial progress in reducing the inhalation of harmful fumes.
If we zoom in on the MAG welding process and the welding of steel, both the welding wire and the material to be welded consist mainly of iron, carbon, silicon and manganese and all other elements are actually superfluous, unnecessary or even undesirable.
The other (unwanted) elements all have an influence on the final welding process, the quality and the smoke development. We know that copper is the most harmful when inhaled and that the copper percentage of the wire can be 0.35% according to EN ISO 14341-A and no less than 0.5% according to AWS A 5.18.
Symptoms of heavy metal toxicity
- Digestive issues
- Sking problems
- Repiratory problems
- cognitive problems
- Emotional problems
CEWELD Ultra Clean III is a NON-copper-plated welding wire of which the total copper content has been reduced to 0.03%, which leads to the lowest possible weld-fume emission values and permanently eliminates the dangers that copper poses to the welder.
For a trouble-free wire transport, the wire surface is of the utmost importance, rough wires causing abrasion and results in more resistance in liner and torch, which requires more power from the wire feed motor. On average, a wire feed motor requires 0.8 amps to push the welding wire through a 4-meter-long torch. CEWELD Ultra Clean III features a new high-performance industrial lubricant that lowers resistance, reducing the power required by up to 55% for the wire feed motor to feed the wire.
Cast is the designation for the straightness of the welding wire and it is measured by cutting 3 meters from the roll and then letting it fall freely to the ground. This circle is usually between 60 and 200 cm in diameter and determines how the wire leaves the contact tip. The Helix indicates the torsion that the welding wire shows over the transverse direction, which shows itself if the wire does not lie flat on the ground.
More information about cast and helix can be found at:
Quality packaging brochure
Wire rod usually arrives at the wire drawing in a soft annealed condition in 5.5 mm from selected factories. From here we want to draw or roll the wire to smaller diameters as cost effective as we can. The faster we reduce the diameter to a smaller diameter, the faster the production process, but this has a downside because it puts a heavier load on the wire and will therefore become harder (cold deformation).
Due to the high competitive pressure, the speed during drawing has also been increased and is now on average between 20 and 30 meters per second for solid welding wires. CEWELD Ultra Clean III is drawn at 12 meters per second to completely exclude hairline cracks in the wire surface and ensure a constant strength in the wire to promote a more stable Cast and Helix.
Silicates are mainly the result of the burning off of alloying elements in the arc that adhere to the weld seam as floating slag remainders. Sometimes we see them along the weld but sometimes also in the middle of the weld. The annoying thing is that it is often difficult to remove these silicates. The position of the torch, the voltage, the travel speed but also the shielding gas influence the amount of silicates that remain on the weld.
Soapy residues and other contaminants on the wire surface also have a major influence on the amount of silicates, the name Ultra Clean not only says something about the inside of the welding wire but especially something about the outside of the welding wire, because Ultra Clean III is spotless! With CEWELD Ultra Clean III, you will be genuinely amazed at the beautiful clean weld that is left with remarkably little silicates.
Regular ER 70S-6 welding wire vs UltraClean III
CEWELD Ultra Clean III falls under the American classification AWS A 5.18: ER 70S-6 and also under the EN ISO 14341-A: G 46 5 M21 4Si1, which guarantees you a notch toughness of at least 47 Joule even at temperatures as low as -50°C. The higher purity contributes to a higher ductility than you are accustomed to with standard welding wires, and the minimum tensile strength is also higher as 460 MPa, so you are also covered for welding S460 type of steels.
✔ 80% less silicates
✔ 100% splash-free
✔ No inhalation of copper vapor
✔ The perfect and cleanest weld seam
✔ Higher yield strength >460MPa
✔ Eco friendly and lowest fume emission on the market
✔ 55% less resistance in the welding torch
✔ Also suitable for offshore with -40°C requirements
✔ Extremely suitable for high power welding with high wire feed speed
✔ Perfect for robots, long torches and long liners
