Automatic welding technologies for long-distance pipelines by use of all-position self-shielded flux cored wires

In order to realize the automatic welding of pipes in a complex operation environment, an automatic welding system has been developed by use of all-position self-shielded flux cored wires due to their advantages, such as all-position weldability, good detachability, arc's stability, low incomplete fusion, no need for welding protective gas or protection against wind when the wind speed is < 8 m/s. This system consists of a welding carrier, a guide rail, an auto-control system, a welding source, a wire feeder, and so on. Welding experiments with this system were performed on the X-80 pipeline steel to determine proper welding parameters. The welding technique comprises root welding, filling welding and cover welding and their welding parameters were obtained from experimental analysis. On this basis, the mechanical properties tests were carried out on welded joints in this case. Results show that this system can help improve the continuity and stability of the whole welding process and the welded joints' inherent quality, appearance shape, and mechanical performance can all meet the welding criteria for X-80 pipeline steel; with no need for windbreak fences, the overall welding cost will be sharply reduced. Meanwhile, more positive proposals were presented herein for the further research and development of this self-shielded flux core wires.