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Together we weld Stainless!
With a delivery from ESAB, your stainless consumable comes
with 80 years of built in experience
What is stainless?
Carbon steel
• Iron with a controlled amount of carbon
• Small additions of other alloying elements
• No protection against corrosion
Stainless steel
• Iron and minimum 12% of Chromium
• A protective oxide film is formed on the surface
• The oxide film protects the steel from corrosion
Page no 4April 2012
Global Product Management
Stainless steel main families
Ferritic grades
Austenitic grades
Duplex grades
Page no 5
• Magnetic
• Low thermal expansion
• Good creep resistance
• High yield strength
• Non-magnetic
• The ”common” stainless
• High strain
• Good low temp. properties
• The ”new” stainless type
• Very high yield & tensile
strength
• Excellent corrosion
resistance
April 2012
Global Product Management
Alloying elements
Page no 6
•The base in all steelsIron (Fe)
•To make iron into steel
•Gives the steel strengthCarbon (C)
•”The stainless element”
•Promotes ferriteChromium (Cr)
•Provides impact toughness and elongation
•Promotes austeniteNickel (Ni)
•Provides corrosion resistance
•Promotes ferriteMolybdenum (Mo)
•Gives impact toughness and increased hot cracking resistance
•Promotes austeniteManganese (Mn)
•Improves weldabilitySilicon (Si)
•Niobium and Titanium are used as stabilizersOthers (Nb, Ti)
April 2012
Global Product Management
Corrosion resistance
Page no 7
• A sample/product corrodes when its corrosion resistance is insufficient
in the surrounding environment.
• Corrosion can be very local on a sample or across larger areas
• Corrosion will start where the corrosion protection is the weakest, i.e.
• where corrosion preventing elements (eg. Cr, Mo, N) are locally
lower in concentration
• where surfaces are rough (eg. crevices, pores, corners, etc)
• where the environment is locally more aggressive
April 2012
Global Product Management
Some types of corrosion
Page no 8
Intergranular corrosion
• Lower Cr content in grain boundaries makes this area susceptible to corrosion
• Prevented by adding stabilizing elements (Nb, Ti) to the alloy
Pitting corrosion
• Occurs at the weakest point of the surface
• The protective oxide film is damaged and not allowed to reform
• The ”pit” becomes increasingly sour and the corrosion accelerates
Crevice corrosion
• In deep crevices the protective film doesn’t reform due to lack of oxygen
• Similar to pitting corrosion, but normally occurs at lower temperatures
• Prevented by higher content of Cr, Mo, N
Stress corrosion cracking
• Occurs only when a combination of high tensile stresses and chlorides are present
• Often at elevated temperatures
• Prevented by higher alloying content as well higher ferrite content
April 2012
Global Product Management
Health & Safety
Any welding process generated hazardous
substances
Pay attention to
warning texts on
labels and packaging
Read and understand Safety Data Sheets for the product being used
Use only products from a
supplier which
understands and explains
how to safely use
the products
Page no 9April 2012
Global Product Management
Manual Metal Arc (MMA) Welding
Shielded Metal Arc Welding (SMAW)
Page no 10April 2012
Global Product Management
MMA process and consumables
• Good welding performance (stable arc, good slag detachability, good tie in with base material etc) ensures high quality welds
• Supplied in VacPac. No need for redrying if package is intact before usage
• Large number of stainless grades are available
High quality welds and large range
• Easy to use and adjust welding parameters
• Easy to weld in all positions
• Less stringent demands on joint preparation
Easy and flexible process
• Low initial capital investment cost
• Low maintenance costs
• People who can weld are available everywhere
Economic and easy to get started
• No need for gas bottles or wire feeders
• Light weight machines
• Provides very good access even to narrow spaces
Provides good access
Page no 11April 2012
Global Product Management
Gas Tungsten Arc Welding (GTAW)
Tungsten Inert Gas (TIG) welding
Page no 12
Power
source
1. Power source
2. Tungsten electrode
3. Shielding gas
4. Work piece
5. TIG rod
April 2012
Global Product Management
GTAW consumables – Solid wires
• It is essential for a TIG consumbable that the alloy fits to the base material
• Low amount of trace elements
Accurate wire chemistry
• Any contamination on the wire surface may cause bad welding results
• A clean manufacturing and packaging process is key
Clean wire surface
• To avoid mix up and welding with the wrong consumable, each rod for TIG welding shall be stamped with unique ID, preferably in both ends
Wire identification
Page no 13April 2012
Global Product Management
Gas Metal Arc Welding (GMAW)
Metal Inert Gas (MIG) welding
Page no 14April 2012
Global Product Management
GMAW consumables – Solid wires
•The structure and roughness of the wire surface is the key to get a good grip on the wire and eliminate troublesome slippage.Stable feeding
•The stiffness of the wire helps in getting a constant contact in the contact tip
•Cast and helix
Consistent current transfer
•Cast and helix are important features
•Cleanliness of the wireStable arc
•The wire surface must be designed to enable lowest possible force required to push the wire through the conduit
•Wire stiffness is of great importance
•This is especially important in high efficiency intermittent welding
Low feeding force
•Spool or Marathon Pac
•Tangling free decoiling minimizes production downtime
Troublefree decoiling
Page no 15April 2012
Global Product Management
SMAW consumables – Rutile cored wires
• Spray arc transfer allows fast travel speed in all welding positions
• Positional wire three times faster than MMA and two times faster than Solid wire
• Downhand types two times faster than MMA
Productivity
• Smooth arc transfer giving low spatter
• Reduces post weld cleaning
• Easy to use
Welder friendly
• No silica islands
• Reduced post weld cleaning time
Full self-releasing slag
• Excellent wetting
• Improved corrosion resistance and appearance
Superb weld appearance
Page no 16April 2012
Global Product Management
GMAW consumables – Metal cored wires
• Stabilisers added to the core improve arc transfer
• Low current settings can be used on thin gauge material
• Low spatter levels, reduced post weld cleaning
Smooth, stable arc
• Larger gaps can be bridged, more tolerant to fit-up variations
• Reduced burn through problems on thin gauge material
Wide arc
• Wetting agents added to the core ensure smooth welds
• Improved corrosion resistance and appearance
Smooth weld profile
Page no 17April 2012
Global Product Management
SAW consumables – Wires & Fluxes
• Low risk of undercut and porosity, no spatter
• Deep and safe penetration
• No lack of fusion
• Deslagging is easy
High weld bead quality
• Fully automated process
• High amperage is possible
• Simultaneous use of mulitple wires
High deposition rate
• High process performance and low repair rate
• Easy to operateLow repair costs
• No need for fume extractionNo radiation, low fumes and noise
Page no 19April 2012
Global Product Management
Submerged arc strip cladding consumables
• Low risk of undercut and porosity, no spatter
• Flux produces a nice bead appearance and good slag detachability
• Deslagging is easy
High weld bead quality
• High deposition rate
• Fully automated process
• Low penetrating process resulting in lowdilution
High productivity
• No need for fume extractionNo radiation, low fumes and noise
Page no 21April 2012
Global Product Management
Electroslag strip cladding consumables
• An arc-less method using ohmic heating to melt the strip, flux and parent metal
• Flux produces a nice bead appearance and good slag detachability
High weld bead quality
• High deposition rate in terms of kg/hours and areacoverage m²/hours the strip, flux and parent metal
• Result is specific chemistry in one pass
• Low penetrating process resulting in low dilution
High productivity
• Flux can be delivered in 1000 kg aluminium lined Big Bag
• Strip coil weight until 400 kg for 90 mm stripsBulk packaging
• No need for fume extractionLow radiation,
fumes and noise
Page no 22April 2012
Global Product Management
Consumable selection
• A chain is only as strong as its weakest link
• The weld shall not be the weakest link
• The consumable needs to match the mechanical and corrosion properties of the base metal
• Matching corrosion resistance
• Matching mechanical properties
Page no 23April 2012
Global Product Management
Consumable selection -
Dissimilar metals welding
Welding of dissimilar stainless steels
• Choose a consumable with better corrosion resistance than the least corrosion resistant base material
Welding of stainless steel to carbon steel
• Avoiding cracking is key to success
• The weld metal needs to contain some ferrite
• Use the Schaeffler diagram to get the correct weld metal composition
Page no 26
1
2
3
4
5
1. Chemical composition of stainless grade
2. Chemical composition of carbon steel
3. 50% weld metal dilution from each base metal
4. Chemical composition of welding consumable (309L)
5. Weld metal composition based on a fixed dilution of
weld metal
April 2012
Global Product Management
ESAB Consumables –
Products that you can trust
Complete product portfolio
•From austenitic to ferritic and duplex grades for all arc processes
•A variety of packaging solutions to fit customer needs
•The ESAB range includes :
•Coated electrodes
•Cored wires
•Solid wires
•TIG rods
•Submerged arc wire
•Flux
Highest product and company quality
ESAB is the first company in the world to achieve all-inclusive, external certification for the three key management standards –ISO 9001, ISO 14001 and OHSAS 18001.
The Environmental, Health and Safety Management System and certification covers all activities, people and units in ESAB globally.
Extensive set of approvals
•Majority of products comply with both EN and AWS classifications
•Majority of the products are CE approved.
•Many products have approvals from any of the marine societies ABS, BV, DNV, GL or LR
•Other common approvals are VdTÜV and DB
Page no 28April 2012
Global Product Management
ESAB Covered electrodes -
Read more about the features and benefits
VacPac
• Factory fresh electrodes straight from the package. No redrying required before usage.
• Enables time and cost savings to be made
Small pack sizes
• More economic ordering levels
• Less stock
• Less risk of transport damage
• Easier to handle
Page no 29April 2012
Global Product Management
ESAB Solid Wires -
Read more about the features and benefits
Matt surfaced products
• Greater arc stability
• Excellent control of cast and helix
• Superior feedability
The Marathon Pac family
• Higher output
• Reduced downtime
• Three different sized to fit the customer volume requirement
Page no 30April 2012
Global Product Management
Cored Wires
Read more about the features and benefits
Ease of use
• Shield-Bright series of cored wires, both positional and downhand types, are very ”welder friendly” wires
• They both operate in the spray arc transfer mode which produces very little spatter
• Both Ar/CO2 and straight CO2 gas mixtures can be used
Productivity
• Higher current spray arc in position gives deposition two times greater than solid wire and three times greater than MMA
• Greater deposition rates in downhand position offer faster travel speeds
• Full, self-releasing slag cover reduces post weld cleaning time
Page no 31April 2012
Global Product Management
ESAB SAW Welding consumables
Read more about the features and benefits
BigBag for submerged arc welding fluxes
•1000 kg bulk package for the efficient handling of high quality submerged arc welding fluxes.
•BigBags are made from strong woven polypropylene material with an internal multi-layered aluminium lining, keeping the flux ”factory dry”.
Marathon Pac® for submerged arc welding wires
•Marathon Pac® is a bulk pack for 450 kg of SAW welding wire diameter 1,6 and 2,0 mm.
•The wire is straight and comes out of the welding head without twisting, making it ideal for SAW welding stations.
Productivity
•High speed welding fluxes for joining and electroslag strip cladding giving greater deposition rates .
•Alloyed and elements compensated fluxes for stainless and Ni based applications.
•Bulk pack of wires and fluxes.
•60x0,5 mm and 90x0,5 mm strips delivered as 200 – 400 kg coils for electroslag strip cladding.
Page no 32April 2012
Global Product Management
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