ICE™


What is ICE™ technology?

One power source, 3 wires
The elegantly simple ICE™ patent pending technology is the next step in SAW development based on ESAB's leading Twin technology. ICE™ technology utilises a third electrically insulated wire in between and parallel to the two hot wires in the same contact device. ICE™ uses the excess heat generated by the welding process to melt an additional non-powered welding electrode - the Integrated Cold Electrode.

Until now, Twin welding has been the most productive single power source SAW process in terms of deposition rates. ICE™ patent pending technology has enabled a 50% increase in deposition rates compared to Twin wire welding, and 100% compared to single wire welding.

Old concept made robust
Submerged arc welding with an added cold wire is not a new method for increasing productivity. Many different technical solutions for feeding cold wire currently exist, with different performance and application areas. Most of these solutions add the cold wire to a single hot wire in the process, at an angle from the side. These types of solution present numerous challenges, process stability being the greatest. Experience has shown that these conventional solutions are insufficiently robust for the vast majority of applications as they are very sensitive to changes in the welding conditions. ESAB's ICE™ technology has been designed to resolve these issues and deliver a safe process insensitive to variations in welding conditions.

Just like Twin wire process
ICE™ process uses and follows the same principle as Twin Submerged Arc Welding, making it safe and easy to use. Penetration, width of the weld bead, the amount of parent material melted, mixing with parent material and distribution of filler metal in weld are all unchanged from Twin wire welding. Adjusting the cold wire feed ratio, however, offers new ways of controlling the deposition rate and reinforcement height of the weld bead (Flat Cap Control™).

Heat input with ICE™ process is unchanged when the same active parameters are used. The cold wire is not an active parameter and therefore not included in the heat input calculation. ESAB's over decade of cold wire SAW research show that Δt8/5, cooling time between 800°C and 500°C is unchanged at different amounts of cold wire.

Process stability
Integrating the cold wire into the same contact device and placing it in parallel with the hot wires adds process stability and robustness. Adding the cold wire using ICE™ patent pending process regulation technology calms the arcs and melt pool. ICE™ technology makes the process more robust and less sensitive to changes in the arcs and stick-out, as the melting point of the cold wire always adapts to the two arcs. The increase in process stability makes it easier to adjust and adapt the different joint types.

ICE™ Process stability     ICE™_Process stability     

Ease of use
ESAB's unique patent pending process regulation method, in combination with the user friendly PEK process controller, makes using ICE™ technology very easy and safe. Only one more parameter to set, and the ESAB process controller does the rest. ESAB's new patent pending process regulation method controls the cold wire feed speed independently from the hot wires. This improves process stability and adapts the welding process automatically to changes in welding conditions, ensuring the most productive and safe welding process.
PEK Process controller PEK screenPEK screen  

 

The coolest innovation since the introduction of SAW technology,
ICE™ puts excess heat to work - for greater productivity!

Read more about the ICE™ performance advantage here