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Contact us to discuss your requirements of Flux Holding OVEN. Our experienced sales team can help you identify the options that best suit your needs.
Below is a list of industries where Keen subarc flux storage and rebake ovens are commonly used:
Made in the USA and ruggedly constructed, Keen submerged arc flux storage and rebake ovens are available in a variety of capacities to suit the most rigorous subarc welding operations. Our flux ovens have industry-leading heat up times due to our proprietary design, and can be found in a wide variety of industries across the world.
Please also see our Frequently Asked Questions
Frequently Asked Questions
What is subarc flux and what is submerged arc welding (SAW)?
Why do I need to store subarc flux in a heated oven?
What are the proper storage and rebaking guidelines for subarc flux?
What is the difference between subarc flux holding and subarc flux rebaking?
What are the key differences between welding flux holding ovens and welding flux rebake ovens?
How can I determine the amp draw for a particular model?
What is subarc flux and what is submerged arc welding (SAW)?
Submerged arc welding (SAW) is a common welding process that is frequently used in the structural and vessel construction industries. The process requires a tubular or consumable solid electrode that is continuously fed into the work area using fully-automatic or semi-automatic methods. As the electrode is fed into the arc and melted, a layer of granular material provides a protective cover beneath which the welding occurs. Called flux, this fusible material consists of lime, silica, manganese oxide, calcium fluoride, and other compounds. The flux forms a hardened layer after it is heated and becomes molten. In this melted state the flux becomes conductive, thus enabling it to supply a constant current between the electrode and the welding work. The remainder of the flux is recovered and reused, unless it has become contaminated.
The granular flux used in SAW serves several functions. In addition to providing a protective cover over the weld, the flux shields and cleans the molten puddle. The flux also affects the chemical composition of the weld metal, the weld bead shape, and the mechanical properties of the weld. Another function of granular flux is to act as a barrier that contains and concentrates the heat into the weld area thus enabling deeper weld penetration.
For more in-depth information on submerged arc welding, click here: http://keenovens.com/products/flux-details.html
Why do I need to store subarc flux in a heated oven?
In order to answer this question, it is pertinent to describe the four types of welding fluxes that are commonly available: fused, bonded, agglomerated and pre-mixed fluxes.
Fused — this type of flux is non-hygroscopic (does not absorb
moisture from the air). Any surface moisture on the particles
can be removed at a low temperature oven setting of 300°F.Bonded — this type of flux is hygroscopic (absorbs moisture from the
air) and is comprised of a combination of dry ingredients that
are glued together with a liquid binder, then baked at a low
oven temperature.Agglomerated — this type of flux is hygroscopic and is manufactured
the same way as bonded fluxes only a ceramic binder
is used instead of a liquid binder.Pre-Mixed — this type of flux is hygroscopic and is simply a combination
of two or more bonded or agglomerated fluxes.Just as stick welding electrodes readily pick up moisture from the surrounding atmosphere, the same applies to bonded welding fluxes that are comprised mostly of dry, powdered ingredients. As described above, the purpose of flux is to clean and shield the weld area from impurities. If moisture has contaminated the flux, hydrogen is released into the metal when heat is applied. When the weld cools, it can become brittle, crack and/or develop pinholes. Moisture-contaminated flux can also accelerate corrosion to certain metals like aluminum and must be kept dry throughout the welding process.
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Welding flux holding ovens and rebake ovens are an indispensable addition to any subarc welding operation to help ensure quality welds. Our flux holding ovens and rebake ovens are suitable for almost any flux heating application that is required for today’s professionals.
What are the proper storage and rebaking guidelines for subarc flux?
For specific storage and rebake temperature guidelines, we recommend contacting the welding consumable manufacturer directly. It is also important to check with local welding codes and/or ask a welding inspector to provide some information. Welding standards change frequently, and each manufacturer often provides a different recommendation regarding welding consumable storage. Check the packaging and also manufacturer websites for information. Keen offers a wide range of products to handle almost any welding consumable storage requirement.
What is the difference between subarc flux holding/storage and subarc flux rebaking/reconditioning?
Generally, there are two involved with the proper maintenance of subarc welding flux: holding (also called storing) and rebaking (also called reconditioning).
The holding process refers to the long-term* heated storage of welding flux to maintain factory-fresh dryness. Storing the flux at elevated temperatures prevents atmospheric moisture contamination of the hygroscopic granules. There are various temperature requirements according to the type of flux and also that are also set forth by welding codes. For specific holding temperature guidelines, please contact the manufacturer of your welding consumable.
The rebaking process refers to the short-term*, high temperature heating of subarc flux that has been contaminated by atmospheric moisture. The rebaking process “reconditions” the welding flux, meaning it bakes out the moisture that has been absorbed thus restoring the flux so it is suitable for reuse. For specific rebake temperature guidelines, please contact the manufacturer of your consumable.
* - In relation to our products, we consider long-term to mean 24 hours/day 7 days/week.
What are the key differences between welding flux holding ovens and welding flux rebake ovens?
Keen ovens are specifically designed according to the temperature range of the process, and the amount of subarc flux to be stored. The standard holding ovens are designed to accommodate a maximum temperature of 550F and the rebake ovens are designed to reach 999F. The higher temperature ovens have larger wall thicknesses to accommodate more insulation and digital programmable temperature controllers. More information is available on the individual product pages. Please select a product from the chart above and you will be taken to the product page which has digital photos of each flux oven and technical specifications.
How can I determine the amp draw for a particular model?
Use this formula: Watts / Voltage = Amps
*Click Here to Learn More About Submerged Arc Flux
The KF-100A is the smallest flux oven in our range, and is an excellent choice for subarc welding operations where portability is a necessity. This particular unit is very easy to use, lightweight and can be moved from station to station with ease using the heavy-duty stand and wheels. Each subarc operation is unique- some customers centrally locate our large flux ovens, and many other customers enjoy the versatility of the KF-100A by having multiple units on hand spread among welding stations. The KF-100A flux oven is easily adapted to a variety of workflows, and particularly allows mobile operations to easily transport just the right amount of ovens they need for a particular job.
Subarc flux is top-loaded by way of a removable lid and discharged through a slide valve located on the bottom of the unit. A container placed by the user beneath the hopper catches the granulated flux as it is dispensed. Flux temperature inside the oven is regulated by a field adjustable dial thermostat with on-indicating light, and monitored with a bimetal thermometer. The KF-100A flux oven is equipped with lifting lugs.
The Keen KF-100A subarc flux holding oven is ruggedly designed to withstand years of use in the most demanding industrial environments. Heavy-gauge steel is used throughout the unit and 2-inch thick, semi-rigid, high-density mineral wool in the oven walls and lid keeps the KF-100A flux oven well-insulated and energy efficient. The exterior features a durable powder-coated paint that is highly resistant to industrial environments and will stand up to years of use. The KF-100A’s hopper has welded seams inside and out, and is securely mounted to a custom-built stand/dolly with wheels for easy mobility on site. The oven hopper can also be removed by the user from the dolly and placed at the weld head for direct dispensing of flux.
Thorough, energy-efficient and quick heating of welding flux is the hallmark of all Keen flux ovens. The KF-100A utilizes two 1000W incoloy-sheathed tubular heating elements evenly dispersed throughout the flux oven hopper cavity for rapid heating of 125 lbs of flux. An externally-located, dial-adjustable capillary thermostat provides even temperature control of the oven chamber.
Efficient heating design must be supported by quality insulation. The Keen KF-100A features a semi-rigid, mineral wool “board” insulation that is bonded together with a high temperature binder. It is highly thermally efficient and is installed within the walls and lid of the unit.
As an optional accessory, Keen offers slag screens that can be installed at the top of the oven chamber. Our slag screens are designed to be a sieve for filtering out contaminants in reused flux as it is being poured back into the flux oven hopper. The hole size on our flux oven slag screens is standard, but we can adjust the screen hole size if you have a different requirement. The slagscreens are a fixed size according to the flux oven with which they are used.
We have the unmatched ability to customize any of our standard ovens, and/or design one-of-a-kind ovens for unique storage requirements. Welding codes are constantly changing, and Keen is ready to meet the demands of today’s welders. Please visit our website http://www.keenovens.com for more information about our products and detailed technical information about welding consumable storage.
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