KF-100A Submerged Arc Flux Holding Oven

About the Keen KF-100A Flux Holding Oven - 125 lbs. Capacity

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.

Heavy-Duty Construction

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.

Performance Heating and Quality Temperature Control

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.

Quality Insulation

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.

Optional Accessories

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 slag screens are a fixed size according to the flux oven with which they are used.

Customization

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.

Frequently Asked Questions

How is the KF-100A subarc flux storage oven used in the field?

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. This oven may be used as a portable oven or may be readily detached from its carrier and mounted directly to the welding manipulator.

Why choose the KF-100A flux oven over a different model offered by Keen?

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, light in weight 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.

Do Keen Ovens come with a manufacturer’s warranty?

Yes. Our ovens have a 1 year manufacturer’s limited warranty.

What is granulated submerged arc welding flux?

Used as a protective layer in the process of submerged arc welding (SAW), subarc flux is a granulated, fusible material consisting 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.

Why does granulated submerged arc welding flux need to be stored in an 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.

Keen 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.

How do I store unopened packaging of sub-arc welding flux?

Submerged arc welding flux is available in a wide-variety of packaging and in various amounts according to how much is used, bulk pricing, etc. It is commonly purchased in single wall plastic or multi-wall plastic bags, paper bags, bulk bags with liners, plastic pails and steel drums. It is recommended by most manufacturers that users follow basic guidelines when storing unopened packaging. For example, storage of unopened bags must be indoors with moderate relative humidity below 70% (RH suggestions vary among flux manufacturers) and within a temperature range of 48°F-122°F. A bag of welding flux is the least durable form of packaging available, and care must also be taken to avoid puncturing or tearing the packaging. Avoidance of condensation is critical and is the main objective when storing unopened bags of welding flux. The more durable plastic pails and steel drums are tightly sealed and are often stored outdoors. Care must be taken to protect the containers from rain and snow. Again, condensation and moisture is damaging to flux and must be avoided. Labeling must never be removed from flux packaging while in storage.

Once I opened packaging, how should I store new, unused flux?

As discussed above, sub-arc welding flux is hygroscopic and once exposed to the atmosphere it will absorb moisture; the amount absorbed depends upon the relative humidity in the air and the period of time the flux remains exposed. It is recommended by most manufacturers of welding flux that unused amounts be stored at elevated temperatures in an oven to stave off moisture and ensure quality welds. Keen flux holding ovens are designed to hold welding flux that has not been exposed to moisture (either new or recycled) in order to preserve quality and maintain performance of the flux in operation.

What is the procedure for recycling welding flux and what are slag screens?

After the weld is completed flux that is not consumed can be collected and recycled to the flux oven hopper. However, contained in the non-consumed flux may be some contaminants such as slag, metal, mill scale, grindings, etc. that need to be filtered out before the flux is introduced back into the hopper to mix with new flux. Many manufacturers of sub-arc flux recommend maintaining a ratio of new flux to recycled flux. Some suggest adding 20% new flux by weight to recycled flux, others recommend a rule of thumb that one part new flux be added to three parts reused. it is always best to check with the manufacturer of your consumable for guidelines.

Keen flux oven 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 slag screens are a fixed size according to the flux oven with which they are used.