346 347
Figure 1 shows the calculated consumption of welding consumables
as a function of plate thickness, welding process, groove angle,
and root opening for butt joints. Figure 2 shows the calculated
consumption of welding consumables as a function of fillet size,
welding process, and reinforcement size. These diagrams were
developed using the calculations obtained by the following equation
for both groove and fillet welding joints under the prerequisites
given below.
C = [(A1 + A2) L GE ] 110
where C: Consumption of welding consumables (kg); A1: Area of
Section A1 weld metal (mm2) (See Fig. 3); A2: Area of Section A2
reinforcement (mm2) (See Fig. 3); L: Weld length (m); G: Specific
gravity of weld metal (7.85 g/cm3); E: Deposition Efficiency (%)
SMAW covered electrodes: 55%; GMAW solid/metal-cored wires: 95%;
FCAW flux-cored wires: 90%; SAW solid wires: 100%.
Fig. 1 Consumption of covered electrodes in SMAW and
solid/metal-cored wires in GMAW of butt joints
Fig. 2 Consumption of covered electrodes in SMAW, flux-cored
wires in FCAW, solid/metal-cored wires in GMAW, and solid wires in
SAW of fillet joints
Butt weld jointH = (2 / 46.8) x T + 0.86
Fillet weld joint(A2 is given in ratio in Fig. 3)
Fig. 3 Weld sizes ( in deg., H, R, S, and T in mm)
A Guide to Estimating the Consumption of Welding Consumables
Overall IndexLists of Welding ConsumablesFor Mild Steel and
490MPa High Tensile Strength SteelFor Weather Proof SteelFor
590-780MPa High Tensile Steel and Low Temperature SteelFor
Heat-Resistant Low-Alloy SteelFor Stainless SteelFor HardfacingFor
Cast IronFor Nickel-Based AlloyHighly Efficient Welding
Processes
For Mild Steel and 490MPa High Tensile Strength SteelGuidance
and tipsSMAWFCAWGMAWGTAWSAW
For Weather Proof SteelGuidance and tipsSMAWFCAWGMAWSAW
For590-780MPaHigh Tensile Strength Steel and Low Temperature
SteelGuidance and tipsSMAWFCAWGMAWGTAWSAW
ForHeat-Resistant Low-Alloy SteelGuidance and
tipsSMAWFCAWGMAWGTAWSAW
ForStainless SteelGuidance and tipsSMAWFCAWGMAWGTAWSAW
For HardfacingGuidance and tipsSMAWFCAWGMAWSAW
ForCast IronGuidance and tipsSMAW
For9%Ni Steel andNickel-BasedAlloyGuidance and
tipsSMAWFCAWGMAWGTAWSAW
Highly Efficient Welding ProcessesFCB ProcessRF ProcessFAB
ProcessmetalElectrogas Arc WeldingHorizontal Submerged Arc
WeldingEnclosed Arc Welding
AppendixRules ofShip Classification Societies for Welding
ConsumablesWelding Consumables Approved by Ship Classification
SocietiesRedrying Conditions forWelding ConsumablesA Guide to
Estimating the Consumption of Welding ConsumablesConversions for
SAW Flux SizesPackage Specifications for FCAW, GMAW and SAW
WiresConversions for unitsTemperatureTensile stress, Impact
energyHardness
F-No. Grouping and A-No.Classification of Welding Consumables
per ASME Sec. IXAWS standardA 5.1-1991:Carbon Steel Electrodes for
Shielded Metal Arc Welding A 5.5-2006:Low-Alloy Steel Electrodes
for Shielded Metal Arc Welding A5.4-1992:Stainless Steel Electrodes
for Shielded Metal Arc Welding A5.11-1997:Nickel and Nickel Alloy
Welding Electrodes for Shielded Metal Arc Welding
A5.15-1990:Welding Electrodes and Rods for Cast Iron A5.17-1997,
A5.23-1997:A5.17:Carbon Steel Electrodes and Fluxes for Submerged
Arc Welding A5.23: Low Alloy Steel Electrodes and Fluxes for
Submerged Arc Welding A5.18-2001, A5.28-2005:A5.18: Carbon Steel
Electrodes and Rods for Gas Shielded Metal Arc Welding A5.28:
Low-Alloy Steel Electrodes and Rods for Gas Shielded Metal Arc
Welding A5.20-1995, A5.29-2005:A5.20: Carbon Steel Electrodes for
Flux Cored Arc Welding A5.29: Low Alloy Electrodes for Flux Cored
Arc Welding A5.26-1997:steelsCarbon and Low Alloy Steel Electrodes
for Electrogas Welding A5.22-1995:Stainless Steel Electrodes for
Flux Cored Arc Welding and Stainless Steel Flux-Cored Rods for Gas
Tungsten Arc Welding
EN standardEN ISO 2560:2005:Covered electrodes for manual metal
arc welding of non-alloy and fine grain steels EN 758:1997:Tubular
Cored Electrodes for Gas Shielded or Self-Shielded Metal Arc
Welding of Non-Alloy and Fine-Grain SteelsFCENISO
18276:2005:Tubular cored electrodes for gas-shielded and non-gas
shielded metal arc welding of high-strength steelsENISO
17634:2004:Tubular cored electrodes for gas shielded metal arc
welding of creep-resisting steelsENISO 17633:2004:Tubular cored
electrodes and rods for gas shielded and non-gas shielded metal arc
welding of stainless and heat-resisting steels
Foreword, Abbreviations, Warning and CautionForeword,
abbreviations and marksWarning and Caution in Welding
Alphabetical IndexAlphabetical index for welding consumables
Manufacturing and Sales Bases
