BOC IPRM S08-Consumables

293IPRM 2006 : SectIon 8 : conSuMableS

WaRnInG Welding can give rise to electric shock, excessive noise, eye and skin burns due to the arc rays, and a potential health hazard if you breathe in the emitted fumes and gases.Read all the manufacturer’s instructions to achieve the correct welding conditions and ask your employer for the Materials Safety Data Sheets. Refer to www.boc.com.au or www.boc.co.nz8

Fundamentals of Manual Metal Arc (MMA) Welding 295

Fundamentals of Metal Inert Gas (MIG) Welding 304

Fundamentals of Flux and Metal Cored Arc Welding 308

Preheating of Materials 312

Mild Steel 316

Low Alloy 359

Stainless Steel 375

Aluminium 407

Copper 422

Cast Iron 427

Gouge 436

Gas Welding, Brazing and Soldering 438

Hardfacing 462

Consumables

8 Consumables

294 IPRM 2006 : SectIon 8 : conSuMableS

WARNINGProtect yourself and others. Read and understand this information. electric shock can kill.

Welding can give rise to electric shock, excessive noise, eye and skin burns due to the arc rays, and a potential health hazard if you breathe in the emitted fumes and gases.

Over exposure to the fumes and gases can give rise to dryness of the nose, throat and eyes, respiratory irritation and in some cases, longer term health effects such as lung deposits.

Read all the manufacturer’s instructions to achieve the correct welding conditions and ask your employer for the Materials Safety Data Sheets. Refer to www.boc.com.au or www.boc.co.nz

For eye protection and body protection always wear a welding visor with the correct filter lens, and suitable welding gloves and clothing to prevent injury from burns, radiation, sparks, molten metal and electric shock. Wear ear protection when required.

Adequate ventilation to prevent an accumulation of fumes and gases should be used. Where fume levels cannot be controlled below the recognised exposure limits, use local exhaust to reduce fumes and gases; in confined spaces without adequate ventilation, an air fed breathing system should be used; outdoors a respirator may be required. Precautions for working in confined spaces should be observed. Refer to AS/NZS 2865 “Safe working in a confined space”.

Keep your head out of the fume

Arc rays and fume can affect others in your workplace.

Comply with your employer’s safety practices and procedures; protect others

Refer to WTIA Technical Note 7 “Health and Safety in Welding”.

Adherence to recognised occupational exposure standards (such as the threshold limit values (TLV)) for all fume constituents should be observed during use. See the Materials Safety Data Sheets for details.

Hardfacing ReD

low alloy andSilver brazing alloy PINK

aluminium PuRPLe

Mild Steel CyAN BLue

Gouge MINT

low Hydrogen GReeN

Stainless Steel LIMe

nickel (cast Fe) yeLLOW

copper BROWN

electrical Hazard Fire Hazard

alert Symbols - type of Hazard

Hazard Source Symbols

Welding electrode causing electric shock

explosion from pressurized gas cylinders

Hot work pieces from welding and cutting; hot mufflers; hot exhaust pipes

Loud noise from engine, machinery, and arc

Flying particles from chipping and grinding

Welding arc rays

Fumes and gases coming from any source

Fumes and gases coming from welding process

Become trained

use welding helmet with correct shade of filter

Keep head out of in fumes

use forced ventilation or local exhaust to remove fumes

Insulate yourself from work and ground

Hazard avoidance Symbols - Precautionary Measure

Wear complete body protection

Wear dry, insulated gloves

colour code explanationThese colour bands appear on BOC consumable packages as an easy reference for indentifing material groups.

Important Safety information

8Consumables


WaRnInG Welding can give rise to electric shock, excessive noise, eye and skin burns due to the arc rays, and a potential health hazard if you breathe in the emitted fumes and gases.Read all the manufacturer’s instructions to achieve the correct welding conditions and ask your employer for the Materials Safety Data Sheets. Refer to www.boc.com.au or www.boc.co.nz

Fundamentals of Manual Metal Arc

(MMA) Welding

Welding techniqueSuccessful MMA welding depends on the following factors:

Selection of the correct electrode

Selection of the correct size of the electrode for the job

Correct welding current

Correct arc length

Correct angle of electrode to work

Correct travel speed

Correct preparation of work to be welded.

electrode SelectionAs a general rule the selection of an electrode is straight forward, in that it is only a matter of selecting an electrode of similar composition to the parent metal. It will be found, however, that for some metals there is a choice of several electrodes, each of which has particular properties to suit specific classes of work. Often, one electrode in the group will be more suitable for general applications due to its all round qualities.

The table below shows just a few of the wide range of electrodes available from BOC with their typical areas of application.

For example, the average welder will carry out most fabrication using mild steel and for this material has a choice of various standard BOC electrodes, each of which will have qualities suited to particular tasks. For general mild steel work, however, BOC Smootharc 13 electrodes will handle virtually all applications. BOC Smootharc 13 is suitable for welding mild steel in all positions using AC or DC power sources. Its easy striking characteristics and the tolerance it has for work where fit-up and plate surfaces are not considered good, make it the most attractive electrode of its class. Continuous development and improvement of BOC Smootharc 13 have provided in-built operating qualities which appeal to the beginner and experienced operator alike. For further advice on the selection of electrodes for specific applications, or to obtain a copy of the ‘Welding Consumables: Selection Chart’, contact your local BOC representative on 131 262.

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Electrodes and Typical Applications

NameAWS Classification Application

BOC Smootharc 13 e6013 A premium quality electrode for general structural and sheet metal work in all positions including vertical down using low carbon steels

BOC Smootharc 24 e7024 An iron powder electrode for high speed welding for H-V fillets and flat butt joints. Medium to heavy structural applications in low carbon steels

BOC Smootharc 18 e7018-1 A premium quality all positional hydrogen controlled electrode for carbon steels in pressure vessel applications and where high integrity welding is required and for free-machining steels containing sulphur

BOC Smootharc S 308L e308L Rutile basic coated low carbon electrodes for welding austenitic stainless steelBOC Smootharc S 316L e316L

BOC Smootharc S 309L e309L Rutile basic coated low carbon electrode for welding mild steel to stainless steel and difficult to weld material

electrode Size

The size of the electrode is generally dependent on the thickness of the section being welded, and the thicker the section the larger the electrode required. In the case of light sheet the electrode size used is generally slightly larger than the work being welded. This means that if 2.0 mm sheet is being welded, 2.5 mm diameter electrode is the recommended size.

The following table gives the maximum size of electrodes that may be used for various thicknesses of section.

8



Fundamentals of Manual Metal Arc (MMA) Welding

Recommended Electrode Sizes

Average Thickness of Plate or Section

Maximum Recommended electrode Diameter

1.5–2.0 mm 2.5 mm

2.0–5.0 mm 3.2 mm

5.0–8.0 mm 4.0 mm

≥8.0 mm 5.0 mm

Welding current

Correct current selection for a particular job is an important factor in arc welding. With the current set too low, difficulty is experienced in striking and maintaining a stable arc. The electrode tends to stick to the work, penetration is poor and beads with a distinct rounded profile will be deposited.

excessive current is accompanied by overheating of the electrode. It will cause undercut, burning through of the material, and give excessive spatter. Normal current for a particular job may be considered as the maximum which can be used without burning through the work, over-heating the electrode or producing a rough spattered surface, i.e. the current in the middle of the range specified on the electrode package is considered to be the optimum.

In the case of welding machines with separate terminals for different size electrodes, ensure that the welding lead is connected to the correct terminal for the size electrode being used. When using machines with adjustable current, set on the current range specified. The limits of this range should not normally be exceeded. The following table shows the current ranges generally recommended for BOC Smootharc 13.

Generally Recommended Current Range for BOC Smootharc 13

electrode Size (mm) Current Range (Amp)

2.5 60–95

3.2 110–130

4.0 140–165

5.0 170–260

arc length

To strike the arc, the electrode should be gently scraped on the work until the arc is established. There is a simple rule for the proper arc length; it should be the shortest arc that gives a good surface to the weld. An arc too long reduces penetration, produces spatter and gives a rough surface finish to the weld. An excessively short arc will cause sticking of the electrode and rough deposits that are associated with slag inclusions.

For downhand welding, it will be found that an arc length not greater than the diameter of the core wire will be most satisfactory. Overhead welding requires a very short arc, so that a minimum of metal will be lost. Certain BOC electrodes have been specially designed for ‘touch’ welding. These electrodes may be dragged along the work and a perfectly sound weld is produced.

electrode angle

The angle which the electrode makes with the work is important to ensure a smooth, even transfer of metal.

The recommended angles for use in the various welding positions are covered later.

correct travel Speed

The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required. At the same time the electrode is fed downwards to keep the correct arc length at all times. As a guide for general applications the table below gives recommended run lengths for the downhand position.

Correct travel speed for normal welding applications varies between approximately 100–300 mm per minute, depending on electrode size, size of run required and the amperage used.

excessive travel speeds lead to poor fusion, lack of penetration, etc., whilst too slow a rate of travel will frequently lead to arc instability, slag inclusions and poor mechanical properties.

Run Length per Electrode – BOC Smootharc 13

electrode Size (mm)

electrode Length (mm)

Run Length (mm)

Minimum Maximum

4.0 350 175 300

3.2 350 125 225

2.5 350 100 225

correct Work Preparation

The method of preparation of components to be welded will depend on equipment available and relative costs. Methods may include sawing, punching, shearing, machining, flame cutting and others.

In all cases edges should be prepared for the joints that suit the application.The following section describes the various joint types and areas of application.

types of Joints

butt Welds

A butt weld is a weld made between two plates so as to give continuity of section.

Close attention must be paid to detail in a butt weld to ensure that the maximum strength of the weld is developed. Failure to properly prepare the edges may lead to the production of faulty welds, as correct manipulation of the electrode is impeded.

Butt Welding

Weld FaceReinforcement

Root FaceRoot Gap


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Two terms relating to the preparation of butt welds require explanation at this stage. They are:

Root Face: The proportion of the prepared edge that has not been bevelled (Land).

Root Gap: The separation between root faces of the parts to be joined.

Various types of butt welds are in common use and their suitability for different thickness of steel are described as follows:

Square Butt Weld

WELD BEADS

LAYERS

70˚ - 85˚

WELD BEADS

LAYERS

ELECTRODE

SLAGWELD POOL

WELD METALARC

DIRECTION OF WELDING

The edges are not prepared but are separated slightly to allow fusion through the full thickness of the steel. Suitable for plate up to 6 mm in thickness.

Single ‘V’ Butt Weld

WELD BEADS

LAYERS

70˚ - 85˚

WELD BEADS

LAYERS

ELECTRODE

SLAGWELD POOL

WELD METALARC


This is commonly used for plate up to 16 mm in thickness and on metal of greater thickness where access is available from only one side.

Double ‘V’ Butt Weld

WELD BEADS

LAYERS

70˚ - 85˚

WELD BEADS

LAYERS

ELECTRODE

SLAGWELD POOL

WELD METALARC


used on plate of 12 mm and over in thickness when welding can be applied from both sides. It allows faster welding and greater economy of electrodes than a single ‘V’ preparation on the same thickness of steel and also has less of a tendency to distortion as weld contraction can be equalised.

Butt Weld with Backing Material

WELD BEADS

LAYERS

70˚ - 85˚

WELD BEADS

LAYERS

ELECTRODE

SLAGWELD POOL

WELD METALARC


When square butt welds or single ‘V’ welds cannot be welded from both sides it is desirable to use a backing bar to ensure complete fusion.

Single ‘U’ Butt Weld

WELD BEADS

LAYERS

70˚ - 85˚

WELD BEADS

LAYERS

ELECTRODE

SLAGWELD POOL

WELD METALARC


used on thick plates as an alternative to a single ‘V’ preparation. It has advantages as regards speed of welding. It takes less weld metal than a single ‘V’, there is less contraction and therefore a lessened tendency to distortion. Preparation is more expensive than in the case of a ‘V’, as machining is required. The type of joint is most suitable for material over 40 mm in thickness.

Double ‘U’ Butt Weld

WELD BEADS

LAYERS

70˚ - 85˚

WELD BEADS

LAYERS

ELECTRODE

SLAGWELD POOL

WELD METALARC


For use on thick plate that is accessible for welding from both sides. For a given thickness it is faster, needs less weld metal and causes less distortion than a single ‘u’ preparation.

Horizontal Butt Weld

WELD BEADS

LAYERS

70˚ - 85˚

WELD BEADS

LAYERS

ELECTRODE

SLAGWELD POOL

WELD METALARC


The lower member in this case is bevelled to approximately 15° and the upper member 45°, making an included angle of 60°. This preparation provides a ledge on the lower member, which tends to retain the molten metal.

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General notes on butt Welds

The first run in a prepared butt weld should be deposited with an electrode not larger than 4.0 mm. The angle of the electrode for the various runs in a butt weld is shown below.

It is necessary to maintain the root gap by tacking at intervals or by other means, as it will tend to close during welding.

All single ‘V’, single ‘u’ and square butt welds should have a backing run deposited on the underside of the joint, otherwise 50% may be deducted from the permissible working stress of the joint.

Before proceeding with a run on the underside of a weld it is necessary to backgouge or grind that side of the joint.

Butt welds should be overfilled to a certain extent by building up the weld until it is above the surface of the plate. excessive reinforcement, however, should be avoided.

In multi-run butt welds it is necessary to remove all slag, and surplus weld metal before a start is made on additional runs; this is particularly important with the first run, which tends to form sharp corners that cannot be penetrated with subsequent runs. electrodes larger than 4.0 mm are not generally used for vertical or overhead butt welds.

The diagrams below indicate the correct procedure for welding thick plate when using multiple runs.

Bead Sequence for 1st and 2nd Layers

WELD BEADS

LAYERS

70˚ - 85˚

WELD BEADS

LAYERS

ELECTRODE

SLAGWELD POOL

WELD METALARC


Bead Sequence for Subsequent Layers

WELD BEADS

LAYERS

70˚ - 85˚

WELD BEADS

LAYERS

ELECTRODE

SLAGWELD POOL

WELD METALARC


Welding Progression Angle

3

81

74

6

2

1 Weld Metal2 Workpiece3 electrode4 Slag5 Welding Direction6 70–85° Angle7 Arc8 Weld Pool

5


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Fillet WeldsA fillet weld is approximately triangular in section, joining two surfaces not in the same plane and forming a lap joint, tee joint or corner joint. Joints made with fillet welds do not require extensive edge preparation, as is the case with butt welded joints, since the weld does not necessarily penetrate the full thickness of either member. It is, however, important that the parts to be joined be clean, close fitting, and that all the edges on which welding is to be carried out are square. On sheared plate it is advisable to entirely remove any ‘false cut’ on the edges prior to welding.

Fillet welds are used in the following types of joints:

‘T’ Joints

A fillet weld may be placed either on one or both sides, depending on the requirements of the work. The weld metal should fuse into or penetrate the corner formed between the two members. Where possible the joint should be placed in such a position as to form a “Natural ‘V’ fillet” since this is the easiest and fastest method of fillet welding.

Lap Joints

In this case, a fillet weld may be placed either on one or both sides of the joint, depending on accessibility and the requirements of the joint. However, lap joints, where only one weld is accessible, should be avoided where possible and must never constitute the joints of tanks or other fabrications where corrosion is likely to occur behind the lapped plates. In applying fillet welds to lapped joints it is important that the amount of overlap of the plates be not less than five times the thickness of the thinner part. Where it is required to preserve the outside face or contour of a structure, one plate may be joggled.

Corner Joints

The members are fitted as shown, leaving a ‘V’-shaped groove in which a fillet weld is deposited. Fusion should be complete for the full thickness of the metal. In practice it is generally necessary to have a gap or a slight overlap on the corner. The use of a 1.0–2.5 mm gap has the advantage of assisting penetration at the root, although setting up is a problem. The provision of an overlap largely overcomes the problem of setting up, but prevents complete penetration at the root and should therefore be kept to a minimum, i.e. 1.0–2.5 mm.

The following terms and definitions are important in specifying and describing fillet welds.

leg length

A fusion face of a fillet weld, as shown below. In Australia and NZ specifications for fillet weld sizes are based on leg length.

throat thickness

A measurement taken through the centre of a weld from the root to the face, along the line that bisects the angle formed by the members to be joined. Many countries uses throat thickness rather than leg length.

effective throat thickness is a measurement on which the strength of a weld is calculated. The effective throat thickness is based on a mitre fillet (Concave Fillet Weld), which has a throat thickness equal to 70% of the leg length. For example, in the case of a 20 mm fillet, the effective throat thickness will be 14 mm.

convex Fillet Weld

A fillet weld in which the contour of the weld metal lies outside a straight line joining the toes of the weld. A convex fillet weld of specified leg length has a throat thickness in excess of the effective measurement.

Convex Fillet Weld

1

2 3

4

4

5

5

6

1 Actual Throat2 effective Throat3 Convexity4 Leg5 Size6 Theoretical Throat

concave Fillet Weld

A fillet in which the contour of the weld is below a straight line joining the toes of the weld. It should be noted that a concave fillet weld of a specified leg length has a throat thickness less than the effective throat thickness for that size fillet. This means that when a concave fillet weld is used, the throat thickness must not be less than the effective measurement. This entails an increase in leg length beyond the specified measurement.

Concave Fillet Weld

1 23

6

54

5

4

1 Actual Throat2 effective Throat3 Concavity4 Leg5 Size6 Theoretical Throat


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The size of a fillet weld is affected by the electrode size, welding speed or run length, welding current and electrode angle. Welding speed and run length have an important effect on the size and shape of the fillet, and on the tendency to undercut.

Insufficient speed causes the molten metal to pile up behind the arc and eventually to collapse. Conversely, excessive speed will produce a narrow irregular run having poor penetration, and where larger electrodes and high currents are used, undercut is likely to occur.

Fillet Weld Data

Nominal Fillet Size (mm)

Min.Throat Thickness (mm)

Plate Thickness (mm)

electrode Size (mm)

5.0 3.5 5.0–6.3 3.2

6.3 4.5 6.3–12 4.0

8.0 5.5 8.0–12 and over 5.0

10.0 7.0 10 and over 4.0

Selection of welding current is important. If it is too high the weld surface will be flattened, and undercut accompanied by excessive spatter is likely to occur. Alternatively, a current which is too low will produce a rounded narrow bead with poor penetration at the root. The first run in the corner of a joint requires a suitably high current to achieve maximum penetration at the root. A short arc length is recommended for fillet welding. The maximum size fillet which should be attempted with one pass of a large electrode is 8.0 mm. efforts to obtain larger leg lengths usually result in collapse of the metal at the vertical plate and serious undercutting. For large leg lengths multiple run fillets are necessary. These are built up as shown below. The angle of the electrode for various runs in a downhand fillet weld is shown below.

Recommended Electrode Angles For Fillet Welds

1st Run 2nd Run

ELEC

TRODE

40˚ 55˚ - 60˚

20˚ - 30˚

1 23

45

6

ELEC

TRODE

40˚ 55˚ - 60˚

20˚ - 30˚

1 23

45

6

3rd Run Multi-run Fillet

ELEC

TRODE

40˚ 55˚ - 60˚

20˚ - 30˚

1 23

45

6

ELEC

TRODE

40˚ 55˚ - 60˚

20˚ - 30˚

1 23

45

6

Multi-run (multi-pass) horizontal fillets have each run made using the same run lengths (Run Length per electrode Table). each run is made in the same direction, and care should be taken with the shape of each, so that it has equal leg lengths and the contour of the completed fillet weld is slightly convex with no hollows in the face.

Vertical fillet welds can be carried out using the upwards or downwards technique. The characteristics of each are: upwards – current used is low, penetration is good, surface is slightly convex and irregular. For multiple run fillets large single pass weaving runs can be used. Downwards – current used is medium, penetration is poor, each run is small, concave and smooth (only BOC Smootharc 13 is suitable for this position).

The downwards method should be used for making welds on thin material only. electrodes larger than 4.0 mm are not recommended for vertical down welding. All strength joints in vertical plates 10.0 mm thick or more should be welded using the upward technique.This method is used because of its good penetration and weld metal quality.The first run of a vertical up fillet weld should be a straight sealing run made with 3.2 mm or 4.0 mm diameter electrode. Subsequent runs for large fillets may be either numerous straight runs or several wide weaving runs.

Correct selection of electrodes is important for vertical welding.

In overhead fillet welds, careful attention to technique is necessary to obtain a sound weld of good profile. Medium current is required for best results. High current will cause undercutting and bad shape of the weld, while low current will cause slag inclusions. To produce a weld having good penetration and of good profile, a short arc length is necessary. Angle of electrode for overhead fillets is illustrated below.

Recommended Electrode Angles for Overhead Fillet Welds

30˚15˚ 45˚


8



Fundamentals of Manual Metal Arc (MMA) WeldingFundamentals of Manual Metal Arc (MMA) Welding

Manual metal arc welding, like other welding processes, has welding procedure problems that may develop which can cause defects in the weld. Some defects are caused by problems with the materials. Other welding problems may not be foreseeable and may require immediate corrective action. A poor welding technique and improper choice of welding parameters can cause weld defects.

Defects that can occur when using the shielded metal arc welding process are slag inclusions, wagon tracks, porosity, wormhole porosity, undercutting, lack of fusion, overlapping, burn through, arc strikes, craters, and excessive weld spatter. Many of these welding technique problems weaken the weld and can cause cracking. Other problems that can occur which can reduce the quality of the weld are arc blow, finger nailing, and improper electrode coating moisture contents.

Defects caused by Welding technique

Slag Inclusions

Slag inclusions occur when slag particles are trapped inside the weld metal which produces a weaker weld. These can be caused by:

erratic travel speed

too wide a weaving motion

slag left on the previous weld pass

too large an electrode being used

letting slag run ahead of the arc.

This defect can be prevented by:

a uniform travel speed

a tighter weaving motion

complete slag removal before welding

using a smaller electrode

keeping the slag behind the arc, which is done by shortening the arc, increasing the travel speed, or changing the electrode angle.

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Wagon tracks

Top View Thru Transparent Bead

Wagon tracks are linear slag inclusions that run the longitudinal axis of the weld. They result from allowing the slag to run ahead of the weld puddle and by slag left on the previous weld pass. These occur at the toe lines of the previous weld bead.

Porosity

Porosity is gas pockets in the weld metal that may be scattered in small clusters or along the entire length of the weld. Porosity weakens the weld in approximately the same way that slag inclusions do.

Porosity may be caused by:

excessive welding current

rust, grease, oil or dirt on the surface of the base metal

excessive moisture in the electrode coatings

impurities in the base metal, such as sulfur and phosphorous

too short an arc length except when using low-hydrogen or stainless steel electrodes

travel speed too high which causes freezing of the weld puddle before gases can escape.

This problem can be prevented by:

lowering the welding current

cleaning the surface of the base metal

redrying electrodes

changing to a different base metal with a different composition

using a slightly longer arc length

lowering the travel speed to let the gases escape

preheating the base metal, using. a different type of electrode, or both.

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Welding Defects and Problems

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Wormhole Porosity (Piping Porosity)

Wormhole porosity is the name given to elongated gas pockets and is usually caused by sulfur or moisture trapped in the weld joint. The best method of preventing this is to lower the travel speed to permit gases to escape before the weld metal freezes.

undercutting

undercutting is a groove melted in the base metal next to the toe or root of a weld that is not filled by the weld metal. undercutting causes a weaker joint and it can cause cracking. This defect is caused by:

excessive welding current

too long an arc length

excessive weaving speed

excessive travel speed.

On vertical and horizontal welds, it can also be caused by too large an electrode size and incorrect electrode angles. This defect can. be prevented by:

choosing the proper welding current for the type and size of electrode and the welding position

holding the arc as short as possible

pausing at each side of the weld bead when a weaving technique is used

using a travel speed slow enough so that the weld metal can completely fill all of the melted out areas of the base metal.

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lack of Fusion

Lack of fusion is when the weld metal is not fused to the base metal. This can occur between the weld metal and the base metal or between passes in a multiple pass weld. Causes of this defect can be:

excessive travel speed

electrode size too large

welding current too low

poor joint preparation

letting the weld metal get ahead of the arc.

Lack of fusion can usually be prevented by:

reducing the travel speed

using a smaller diameter electrode

increasing the welding current

better joint preparation

using a proper electrode angle

overlapping

Overlapping is the protrusion of the weld metal over the edge or toe of the weld bead. This defect can cause an area of lack of fusion and create a notch which can lead to crack initiation. Overlapping is often produced by:

too slow a travel speed which permits the weld puddle to get ahead of the electrode

an incorrect electrode angle that allows the

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8




It is the composition of the coating that differentiates one type of electrode from another, and to a degree, what type of application it can be used for. MMA electrodes, with a solid wire core, are generally categorised by the type of flux coating they employ. There are three main groups of electrode coating: rutile, basic, and cellulosic, plus a less-widely-used acid type. The name of each group is a description of the main constituent of the coating. Although not strictly a coating type, iron-powder electrodes are often considered as a separate group.

electrodes for cutting, grooving and gouging, plus those for hard-surfacing, including tubular MMA electrodes, are not classified by coating type.

Rutile electrodesRutile electrodes have a coating that contains about 50% rutile sand (a pure form of titanium dioxide), plus additions of ferro-manganese, mineral carbonates and silicates, held together with approximately 15% sodium silicate, also known as waterglass. The rutiles’ characteristics include easy striking, stable arc, low spatter, good bead profile and generally, easy slag removal from the electrode.

The electrode can operate on both AC and DC currents and can operate in all positions if the formulation of the coating is so designed.

One negative aspect of these electrodes is that they produce a high level of hydrogen, typically greater than 15ml / 100g of deposited weld metal. This cannot be avoided because they rely on a certain amount of moisture being present in the coating to operate properly. If the electrodes are dried too much, they will fail to function properly.

Rutile-coated electrodes are manufactured for welding mild and low-carbon steels. In this context, they are often referred to as general-purpose or GP electrodes. Some low-alloy grades also use rutile coatings. Rutile-type coatings, which are modifications of those used for ferritic steels, are also used on many austenitic stainless steel electrodes.

basic electrodesBasic, or low-hydrogen, electrodes contain calcium carbonate and calcium fluoride in place of the rutile sand and mineral silicates. This makes them less easy to strike and more difficult to re-strike, due to the very deep cup formed at the tip during operation. They also have a poorer, more convex bead profile than rutile electrodes. The slag is more difficult to remove than the rutile types but they do give improved weld metal properties than rutile types, with a higher metallurgical quality.

Basic electrodes are capable of being used on AC or DC currents and can be used in multi-pass welds on materials of all thicknesses.

Basic electrodes do not rely on moisture to function properly, and for the more critical applications should be used completely dry. It is important to note that basic electrodes are only low-hydrogen electrodes if they have been correctly dried before use. This conventionally involves re-drying in ovens on site in accordance with manufacturers’ recommendations. Drying can reduce weld metal hydrogen to less than 5ml / 100g, as can vacuum-packing the electrodes. These can be used straight from the packs without any form of drying being required. BOC Smootharc 16 and 18 electrodes are supplied in hermetically sealed containers which ensure that they meet the H4 grade.

Basic-type electrodes for ferritic steels, with low-alloy additions to the coatings or the core wire, allow a much wider use, including sub-zero and elevated-temperature application. Basic coatings are also widely used for electrodes for welding stainless steels, nickel alloys, cast irons, copper and aluminium alloys and for hard-facing applications.

cellulosic electrodesCellulosic electrodes contain a high proportion of organic material, replacing all or some of the rutile sand. This produces a fierce, deep penetrating arc and a faster burn-off rate. Cellulosic electrodes are more prone to spatter than rutile types. Only carbon and some low-alloy steels are made with a cellulosic coating and most run only on DC+ polarity, but some are made that will also operate on AC and DC-. They are truly all-positional electrodes in all sizes and even larger diameters up to 6 mm will operate vertical-down. Cellulosic electrodes are used for root passes and pipeline welding.

It should be noted that celullosic electrodes generate high amounts of hydrogen. This presents a risk of hydrogen-induced cracking if correct welding procedures are not followed.

acid electrodesAcid electrodes for mild steels have been largely replaced by rutile types but some are still produced by a few manufacturers. These electrodes contain high amounts of iron oxide, are relatively easy to use and give a voluminous glassy slag, which detaches easily. They are lower-strength products, so are confined to use on non-structural components.

Acid-rutile electrodes for stainless steel are now replacing conventional rutile types. They are higher in silicon, which gives improved operating and wetting characteristics and are much more welder-friendly. They strike and re-strike readily and will operate on AC and DC current. They produce low spatter levels and an easily removed slag. However, they are prone to ‘start porosity’, and need re-drying before use to avoid this.

Iron-powder electrodesIron-powder electrodes are often considered as an independent group of consumables. As their name suggests, these electrodes contain high levels of iron powder held within the coating – as the coating melts, the iron powder creates more weld metal. This effectively improves the productivity from the electrode, allowing either larger or longer welds to be created from a single rod. The amount of iron powder added depends upon the consumable being produced, but it is not uncommon for 75% of the core weight to be added.

The addition of the iron powder to the coating has the effect of increasing the overall diameter of the electrode and reducing the amount of fluxing agent present in the coating. With less fluxing agent available, the slag coating tends to be thinner, so many of the MMA electrode’s positional welding characteristics are lost. This means that many of the electrodes can only be used in the flat or horizontal-vertical (H-V) positions.

Coatings for iron-powder electrodes may be based on either the rutile or basic systems.

coating types

8




Practical considerations

Storage and Re-drying

MMA electrodes should be stored in dry, well-ventilated and preferably heated stores. For critical applications it is also recommended that they be held in temperature- and humidity-controlled conditions, maintaining humidity below 60%RH (Relative Humidity) and a temperature above the dew point, to avoid moisture condensing onto the electrodes. electrodes held in dry conditions will remain in prime condition for several years but if the coating absorbs moisture, this will lead to a gradual deterioration. evidence of deterioration includes the presence of white powdery areas on the surface of the coating, cracks in the coating or pieces of coating missing.

electrodes with rutile or cellulosic coating require some moisture in the coating to operate properly and should not be re-dried. If rutile electrodes get wet, re-drying at about 80ºC is all that is needed. Cellulosic electrodes must not be dried. In some hot environments they may need wetting to function efficiently.

Basic coated electrodes need to be dry to give low-hydrogen weld metal. Before use, these electrodes should be re-dried according to manufacturers’ recommendations, be put in holding ovens and then transferred to the workstations in heated quivers until needed. Vacuum-packed basic electrodes can be used straight from the packet.

eletrodes for non-ferrous alloys and stainless steel always need to be completely dry before use and should be treated in accordance with manufacturers’ requirements.

Welding Parameters

Some electrodes will operate satisfactorily on AC or DC current and for AC operation, manufacturers will recommend a minimum OCV (Open Circuit Voltage) in order to initiate a welding arc with the electrode.

care and conditioning of consumables

8 Consumables



Fundamentals of Metal Inert Gas (MIG) Welding

Welding techniqueSuccessful welding depends on the following factors:

Selection of correct consumables

Selection of the correct power source

Selection of the correct shielding gas

Selection of the correct application techniques a Correct angle of electrode to work b Correct electrical stickout c Correct travel speed

Selection of the welding preparation.

Selection of correct consumable

chemical composition

As a general rule the selection of a wire is straightforward, in that it is only a matter of selecting an electrode of similar composition to the parent material. It will be found, however, that there are certain applications that electrodes will be selected on the basis of mechanical properties or level of residual hydrogen in the weldmetal. Solid MIG wires are all considered to be of the “low Hydrogen type” consumables.

The following table gives a general overview of the selection of some of the BOC range of MIG wires for the most common materials. More detailed selection charts for specific materials can be found in the appropriate materials sections

Material Page No

Mild and Alloy steel 341

Quench and tempered steels 343

Ferritic materials 342

Stainless steel 401

Aluminium 429

1�

2�

3�

4�

5�

Common Materials Welded with BOC MIG Wire

Material BOC MIG Wire

AS2074 C1, C2, C3, C4-1, C4-2, C5, C6

BOC Mild Steel MIG Wire

AS/NZS 3678-9 250, 300, 350, 400 BOC Mild Steel MIG Wire

AS1548-430, 460,490 BOC Mild Steel MIG Wire

ASTM A36, A106, eN8, 8A BOC Mild Steel MIG Wire

Stainless Steel

Grade 304 BOC Stainless Steel 308LSi

Stainless to Carbon-Mn steels

Grade 316 BOC Stainless Steel 316LSi

Aluminium

1080 BOC Aluminium MIG 1080

6061, 3004 BOC Aluminium MIG 4043

5005 BOC Aluminium MIG 5356

Physical condition

Surface condition.

The welding wire must be free from any surface contamination including mechanical damage such as scratch marks.

A simple test for checking the surface condition is to run the wire through a cloth that has been dampened with acetone for 20sec. If a black residue is found on the cloth the surface of the wire is not properly cleaned

Cast and Helix.

The cast and helix of the wire has a major influence on the feedability of MIG wire

Cast

Helix

8




Cast – Diameter of the circle

Helix – Vertical height

If the cast is too small the wire will dip down from the tip. The result of this is excessive tip wear and increased wear in the liners.

If the helix is too large the wire will leave the tip with a corkscrew effect and cause feeding problems.

Selection of the correct Power SourcePower sources for MIG / MAG welding is selected on a number of different criteria, including:

Maximum output of the machine

Duty cycle

Output control (voltage selection,wire feed speed control)

Portability

The following table gives an indication of the operating amperage for different size wires

Wire Size Amperage Range (A)

0.8 mm 60–180

0.9 mm 70–250

1.0 mm 90–280

1.2 mm 120–340

A BOC power sources selection chart is contained in the arc equipment section of this manual (see pages 232–233).

Selection of the correct Shielding GasThe selection of the shielding gas has a direct influence on the appearance and quality of the weldbead.

The type and thickness of the material to be welded will determine the type of shielding gas that is selected. As a general rule the thicker the material (C-Mn and Alloy Steels), the higher the percentage of CO2 in the shielding gas mixture.

1�

2�

3�

4�

Different grades of shielding are required for materials such as stainless steel, aluminium and copper.

The following table gives an indication of the most common shielding gases used for Carbon Manganese and Alloy Steels:

Material thickness Recommended shielding gas

1–4 mm (dip transfer) Argoshield Light

4–12 mm Argoshield universal

>10 mm Argoshield Heavy

Material thickness Recommended shielding gas

1–8 mm Argoshield Light

5–12 mm Argoshield universal

>12 mm Argoshield Heavy

More detailed selection charts, including recommendations for welding parameters (voltage, amperage, electrical stickout, travel speed and gas flow rate) can be found in the following sections:

Material Page

C-Mn and Alloy Steels

Argoshield Light 58

Argoshield universal 59

Argoshield Heavy 60

Argoshield 52 61

Stainless Steel

Stainshield 63

Stainshield Heavy 63

Aluminium

Argon xxx

Undercutting and burnback

No working condition

Dip Transfer (Steel Thickness (mm))

Spray Transfer (Steel Thickness (mm))

0

0 1 2 3 4 5

1 2 3 4 5

Burnback and arc instability

Spray TransferOptimum Parameters

DipTransferOptimum Parameters

Defect Free Zone

Defect Zone

Electrode (wire) stubbing and spatter

Current (A)

Wire Operating Limits

Volta

ge (

V)

35

30

25

20

15

10

50 50 100 150 200 400250 300 350

1.0mm 1.2mm

0.8mm0.9mm 1.0mm

WHICH ONe?

8




Material Page

Alushield Light 65

Alushield Heavy 65

Copper

Specshield Copper 68

correct application techniques

Direction of welding.

MIG welding with solid wires takes place normally with a push technique. The welding gun is tilted at an angle of 10° towards the direction of welding. (Push technique)

10°

Torch perpendicular to workpiece Narrow bead width with increased reinforcement

The influence of changing the torch angle and the welding direction on the weld bead profile can be seen below

10°

Torch positioned at a drag angle of 10° Narrow bead with excessive reinforcement

90° 90°

0–15°

Torch position for butt welds

When welding butt welds the torch should be positioned within the centre of the groove and tilted at an angle of ±15° from the vertical plane. Welding is still performed in the push technique

0–15°

45°

45°

Torch position for fillet welds

When welding fillet welds the torch should be positioned at an angle of 45° from the bottom plate with the wire pointing into the fillet corner. Welding is still performed in the push technique

electrical stickout

1 Gas Nozzle2 Contact Tube Setback3 Consumable electrode4 Workpiece5 Standoff Distance6 Contact Tube7 Visible Stickout8 Arc length9 electrical Stickout

1

2

35

6

7

8

9

4

The electrical stickout is the distance between the end of the contact tip and the end of the wire. An increase in the electrical stickout results in an increase in the electrical resistance. The resultant increase in temperature has a positive influence in the melt off rate of the wire that will have an influence on the weldbead profile

Short Normal Long

Influence of the change in electrical stickout length on the weldbead profile

travel speed

Slow Normal FastThe travel speed will have an influence on the weldbead profile and the reinforcement height.

If the travel speed is too slow a wide weldbead with excessive rollover will result. Conversely if the travel speed is too high, a narrow weldbead with excessive reinforcement will result.

Recommendation about travel speed are contained in the detailed gases datasheets found in pages 58–68 of this manual.

8




Improved productivity

Reduced equipment downtime

enhanced weldability and accuracy

Reduced wear on liners and contact tips

Drum hood keeps wire free of dust and dirt

The BOC Smoothpak bulk MIG wire system has been designed specifically to enhance the performance of automated and dedicated welding systems. each Smoothpak contains 250 kg of wire – the equivalent of 16 standard spools – amounting to four hours of additional production if changeover time is estimated at 15 minutes a spool.

The secret of the success of the Smoothpak system is the packaging system. Welding wire is introduced into each Smoothpak drum using a unique reverse-twist coiling method, ensuring that a virtually straight wire emerges from the container during welding. Consequently, the welding wire can be positioned precisely, enhancing weldability and accuracy, and reducing wear on liners and contact tips. The negative effects of the cast and / or helix which can be experienced with conventionally-spooled wire are also eliminated.

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advantage of boc Smoothpak

8 Consumables



eTP – GCP – W50 4 A . CMI H10

Designates the diffusable hydrogen-content of deposited weld

metal-(DWM).H10

H5 ≤ 5 ml H2 / 100 g of DWM

H10 ≤ 10 ml H2 / 100 g of DWM

H15 ≤ 15 ml H2 / 100 g of DWM

Welding techniqueSuccessful flux and metal cored arc welding depends on the following factors:


Selection of the correct power source

Selection of the correct shielding gas

Selection of the correct application techniques a Correct angle of electrode to work b Correct electrical stickout c Correct travel speed

Selection of the welding preparation.

Selection of correct consumable

chemical composition

As a general rule the selection of a wire is straightforward, in that it is only a matter of selecting an electrode of similar composition to the parent material. It will be found, however, that there are certain applications that electrodes will be selected on the basis of mechanical properties or level of residual hydrogen in the weldmetal. The classification system for flux cored wires will provide an indication of the residual Hydrogen level that can be expected in the weldmetal

The following table gives a general overview of the selection of some of the BOC range of Flux and Metal cored wires for the most common materials. More detailed selection charts for specific materials can be found in the appropriate materials sections

1�

2�

3�

4�

5�

Material Page No

Carbon and Alloy steel castings 341

Quench and tempered steels 343

Ferritic steels 342

Common Materials Welded with Flux and Metal Cored Wire

Material BOC MIG Wire

AS2074 C1, C2, C3, C4-1, C4-2, C5, C6

BOC Smooth-Cor 711,

Smooth-Cor 70C6, Smooth-Cor 715

AS/NZS 3678-9 250, 300, 350, 400

BOC Smooth-Cor 711,


AS1548-430, 460, 490 BOC Smooth-Cor 711,


ASTM A36, A106, eN8, 8A BOC Smooth-Cor 711,


BS970 eN 43A, AS3597-500 BOC Smooth-Cor 811K2

BS970 eN24, AS3597-700 BOC Smooth-Cor 115

Stainless Steel

Grade 304 Cigweld Shieldchrome 308LT

Stainless to mild steel Cigweld Shieldchrome 309LT

Grade 316 Cigweld Shieldchrome 316LT

Fundamentals of Flux and Metal Cored Arc Welding

8




Physical condition

Surface condition

BOC flux and metal cored wires are supplied as an in line baked product and therefore has a typical dark surface appearance.

The wire must however be free from any surface contamination including surface rust. Most flux and metal cored wires have a thin film of graphite on the surface of the wire to assist with the feedability.

BOC SmoothCor wires are supplied in tough vacuum packs to ensure performance as manufactured.

cast and Helix

The AWS standard for Flux cored wires do not specify a cast or helix other than to stipulate that it should be of such a nature that the wire can be fed uninterrupted.

Selection of the correct Power SourcePower sources for Flux and Metal cored welding is selected on a number of different criteria, including:

Maximum output of the machine

Duty cycle

Output control ( voltage selection,wire feed speed control)

Portability

1�

2�

3�

4�

The following table gives an indication of the operating amperage for different size wires

Wire Size (mm) Direction Amperage Range (A)

FCAW

1.2 Horizontal 200–300

1.2 Vertical up 150–250


1.6 Vertical up 180–250

MCAW



A BOC power sources selection chart is contained in the arc equipment section of this manual (see pages 232–233)

Selection of the correct Shielding GasThe selection of the shielding gas has a direct influence on the appearance and quality of the weldbead.

Flux cored wires are manufactured to be welded with either 100% CO2 or a Argon / CO2 gas mixture. Mostly these mixtures will contain 25% CO2 as is the case with BOC Argoshield 52.

Undercutting and burnback

No working condition

Plate Thickness (mm) Positional Welding

Plate Thickness (mm) Flat and Horizontal

0

0 5 10 15 20

10 20

Burnback and arc instability

Flat and HorizontalOptimum Paramaters

Positional WeldingOptimum Paramaters

Defect Free Zone

Defect Zone

Electrode stubbing and spatter

Current (A)

Current / Voltage Envelope for Argoshield 52

Volta

ge (

V)

40

30

25

20

15

35

1050 400100 150 200 450250 300 350

1.6 mm1.2 mm

8




correct application techniques

Direction of travel

Flux cored welding are normally performed using a “drag” technique. The welding gun is tilted to between a 50–60° backhand angle. If however a flatter bead profile is required the backhand angle can be reduced.

Metal cored wire because of it’s similarity to solid wires (no slag formers added to the core mainly metallic powders) are normally welded with the “Push” technique

Travel direction (Flux cored)

50–60°

5mm

2–3mm

Travel direction (Metal cored)10°

When welding butt welds with flux or metal cored wires the torch should be positioned within the centre of the groove and tilted at an angle of ±20°. Flux cored welding is still performed with the “drag” technique and metal cored welding with the “push” technique.

Torch position for butt welds

90° 90°

0–15°

Torch angle for fillet welds

60–70°

30–40°

When welding horizontal – vertical fillet welds the wire tip must be aimed exactly in the corner of the joint. For the first bead the welding gun is tilted at an angle of 30–40° from the horizontal plane. Flux cored welding is still performed with the “drag” technique and metal cored welding with the “push” technique.

Vertical up

Vertical up welding can be undertaken in a similar way as MMA with a slight weave motion.

Vertical up welding with metal cored wire can successfully be undertaken with pulsed MIG welding equipment

electrical stickout

1 Gas Nozzle2 Contact Tube Setback3 Consumable electrode4 Workpiece5 Standoff Distance6 Contact Tube7 Visible Stickout8 Arc length9 electrical Stickout

1

2

35

6

7

8

9

4

The electrical stickout is the distance between the end of the contact tip and the end of the wire. An increase in the electrical stickout results in an increase in the electrical resistance. The resultant increase in temperature has a positive influence in the melt off rate of the wire that will have an influence on the weldbead profile

travel speed

The construction of flux and metal cored wires ensures the highest current density for a any given current setting compared to all other welding processes.

8




High current densities produce high deposition rates.

Current Density =Amperage

Cross-sectional area of wire

or J =I

A

electrode / Wire Dia. (mm) Cross section area (mm2) Current (A) Current Density (A / mm2) Deposition rate (kg / h)

MMA electrode (e7024) 4 12.57 235 18.7 3.0

FCAW wire (e71T-1) 1.2 0.625 235 376 3.8

MIG wire (eR70S-6) 1.2 1.130 235 287.5 3.3

MCAW wire (e70C-6M) 1.2 0.625 300 480 5.2

Consequently, travel speed must be increased proportionately to maintain control of the weld pool, bead shape and balance the deposited weld metal versus fusion obtained

Travel speed too slow

excessive penetration

excessive weldmetal deposited

Roll over of weldmetal on horizontal plate

Correct travel speed

Recommended penetration depth

Proper sidewall fusion without roll over or undercut

Travel speed too fast

Weldbead too small

Inadequate sidewall fusion

Lack of root penetration

8 Consumables


What is Preheat?A heating procedure applied to parent metal components immediately before welding commences, and considered as an essential part of the welding operation, is called ‘Preheat’.

Preheating can be applied locally to the areas to be welded, or to the whole component. It is usually done to raise the temperature of the weld area so that the weld does not cool too quickly after welding. This protects the material being welded from the various adverse effects that can be caused by the normally rapid cooling cycle created by the welding process.

Note that while preheat is applied before welding begins, it is essential that the minimum preheat temperature is maintained throughout the welding operation.

What does Preheat do?

Basically, preheat puts the parent metal components in a suitable condition for the subsequent welding operation. Preheating may be carried out for any of the following reasons;

Slow down the cooling rate

Reduce shrinkage stress and weld distortion

Promote fusion

Remove moisture

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Slow Down the cooling Rate

Some alloys (notably high carbon and low alloy steels), if welded and allowed to cool quickly, can develop hard or brittle phases in the heat affected zone (HAZ). These phases can render such alloys susceptible to cracking under the action of tensile shrinkage stresses as the weld area cools down, or they can result in low toughness of the HAZ.

Many steels are susceptible to hydrogen cracking, and fast cooling rates not only promote the formation of hard, susceptible microstructures but also lock the hydrogen into the solidifying weld metal. Because of this trapped hydrogen gas, pressure builds up in the weld and the heat affected zone which can result in cracking of the already brittle microstructure. Such cracks are normally detected by post weld inspection techniques, but should they escape detection, they may lead to premature failure in service, with potentially disastrous consequences.

Preheating of components prior to welding in these situations is designed primarily to slow down the rate of cooling of the weldment. In reducing the cooling rate, preheat is protecting the parent metal by helping to prevent hardening of the weld by the formation of brittle phases. A softer, more ductile structure is more resistant to cracking. The slower cooling rate also gives more time for any hydrogen introduced into the weld to diffuse away from the welded joint.

Reduce Shrinkage Stress and Weld Distortion

If welds are made in highly restrained joints, or in materials with very low ductility (e.g. cast irons), the welding cycle of heating, followed by rapid cooling, can result in cracking in the weld or the surrounding area. This is due to the weld metal or adjacent parent metal not being able to withstand the effects of shrinkage stresses created by contraction.

Metals and alloys that should not be preheated

Preheat and high interpass temperatures can have a negative effect on the mechanical properties or corrosion resistance of some alloys e.g.

Austenitic manganese (13% Mn) steel

Austenitic stainless steels

Duplex stainless steels

Titanium alloys** For futher information, please consult your local BOC Welding Specialist, BOC Technical

Manager or Welding engineers.

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Preheating of Materials

8




Residual stresses present in a welded joint.

Distortion due to the presence of residual stress

Here preheating is used to balance the thermal cycle and so reduce the shrinkage stresses in the weld and in the adjacent parent material.

When welding wrought materials in highly restrained joints, preheat is normally applied locally in the weld area.

When welding castings, the preheat applied may be ‘local’ (heating in the area of the weld only), ‘total’ (the whole casting is heated), or ‘indirect’ (heating a part of the casting away from the weld area to balance the effects of expansion and contraction).

Promote fusion

Some alloy systems (e.g. copper and aluminium) have very high thermal conductivity, and if a weld is attempted on thick, cold, plate, the parent material could chill the deposited weld metal so quickly that it does not fuse with the parent metal. This may be referred to as a ‘cold start’. The heat conduction away from the joint area can be such that a weld may be impossible using a conventional arc welding process.

Preheat is used in this case to raise the initial temperature of the material sufficiently to ensure full weld fusion from the start. This is particularly important when using a welding process / plate thickness combination that is likely to produce a cold start.

Remove Moisture

Any metallic components left overnight in a cold workshop or brought in from outside are likely to be damp or even wet. If they are welded in that condition, problems can arise in the resultant welds. For example, if the components are made of steel, then the moisture will act as a source of hydrogen and the result could be hydrogen cracking. Aluminium has a porous oxide layer, which will absorb moisture from the atmosphere, and, if not removed before welding, this can result in weld metal porosity and subsequent rejection of the weld.

Whilst not normally the main objective of preheating, its use for removal of surface moisture prior to welding is not only advisable, but very often essential.

carbon Steel and alloy SteelThese two groups of materials have, quite rightly, been given more attention regarding estimation of preheat temperature than any other alloy system, as the penalty for getting it wrong can be severe.

The following list is intended only to give some indication of the level of preheat required for certain types of steel. In these examples it is assumed that the weld is a butt weld, and the thicknesses given are the normally used ‘combined thickness’, where this is the total thickness of all the parts to be joined.

When calculating the ‘combined thickness’ of parts with varying thicknesses (such as forgings), the thickness of each part is usually averaged over a distance of 75 mm from the weld line. However for some processes and materials, account must be taken of any difference of thickness beyond the 75 mm point, and it is important to refer to the specific welding procedures, or relevant standards in each case.

8




Steel typeCombined Thickness (mm) Typical Preheat (°C)

Low C and mild steels <50 ≤50

>50 100–150

Medium C, C-Mn steels <40 100–200

>40 150–250

High C, C-Mn steels All 200–300

QT steels, HSLA steels All None to 150 (max.)

0.5% Mo, 1% Cr-0.5% Mo steels*

All 100–250

2% Cr-1% Mo, 5% Cr-0.5% Mo steels*

All 200–300

Direct hardening steels All 150–300

Case hardening steels All 150

13% Manganese steel All None

*Preheat is usually specified by procedure and tightly monitored and controlled with these materials.

It is recommended that more comprehensive documentation be consulted when selecting a temperature for a specific application.

Information to assist with calculation of preheat for C-Mn steels can be found in international standards, for example BS 5135, AWS D1.1 and AS / NZS 1554.1. These standards set out minimum preheat temperatures based on factors such as, the type of steel specification or carbon equivalent, thickness, the welding process or heat input, and the hydrogen class of the welding consumable. The guidelines do not take restraint into consideration, and so highly restrained joints may need higher levels of preheat than indicated.

The information in these standards is often used as a rough guide to determine preheat for low alloy steels; this should be done with extreme caution as low alloy steels will frequently need much higher preheat than estimated by this means because of their alloy content.

When joining or surfacing hardenable steels (steels with high Ce) it is sometimes possible to weld with an austenitic type consumable and use a lower preheat than would be needed if ferritic consumables were to be used.

The decision making process when deciding whether to use preheat with Carbon Steel and Alloy Steel can become quite complicated. Carbon and carbon-manganese steels and low alloy steels may require preheating, but this depends on their carbon equivalent, combined thickness, and proposed welding heat input.

Preheat with these ferritic materials is primarily aimed at reducing the severity of the “quench” after welding, and helping to prevent the formation of hard brittle microstructures in the weld and HAZ. It also allows hydrogen to diffuse away from the weld area, so reducing the risk of hydrogen cracking. The objective is to keep the maximum HAZ hardness to below about 350 Hv, although this will not always be possible, particularly with some low alloy steels with high hardenability. These low alloy types may, additionally, need a post-weld heat treatment to restore properties.

How much Preheat to apply

The actual preheat temperature required for a specific welding operation depends not only on the material or materials being welded, but also the combined thickness of the joint, the heat input from the welding process being used, and the amount of restraint imposed upon the components. There are no hard and fast rules regarding how much preheat to apply, but there are many publications available giving helpful guidance. These publications include national and international standards or codes of practice, guides from steel and aluminium alloy producers, and from consumable manufacturers. Some guidelines are included here, and as in the previous section, categorised for convenience by alloy type.

Preheating of aluminium and aluminium alloys

When to Preheat

Preheat is needed when there is a risk that if a welding operation is carried out ‘cold’ an unsound weld could be produced. Whilst it is not possible here to cover all eventualities, there are certain guidelines that can be followed in making the decision whether to preheat or not, and these are outlined here, categorised for convenience, by alloy type.

aluminium alloys

Aluminium Alloys have a high thermal conductivity and preheat is used to provide additional heat to the weld area in order to help ensure full fusion of the weld. Application of preheat is also used to drive off any moisture in the surface oxide. Preheating is not necessary when welding thin sheet, but becomes increasingly important as thickness increases. High conductivity aluminium busbars are a prime example.

As a rule, aluminium alloys are only preheated to temperatures between 80–120°C. Certain heat treatable aluminium alloys (Al-Si-Mg) are sensitive to HAZ liquation cracking if overheated, and preheat must be carefully controlled within this range. With less sensitive alloys preheat may be increased up to a maximum of 180–200°C. Remember that aluminium alloys have relatively low melting points and care must be taken to avoid overheating which can result in poor weld quality and cracking in some alloys.

8




Preheating of Stainless Steel

Stainless Steel

Martensitic stainless steels generally require preheating to 200–300°C, depending on carbon content plus post weld heat treatment in order to prevent cracking in the weld and/or HAZ. This applies whether they are welded with matching consumables or, as is quite common, with austenitic consumables.

Some ferritic stainless steels should be preheated to about 200°C to prevent embrittlement. They may also need a post weld annealing treatment, depending on application.

Should it be necessary to preheat duplex stainless steel, it is normal to keep it fairly low, up to a maximum of 150°C for ‘Duplex’ and 100°C for ‘Super Duplex’. Preheat is invariably specified by procedure and tightly monitored and controlled with these materials.

No preheat at all is required when welding austenitic stainless steels.

Preheating of copper and copper alloys

copper and copper alloys

High conductivity copper, phosphorus de-oxidised (PDO) copper and many of the leaner copper alloys have high thermal conductivities and consequently need a very high preheat to ensure full fusion of the joint.

Those high conductivity copper alloys requiring to be preheated before welding are normally heated to temperatures of 600–700°C.

Bronzes and brasses, on the other hand, are normally welded without preheat. Their thermal conductivity is low enough to allow full fusion to be readily achieved, and some alloys suffer from ‘hot shortness’ and so need to cool relatively quickly after welding to avoid cracking. Any applied preheat would prolong this cooling period and so render them more liable to crack.

8 Consumables



Mild Steel

Weldability of SteeloverviewWeldability is a term used to describe the relative ease or difficulty with which a metal or alloy can be welded. The better the weldability the easier it is to weld. However, weldability is a complicated property as it encompasses the metallurgical compatibility of the metal or alloy with a specific welding process, its ability to be welded with mechanical soundness, and the capacity of the resulting weld to perform satisfactorily under the intended service conditions.

Before attempting to weld any material it is essential to know how easy it is to weld and to be aware of any problems that might arise. One of the main problems likely to be encountered when welding carbon and alloy steels is hydrogen cracking. For hydrogen cracking to occur it is necessary to have a supply of hydrogen to the weld and a heat affected zone (HAZ), a susceptible hardened microstructure, and tensile stress. If any one of these three components is eliminated then hydrogen cracking will not happen. Solidification cracking and lamellar tearing are other potential problems associated with welding of steel.

The main problem when welding steel is hardenability. Provided the steel contains sufficient carbon, when it is cooled rapidly from high temperature a phase transformation takes place. The phase transformation from austenite to martensite causes the material to harden and become brittle. It is then liable to crack on cooling due to restraint or later under the action of hydrogen.

Liquid

Austenite

Iron carbon equilibrium Diagram

Ferrite + Cementile

0.2% Carbon

temperate Distribution across Half the Weld

d

cb

a

Variation in temperature from the centre of the weld to the base material.

The weldability of steel depends primarily on its hardenability and this in turn depends largely on its composition, most importantly its carbon content. Steels with carbon content under 0.3% are reasonably easy to weld, steels with over 0.5%C are difficult. Other alloying elements having an effect on the hardenability of steel, but to a much lesser extent than carbon, are manganese, molybdenum, chromium, vanadium, nickel, and silicon. These, together with carbon, are all generally expressed as a single value, the carbon equivalent. The higher the carbon equivalent, the higher the hardenability, the more difficult the steel is to weld, and the more susceptible the microstructure is likely to be to hydrogen cracking.

This effect can be overcome by use of preheat combined with use of a low hydrogen process or low hydrogen welding consumables. Calculation of preheat is usually based on carbon equivalent (derived from steel composition), combined thickness of the components, and heat input from the welding process. It also takes account of the amount of hydrogen likely to be introduced into the weld metal by the welding process. If welding under high restraint extra preheat may need to be applied. Some high carbon steels and low alloy steels may also need a post weld stress relief or tempering.

8



Mild Steel

Hardenability and HardnessIn order to become harder, steel must undergo a phase change. The starting point is austenite, so the steel must first be heated into the austenitic temperature range (see iron-carbon equilibrium Diagram on previous page).

Austenite, quenched rapidly, will be transformed into martensite, a hard but brittle phase

A slower cooling rate will promote formation of bainite and / or other softer phases

Cooled even more slowly a soft structure of ferrite plus cementite, called pearlite, results

Martensite, Tempered Martensite and Heavily Tempered Martensite

Hardenability

Hardenability is the potential for any particular steel to harden on cooling and, as the carbon content of the steel increases towards 0.8% so the potential of the steel to harden increases. Increasing the alloy content of the steel also increases the hardenability.

While hardness and strength may be desirable in a welded steel structure, martensite can be brittle and susceptible to cracking, and it should be noted that the potential brittleness of the material also increases as hardenability increases.

Hardenability describes the potential of steel to form hard microstructures. What hardness is actually achieved in steel with known hardenability depends on the maximum temperature to which it is heated and the cooling rate from that temperature. During welding parent material close to the weld will be heated to temperatures near melting point while further away it will remain at ambient temperature. Cooling rate depends on the mass of material, its temperature, and the welding heat input. Therefore, when welding any given hardenable steel the hardness in the HAZ depends on the cooling rate, the faster the cooling rate the harder the microstructure produced and the more susceptible it is to cracking.

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After welding, the hardness in the HAZ may range from less than 300 Hv to more than 550 Hv, depending on the parent steel composition and the other factors described above. As the hardness of the HAZ increases so does its susceptibility to hydrogen cracking. However, as a rule of thumb, it is generally considered that if the maximum hardness in the HAZ is maintained below 350 Hv then hydrogen cracking will be avoided.

carbon equivalent

Carbon has the greatest effect on hardenability of steel but other alloying elements may be added to increase its hardenability. The addition effectively reduces the critical cooling rate and the temperature at which the austenite to martensite transformation takes place, making it easier for martensite to form at slower cooling rates.

Alloying elements having the greatest influence on the hardenability of steel are manganese, molybdenum, chromium, vanadium, nickel, copper, and silicon, but they have a much smaller effect than carbon.

The effect of these elements on the tendency to form HAZ martensite, and hence the likelihood of hydrogen cracking, is expressed conveniently as a Carbon equivalent (Ce). This basically describes the influence on hardenability of each element in terms of the effect that carbon has. There have been many different formulae derived to express carbon equivalent, but the one quoted here is the International Institute of Welding (IIW) equation applicable to carbon steel and is widely used:

carbon equivalent (ce) =

%C +%Mn

+(%Ni + %Cu)

+(%Cr + %Mo + %V)

6 15 5

The equation is only valid for certain maximum percentages of each element and these percentages can be found in the technical literature.

The carbon equivalent is used mainly for estimating preheat. Preheat is necessary to slow down the cooling rate sufficiently to reduce hardening in the HAZ of welds in susceptible carbon and low alloy steels. This in turn helps to prevent subsequent HAZ hydrogen cracking. The overall effect is to improve the weldability of the steel being welded, or at least to overcome the weldability problems presented by it.

Ce is calculated from the composition of the steel in question and is used, together with welding heat input, potential hydrogen from the consumable, and combined thickness, or by reference to published data, to determine the preheat. It is recommended that actual composition of the steel is used to ensure accuracy of calculation of Ce but nominal or maximum specified compositional data may be used when this is unavailable. The use of nominal composition obviously carries some risk that Ce will be under-estimated and too low preheat will be used, with potential cracking problems.

8



Mild Steel

Weldability

Weldability describes the relative ease or difficulty with which a metal or alloy can be welded.

The relative weldability of carbon and low alloy steels are summarised here.

As has already been stated, weldability varies with the chemistry of the steel, particularly with reference to its carbon content.

The majority of carbon steels are weldable, but some grades have better weldability and, therefore, are more easily welded than others. As the carbon content increases, weldability tends to decrease as the hardenability increases and the steel becomes more prone to cracking.

Low carbon steels containing <0.15% C and manganese <0.6% generally have good weldability, as the composition is too lean to give any significant hardening effect during welding. However, steels with <0.12% C and low levels of manganese can be prone to porosity but they are not susceptible to hydrogen cracking.

Steels with carbon contents between 0.15–0.3% C and manganese up to 0.9%, have good weldability, particularly those with carbon content below 0.22%. These are mild steels and they rarely present problems provided impurity levels are kept low. They are all weldable without preheat, using any of the common welding processes. Those at the top end of the composition range, above about 0.25% C, may be prone to cracking under certain circumstances. They may be welded using any of the common welding processes but are best welded with a low hydrogen process such as MIG or low hydrogen consumables. Thick sections may require pre-heating to reduce the cooling rate.

Medium carbon steels containing between 0.25–0.5% C, with manganese generally <1%, are hardenable by heat treatment and so are prone to cracking when welded. They can be welded but require suitable welding procedures, specifying pre-heat and interpass temperature control, to account for the carbon content or Carbon equivalent and the combined thickness of the joint being produced. These steels should always be welded using a low hydrogen welding process or controlled hydrogen consumables.

Steels with even higher carbon levels, between 0.5–1.0%, with manganese <1% are used where their higher hardness and strength can be exploited. However, their high hardenability means that they have poor weldability and are difficult to weld without cracking. They are generally welded in the hardened condition and so require pre-heating, interpass temperature control and post weld stress relief to give any chance or avoiding cracking. Low hydrogen processes, such as MIG and TIG welding or low hydrogen consumables, such as low hydrogen MMA electrodes will always be required when welding these steels.

Carbon-manganese steels have carbon typically between 0.15–0.5%, and manganese levels between 1.0–1.7%. For structural purposes, carbon is normally held below 0.3%, manganese not above 1.2% and sulphur and phosphorous are required to be below 0.05%. Generally, they are weldable, although some will require controls on pre-heat and heat input. Those at the higher end of the carbon range also benefit from use of low hydrogen welding processes or controlled hydrogen consumables.

Structural steels often have limits imposed on maximum carbon equivalent to ensure good weldability and ease of welding for the fabricator.

Weldable high strength low alloy (HSLA) steels have weldability similar to the low carbon steels, and so do not usually present problems.

Most quenched and tempered steels can be welded, but they rely on relatively high cooling rates for the strong martensitic structures to form. Careful control of pre-heat, heat input and interpass temperature is required to achieve the correct structure without cracking. Welding must be carried out using a low hydrogen process, or hydrogen controlled consumables, and welding procedures need to be tested and approved.

alloy SteelsMany low alloy steels are weldable but some grades are easier to weld than are others. Weldability again varies with the chemistry of the steel, particularly with reference to its carbon content, but also with reference to alloying additions, particularly manganese, chromium, molybdenum, vanadium and nickel content. The weldability of alloy steels therefore depends on its carbon equivalent.

Nickel steels with from 1–3% Ni may be welded with suitable welding procedures, specifying pre-heat and interpass temperature, current levels and heat inputs. As carbon and nickel content increases, so the weldability of these steels becomes worse. This is due to an increase in hardenability and is reflected by an increase in the carbon equivalent. Nickel steels should always be welded using a low hydrogen process, such as MIG or TIG, or with controlled hydrogen consumables.

Steels containing 5% Ni or 9% Ni have poor weldability. As they fall outside the maximum nickel content for which the carbon equivalent formula is valid, preheat must be estimated by other means.

All molybdenum, chromium-molybdenum, and chromium-molybdenum-vanadium steels are hardenable and their weldability is not good. They will crack when welded unless attention is paid to preheat, interpass temperature, cooling rate, and post weld stress relief heat treatment. Normally, low hydrogen processes or hydrogen-controlled consumables are used to reduce the likelihood of cracking occurring.

The weldability of direct hardening steels is not good, since, because of their medium carbon and alloy content, they are very hardenable, and any welding must be carried out with due attention to preheat and maintenance of heat during welding, or they will crack. Consumable selection is important and low hydrogen or austenitic types may be used.

Case hardening steels are basically low carbon alloy steels with reasonable weldability as long as precautions are taken. usually this means using a moderate preheat and using standard, low hydrogen carbon-manganese consumables. However, welding will destroy the case hardened layer.

8



Mild Steel

Weld and HaZ crackingWith steel, poor weldability often manifests itself in a reduction of the resistance of the steel to cracking after welding

Base MetalHeat affected ZoneWeldmetal

The main causes of cracking in steel are:

High levels of carbon and other alloys elements resulting in brittle zones around the weld

High cooling rates after welding increasing the hardness, which increases the susceptibility to cold cracking

Joint restraint preventing contraction after welding leading to cracking

Hydrogen in the weld bead or HAZ leading to hydrogen induced cold cracking

Contaminants like sulphur and phosphorus resulting in solidification cracking

Lamellar tearing due to inclusions layering during rolling resulting in deterioration of the through-thickness properties

The most common cause of cracking in steel is the presence of hydrogen. Hydrogen, or cold, cracking is usually considered to be the most serious potential problem with modern steels. Hydrogen cracking is most frequently a HAZ phenomenon, but it can also occur in weld metal, particularly in high alloy steels. Hydrogen, like carbon, is more soluble in austenite than ferrite and can easily be picked up by the weld metal. When ferrite is formed as the material cools, hydrogen solubility decreases, and hydrogen diffuses to the HAZ where it becomes trapped and can cause crack propagation.

Heat Affected Zone (Cold cracking)

There are published guidelines and standards containing welding procedures to avoid hydrogen cracking. For hydrogen cracking to occur it is necessary to have a supply of hydrogen to the weld and HAZ, a susceptible hardened microstructure, and tensile stress. If any one of these three components is eliminated then hydrogen cracking will not happen.

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To avoid cold cracking the following point should be noted:

The lower the carbon equivalent the lower the potential for cracking

Limit the hydrogen content of weld metal and HAZ by using a low hydrogen process or low hydrogen consumables

Keep joint restraint to a minimum by careful joint design

Reduce cooling rate of weld area by use of pre-heat and suitable welding heat input

eliminate hydrogen after weld is completed by keeping weld hot - hydrogen release treatment

ensure impurities are kept at a low levels

The above guidance is of a very general nature and if in doubt seek expert technical advice.

Factors Influencing Weldability

In terms of avoiding weldability problems, particularly hydrogen cracking, when welding carbon or low alloy steels there are several factors that demand consideration. These include the amount of hydrogen generated by the welding process or consumable, the heat input into the weld, the combined thickness (heat sink) of the joint, and the level of preheat applied to the components prior to welding. Joint configuration and restraint are also important factors when considering weldability.

Process HydrogenOne of the three key components necessary for hydrogen cracking is a source of hydrogen. During welding the most likely sources of hydrogen are the welding consumables or contaminants on the parent material. Here we consider hydrogen from the welding process and consumables only.

The amount of hydrogen put into the weld will vary from one welding process to another and may also vary within a process from one consumable type to another. The risk of hydrogen cracking increases as the amount of hydrogen from the process or consumable gets larger.

Solid wire processes, such as MIG and TIG, are capable of giving hydrogen levels below 5ml / 100g of weld metal. These are generally thought to be low hydrogen processes, provided the MIG wire is clean.

The manual metal arc process can give a wide range of hydrogen levels, from well over 15ml / 100g of weld metal, with cellulosic and rutile coated electrodes, to less than 5ml / 100g of weld metal with basic coated electrodes given the appropriate baking or re-drying treatment.

The potential hydrogen levels can vary with product type for cored wire welding processes too. Basic type flux-cored wires may be capable of getting below 5ml / 100g of weld metal but rutile-cored and metal-cored wire types may give 10 or 15ml / 100g of weld metal. Some recent developments have enabled metal-cored and rutile-cored wire to achieve hydrogen levels below 10ml / 100g and some even below 5ml / 100g.

Submerged arc wires, like MIG wires, should be able to give low levels of hydrogen, but when used in combination with different fluxes the hydrogen level may vary between <5 to 15ml / 100g of weld metal.

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8



Mild Steel

Welding Heat Input

The heat input from the welding process plays a major role in the heating and cooling cycles experienced by the weld and parent plate during welding. For a given plate thickness, a high heat input is likely to result in a slower cooling rate than a low heat input, and therefore produce a softer microstructure in the HAZ less prone to hydrogen cracking. However, that does not mean that welding should always be carried out with a high heat input because this brings with it other problems, such as loss of mechanical properties and an increased risk of solidification cracking. So it is necessary to select a heat input to give a sound weld with the desired mechanical properties and to use preheat to exert control of the cooling rate.

Heat input, ‘Q’ may be calculated as:

Q =k x V x I x 60

kJ / mmS x 1000

where ‘V’ is arc Voltage (V), ‘I’ is welding current, and ‘S’ is welding speed in mm/min

The value derived from this formula may be multiplied by a factor ‘k’, the thermal efficiency factor for the welding process, to give an energy input that takes the efficiency of the welding process into account. Typical thermal efficiency factors are:

‘k’ = 1.0 for submerged arc welding

‘k’ = 0.8 for MIG / MAG, MMA, flux-cored and metal-cored arc welding

‘k’ = 0.6 for TIG and plasma welding

For example, when MIG welding, the welding heat input formula becomes:

Q =0.8 x V x I x 60

kJ / mmS x 1000

Welding heat input will vary with process and consumable type and size. With small diameter electrodes, low current, and fast welding speeds, heat inputs below 1.0kJ / mm are readily attained. With large diameter electrodes, high currents, and slower welding speeds, heat inputs in excess of 6.0kJ / mm can be reached.

Note that a weld made using a stringer bead technique will have a lower heat input than a weld made with the same size electrode, at the same current, but using a weave bead technique.

For more extensive calculation on heat input and preheat requirements of steel, refer to the WTIA Technical Note 1 and AS/NZS 1554.1

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combined thicknessThe cooling rate of plate in the region of a weld depends on the thickness of the plates in the joint, the number of plates meeting at the joint, the amount of heat put into the weld area, and the initial temperature of these plates. Cooling occurs by conduction and so the greater the heat sink the faster the cooling rate is. Therefore, other factors being constant, the thicker the plate the greater the potential for rapid cooling, and so the greater the likelihood of hardening in the HAZ of susceptible steels.

estimates of preheat will normally take into account the thickness of each of the components in the joint to allow for the cooling effect. The thickness of each component is added together to give what is normally referred to as ‘combined thickness’ (CT).

How the combined thickness is derived depends on the joint configuration and is illustrated below:

CT = T1 + T2 + T3…

Example of combined thickness calculation for butt joint

T1 T2

Example of combined thickness calculation for fillet joint

T3

T1 T2

For butt welds, the CT equals the sum of the thicknesses of the two plates being welded; for fillet welds, the CT equals twice the thickness of the base plate plus the thickness of the up-stand. Therefore, for a given plate thickness a fillet joint has a faster cooling rate than a butt joint.

8



Mild Steel

Welding consumables Selection chartCarbon and Low Alloy Steel Castings

Material Specification Welding Process

AS 2074 ASTM BS MMAW GMAW FCAW SAW

c1 bS3100 aW1 BOC Smootharc 16

BOC Smootharc 18

BOC Mild Steel BOC SmoothCor 711

BOC SmoothCor 70C6

BOC SmoothCor 715

Lincoln L60 + 780

Lincoln L61 + 860

Lincoln L70 + 860

Lincoln L-S3 + 8500c2 – bS3100 aM1,

aM2BOC Smootharc 13

BOC Smootharc 16

BOC Smootharc 18c3 a27 n-1 bS3100 a1

c4-1 a27 65-35 – BOC Smootharc 16

BOC Smootharc 18c4-2 a27 70-36 bS3100 a2

c5 – bS3100 a3

c6 – bS3100 aW2

c7a-1

c7a-2

c7a-3

a214 Wca

a214 Wcb

a214 Wcb

bS1504 430

bS1504 480

bS1504 540

l1a

l1b

– bS3100 a4

bS3100 a5, a6

BOC Smootharc 16

BOC Smootharc 18

l2a

l2b

– bS3100 bW2, bW3

bS3100 bW4

Alloycraft 80-B2

Lincoln SL19G

Autocraft CrMo1 W55X.B2H (NA) Lincoln LAC-B2 + 880

l3a a352 lc2 bS3100 bl2 e5518-C2 (NA)

[Alloycraft 80-C1]

[Jet-LH 8018-C1 MR]

W559AH-Ni3 (NA)

[Autocraft Mn-Mo]

W559.Ni3H (NA)

[BOC SmoothCor 811K2]

W559.Ni3H (NA)

[Lincoln LAC-Ni2 + 880]

l4a – – Alloycraft 80-C1

Jet-LH 8018-C1 MR

Autocraft Mn-Mo BOC SmoothCor 811K2 Lincoln LAC-Ni2 + 880

l5a-1

l5a-2

a217 Wc1

a356 - 2

bS3100 b1 e4818-A1 (NA)

[BOC Smootharc 16]

[BOC Smootharc 18]

W501AH-A1

[Autocraft Mn-Mo]

W501.A1H Lincoln LA-90 + 880

l5b a217 Wc6, W11

bS3100 b2 Alloycraft 80-B2

Lincoln SL19G

Autocraft CrMo1 W551.B2H (NA) Lincoln LAC-B2 + 880

l5c a217 Wc9

a356 - 10

bS3100 b3 Alloycraft 90-B3

Lincoln SL20G

W629AH-B3 (NA) W621.B3H (NA) Lincoln LA-93 + 880M

l5D bS3100 b4

l5e – bS3100 b5 e6218-5Cr (NA) W621AH-5Cr (NA) W621.5CrH (NA) W621.5CrH (NA)

l5F – bS3100 b6 Alloycraft 90-B3

Lincoln SL20G

W629AH-B3 (NA) W62X.B3H (NA) Lincoln LA-93 + 880M

l5G – – Alloycraft 80-B2

Lincoln SL19G

Autocraft CrMo1 W55X.B2H (NA) Lincoln LAC-B2 + 880

l5H – bS3100 b7

l6 a148 90-60 – Alloycraft 90

Lincoln 9018G

W62XAH-G (NA)

Autocraft NiCrMo

BOC SmoothCor 115 Lincoln LA-100 + 880

l6a-1

l6a-2

a148 105-85 bS3100 bt1 Alloycraft 110

Jetweld LH-110M MR

Autocraft NiCrMo BOC SmoothCor 115 Lincoln LAC-M2 + 880

l6b-1

l6b-2

l6c

a148 115-95

a148 150-135

bS3100 bt2

bS3100 bt3

e8318-M (NA)

{Alloycraft 110}

{Jetweld LH-110M MR}

W831AH-G (NA)

{Autocraft NiCrMo}

W831.GH (NA)

{BOC SmoothCor 115}

W831.GH (NA)

{Lincoln LAC-M2 + 880}

NOTeS (1) NA indicates product not available in Australia / NZ. (2) Products in [ ] brackets have similar specified minimum tensile strength. (3) Products in { } brackets have under matching specified minimum tensile strength. (4) Products in [ ] and { } brackets are not pre-qualified to AS 1988–1989. (5) Welding procedure qualification should be carried out prior to welding for structural and matching strength applications. (6) Consult you BOC welding process specialist or visit BOCs Inform website (subscription required) for more detailed information.

8



Mild Steel

Ferritic Steels

Steel Type Grade Welding Process

Carbon SteelsAS, AISI or SAe

ASTM or BS970 MMAW electrode GMAW Wire

FCAW Gas Shielded

FCAW Gasless SAW Wire and Flux

Mild Steel 2002503001006101010151016102010227-4307-460

a36a106en3aen201

BOC Smootharc 13 BOC Mild Steel BOC SmoothCor 711BOC SmoothCor 70C6

InnershieldNR-211-MPNR-232NS-3MNR-311

Lincoln L60 + 780 or 860

350–500 MPa Yield Strength Steels

350400450XF5007-4901030X1033103510401045X13208620

a105a106en5en5ben8aen8en14a

BOC Smootharc 16BOC Smootharc 18

BOC Mild Steel BOC SmoothCor 711BOC SmoothCor 70C6BOC SmoothCor 715

InnershieldNR-211-MPNR-232NS-3MNR-311

Lincoln L61 + 860

Medium tensile Steels

10501055X1340

en43aen33en9en15a

Alloycraft 80-C1Jet-LH 8018-C1 MR

Autocraft Mn-Mo

BOC SmoothCor 811K2

Innershield NR-208-H

Lincoln LA-90 + 880

High tensile Steels

u1058107041404340K5140P206F7

en42en19en24en18Den25en30b

Alloycraft 90Lincoln 9018G

Autocraft NiCrMo

BOC SmoothCor 115 Innershield NR-208-H

Lincoln LA-100 + 880

High tensile Steels

u1058107041404340K5140P206F7

en42en19en24en18Den25en30b

Alloycraft 110Jetweld LH-110M MR

Autocraft NiCrMo

BOC SmoothCor 115 NA Lincoln LAC-M2 + 880

Spring Steels XK5155SXK5160SXK9258S9255XK9261S

en48en45a

Alloycraft 110Jetweld LH-110M MR

Autocraft NiCrMo

BOC SmoothCor 115 NR NR

Free cutting Steels

1137X1112114111441146X11471214

en1a BOC Smootharc 18 NR NR NR NR

Galvanised Steels

– – BOC Smootharc 13 BOC Mild Steel NR NR-211-MP NR

NOTeS (1) Steels listed on one line are not necessarily equivalent. (2) Consumables listed against a steel may not achieve matching mechanical properties depending on the condition (heat treatment history) of the steel. (3) Welding procedure qualification should be carried out prior to welding for structural and matching strength applications. (4) Consult you BOC welding process specialist or visit BOCs Inform website (subscription required) for more detailed information.

NR = Not Recommended, NA = Not Available

8



Mild Steel

Quenched and Tempered High Strength Steels and Wear Plate

Material Specification MMAW GMAW (Solid) FCAW SAW

aS / nZS 3597 Grade 500

(e.g. Bisplate60, Welten60, Weldox 420)

MS Alloycraft 90

Lincoln 9018G

Autocraft Mn-Mo BOC SmoothCor 115 Lincoln LA-100 + 880

lS Alloycraft 80-C1

Jet-LH 8018-C1 MR

BOC Smootharc 16

BOC Smootharc 18

BOC Mild Steel BOC SmoothCor 711

BOC SmoothCor 715

BOC SmoothCor 70C6

Lincoln LA-90 + 880



(e.g. Bisplate 70,

Welten 70, Weldox 500)

MS Alloycraft 110

Jetweld LH-110M MR


lS Alloycraft 90

Lincoln 9018G

BOC Smootharc 16

BOC Smootharc 18

Autocraft Mn-Mo

BOC Mild Steel

BOC SmoothCor 811K2

BOC SmoothCor 711

BOC SmoothCor 715

BOC SmoothCor 70C6


Lincoln LA-90 + 880



(e.g. bisplate 80, 80PV, Welten 80, Weldox 700)

MS Alloycraft 110

Jetweld LH-110M MR


lS Alloycraft 90

Lincoln 9018G

BOC Smootharc 16

BOC Smootharc 18

Autocraft Mn-Mo

BOC Mild Steel

BOC SmoothCor 811K2

BOC SmoothCor 711

BOC SmoothCor 715

BOC SmoothCor 70C6


Lincoln LA-90 + 880


Wear Plates

(e.g Bisplate320, 360, 400, 500, Welten Re, Hardox 400, 500)

MS NA NA BOC SmoothCor 115 NR

lS Alloycraft 110

Jetweld LH-110M MR

Alloycraft 90

Lincoln 9018G

BOC Smootharc 16

BOC Smootharc 18

Autocraft NiCrMo

Autocraft Mn-Mo

BOC Mild Steel

BOC SmoothCor 811K2

BOC SmoothCor 711

BOC SmoothCor 715

BOC SmoothCor 70C6

Lincoln LAC-M2 + 880


Lincoln LA-90 + 880


NOTeS MS = Matching Strength LS = Lower Strength NR = Not Recommended NA = Not Available

8



Mild Steel

MMa electrodes

Smootharc™ 12

DescriptionSmootharc™ 12 is a multi-purpose rutile-cellulosic electrode suitable for a wide range of applications in mild steel. The electrode is fully positional, including very good appeal in the vertical down position. The electrode welds with a crisp steady arc to produce a smooth weld bead surface to enhance good slag detachability. Performance can be insensitive to rust, dirt and surface coatings, and has good ability to bridge gaps or poor fit-up.

applicationFor the welding of all mild steels, sheet metal, tank work and general fabrication. Combined with the excellent strike / re-strike and a high tolerance to large gaps or poor fit up, this electrode is easy to use and recommended for all round fabrication work.

techniqueeither the contact or free arc technique can be used. For vertical-down welding the contact weld technique must be used with a high rate of travel.

Storageelectrodes, once the seal is broken should be stored in heated cabinets at 40–50°C.

Re-Drying / conditioningBOC Smootharc™ 12 electrodes are sealed from moisture during manufacture, but all fluxes are hydroscopic, and when left in the opened state for a period of time will absorb moisture. Moisture is indicated by a noisy or “digging arc”, high spatter, tight slag, undercut or excessive “cup” on the end of an electrode. Re-dry damp electrodes for 2 hours at 80–90°C.

Welding Positions

Specifications

Coating Type Rutile-Cellulosic

Classification AWS / ASMe-SFA A5.1 e6013

AS / NZS 1553.1 e4112-0

Approvals Lloyds Register of Shipping

Grade 2

Det Norske Veritas Grade 2

American Bureau Shipping

Grade 2

Welding Current* AC, OCV >50V or DC+-

Metal Recovery 90%

* DC– is recommended for root passes.

Chemical Composition, wt% – All-Weld Metal

C Si Mn

Typical 0.07 0.4 0.5

Mechanical Properties – All-Weld Metal

Typical (as welded)

yield strength 470 MPa

Tensile strength 540 MPa

elongation 24%

Impact energy, CVN 50J @ 0ºC

Packaging Data

Dia. (mm) 2.5 3.2 2.5 3.2 4.0

Part No. 184133 184134 184135 184136 184137

Weight packet (kg) 1.0 1.0 5.0 5.0 5.0

Weight carton (kg) 10.0 10.0 15.0 15.0 15.0

electrodes pkt (approx) 55 33 278 168 109

Welding Parameters

Dia. (mm) 2.5 3.2 4.0

Length (mm) 350 350 350

Current (A) 70–100 90–145 120–195

Voltage (V) 25 25 25

Deposition Data

Dia. (mm) 2.5 3.2 4.0

Kg weld metal / kg electrodes 0.7 0.7 0.7

No. of electrodes / kg weld metal 98 48 33

Kg weld metal / hour arc time 0.8 1.2 1.7

Burn off time / electrode (sec) 48 49 58

Data for Welding Horizontal Fillet Joints

Dia. (mm) 2.5 3.2 4.0

Throat thickness 2.0 3.5 5.0

Leg length 2.8 5.0 7.0

Amps 65 125 165

Arc time (sec) 50 52 59

Bead length / electrode (mm) 201 195 208

Weld speed (m / hr) 15.0 12.4 11.2

Note: Operator technique will influence the values shown

General Purpose

8



Mild Steel

Smootharc™ 13

DescriptionSmootharc™ 13 is a thicker coated all positional rutile electrode that performs very well in the down hand position, exceptionally well in the vertical up and overhead positions and can also be used in the vertical down position. The electrode welds with a very smooth, low spatter arc to produce a finely rippled bead surface with excellent slag detachability.

applicationFor welding mild steels, sheet metal, tank work and general fabrication. Combined with the excellent strike / restrike and a high tolerance to large gaps or poor fit up, this electrode is easy to use and recommended for all round fabrication work. especially good for the less experienced welder.

techniqueeither the contact or free arc technique can be used. For vertical-down welding the contact weld technique must be used with a high rate of travel.


Re-Drying / conditioningBOC Smootharc™ 13 electrodes are sealed from moisture during manufacture, but all fluxes are hydroscopic, and when left in the opened state for a period of time will absorb moisture. Moisture is indicated by a noisy or “digging arc”, high spatter, tight slag, undercut or excessive “cup” on the end of an electrode. Re-dry damp electrodes for 2 hours at 80–90°C.

Welding Positions

Specifications

Coating Type Rutile


AS / NZS 1553.1 e4113-0


Grade 2



Grade 2

Welding Current* AC, OCV >50V or DC+-

Metal Recovery 95%



C Si Mn

Typical 0.06 0.4 0.5

Mechanical Properties Typical All-Weld Metal Analysis



elongation 25%

Impact energy, CVN 70J @ 0ºC

Packaging Data

Dia. (mm) 2.5 3.2 2.5 3.2 4.0

Part No. 187143 187144 187145 187146 187147

Weight packet (kg) 1.0 1.0 5.0 5.0 5.0

Weight carton (kg) 10.0 10.0 15.0 15.0 15.0

electrodes pkt (approx) 46 34 230 170 106

Welding Parameters

Dia. (mm) 2.5 3.2 4.0

Length (mm) 350 350 350

Current (A) 60–95 110–130 140–165


Deposition Data

Dia. (mm) 2.5 3.2 4.0






Dia. (mm) 2.5 3.2 4.0



Amps 65 125 165



Weld speed (m / hr) 15.2 12.4 11.2

Note: Operator technique will influence the values shown.

MMa electrodesGeneral Purpose

8



Mild Steel

Smootharc™ 24

DescriptionSmootharc™ 24 is a rutile-coated iron powder electrode with 160% recovery designed for high productivity welding in heavier section mild steel. excellent profile mitre fillets are produced having a smooth transition with the base material, ensuring excellent slag detachability.

applicationSmootharc™ 24 has been designed to produce the highest possible productivity when depositing fillet welds with a leg length in the 4 to 6 mm range in the heavier section construction steels. This electrode performs exceptionally well when welding “inside corner” fillets. Fillet welds can also be made in primer treated material without porosity or fusion defects along the top edge.

techniqueThe best results are obtained using the touch welding technique with the electrode held at a sufficient angle to prevent the molten slag from crowding the arc. AC is recommended as it reduces arc blow, particularly at the high currents required with large diameter electrodes.


Re-Drying / conditioningBOC Smootharc™ 24 electrodes should be re-dried at 100–120°C for 2 hours.

Welding Positions

Specifications

Coating Type Rutile, Iron powder


AS / NZS 1553.1 e4824-0


Grade 2



Grade 2

Welding Current AC, OCV >50V or DC+-

Metal Recovery 160%


C Si Mn

Typical 0.07 0.5 0.7

Mechanical Properties Typical All-Weld Metal Analysis



elongation 24%

Impact energy, CVN 50J @ 0°C

Packaging Data

Dia. (mm) 3.2 4.0 5.0

Part No. 186166 186167 186168

Weight packet (kg) 6.0 6.0 5.5

Weight carton (kg) 18.0 18.0 16.5

electrodes pkt (approx) 91 60 36

Welding Parameters

Dia. (mm) 3.2 4.0 5.0

Length (mm) 450 450 450

Current (A) 130–160 150–235 200–320


Deposition Data

Dia. (mm) 3.2 4.0 5.0






Dia. (mm) 3.2 4.0 5.0



Amps 135 200 275



Weld speed (m / hr) 14.7 16.6 18.6


MMa electrodes Iron Powder

8



Mild Steel

Smootharc™ 16

DescriptionSmootharc™ 16 is a basic coated 105% recovery electrode intended for general welding applications where controlled hydrogen and medium tensile properties are required. It has excellent mechanical and X-ray properties.

applicationFor the welding of all section steels, tank work and general fabrication. Suitable for unalloyed, micro alloyed and low alloyed steels.

techniqueAs with all hydrogen-controlled electrodes, as short an arc as possible should be kept at all times. When starting with a new electrode the arc should be initiated ahead of the start of the weld or crater and worked back over this distance before continuing the weld in the required direction. On larger size joints several stringer beads should be used in preference to one large weave bead to ensure optimum mechanical properties. DC– should be used for root passes where poor fit-up is a factor which should be taken into account.

StorageBOC Smootharc™ 16 electrodes when removed from a freshly opened tin will have <4 ml / 100g hydrogen. Once the seal is broken electrodes should be stored in heated cabinets at 80–120°C.

Re-Drying / conditioningBasic (Low Hydrogen) type electrodes are redried at temperatures of 350–400°C for 1–2 hours to achieve a hydrogen level of 5–10 ml / 100g of weld metal, and restricted to 5 redries. To achieve extreme low hydrogen levels, <4 ml / 100g, 420–440°C is recommended for 1–2 hours and restricted to 1 re-dry.

Welding Positions

Specifications

Coating Type Basic

Classification AWS / ASMe-SFA A5.1 e7016-1 H4

AS / NZS 1553.1 e4816-4 H5


Grade 3, 3ym H5

Det Norske Veritas Grade 3y H5


Grade 3, 3y HH

Welding Current* AC, OCV 60V or DC+-

Metal Recovery 105%

Hydrogen content /100g weld metal

<4ml



C Si Mn P S

Typical 0.06 0.5 1.0 0.015 0.005


Typical (as welded) PWHT Typical*

yield strength 470 MPa 420 MPa

Tensile strength 560 MPa 515 MPa

elongation 25% 31%

Impact energy, CVN 70J @ -46°C 150J @ -40°C

*PWHT 620°C 1 hour

Packaging Data

Dia. (mm) 2.5 3.2 4.0 5.0

Part No. 184143 184144 186148




Part No. 186145N 186146N 186147N




Welding Parameters

Dia. (mm) 2.5 3.2 4.0 5.0

Length (mm) 350 350 350 450

Current (A) 60–90 80–160 110–210 155–290

Voltage (V) 24 26 25 25

Deposition Data

Dia. (mm) 2.5 3.2 4.0 5.0

Kg weld metal / kg electrodes 0.64 0.66 0.66 0.70

No. of electrodes / kg weld metal 80 44 29 14

Kg weld metal / hour arc time 0.9 1.2 1.7 2.4

Burn off time / electrode (sec) 50 65 70 96


Dia. (mm) 2.5 3.2 4.0 5.0

Throat thickness 3.2 4.2 5 6

Leg length 4.5 6 7 8.5

Amps 75 115 170 220

Arc time (sec) 55 67 73 98

Bead length / electrode (mm)

135 160 200 270

Weld speed (m / hr) 0.64 0.72 0.72 0.76


MMa electrodesHydrogen controlled

8



Mild Steel

Smootharc™ 18

DescriptionSmootharc™ 18 is a basic-coated low hydrogen AC / DC electrode for which the outstanding all round operability has been optimised. The smooth, soft arc, easy slag control, all positional welding with low spatter and excellent slag removal provide maximum operator appeal. The electrode is suitable for welding mild and higher strength steels. It combines strength and toughness and is particularly suitable for heavily restrained sections where there can be risk of cracking due to weld stress.

applicationWith its excellent general operability and good positional welding characteristics, the Smootharc™ 18 is used for general fabrication work as well as pipe welding where the fine spray transfer provides precise weld pool control. The fine arc spray also makes it an ideal electrode for the experienced welder, and for positional work in demanding applications.

The electrode produces a finely rippled bead surface and smooth transition with the base material. This together with the exceptionally good slag detachability, even in root runs, gives the Smootharc™ 18 superior radiographic quality. It is also an ideal electrode for use on AC machines with an OCV of 70V.

techniqueAs with all basic hydrogen-controlled electrodes, as short an arc as possible should be kept at all times. When starting with a new electrode the arc should be initiated ahead of the start of the weld or crater and worked back over this distance before continuing the weld in the required direction. On larger size joints several stringer beads should be used in preference to one large weaved bead to ensure optimum mechanical properties.

DC– should be used for root passes where poor fit-up is a factor which should be taken into account.

StorageBOC Smootharc™ 18 electrodes when removed from a freshly opened tin will have <4 ml / 100g weld metal hydrogen. Once the seal is broken, electrodes should be stored in heated cabinets at 80–120°C.

Re-Drying / conditioningBasic (Low Hydrogen) type electrodes are re-dried at temperatures of 350–400°C for 1–2 hours to achieve a hydrogen level of 5–10 ml / 100g of weld metal, and restricted to 5 re-dries. To achieve extreme low hydrogen levels, <4 ml / 100g, 420–440°C is recommended for 1–2 hours and restricted to 1 re-dry.

Welding Positions

Specifications

Coating Type Basic

Classification AWS / ASMe-SFA AS.1 e7018-1 H4

AS / NZS1553.1 e4818-4 H5


Grade 3, 3y, H5

Det Norske Veritas Grade 3yH5


Grade 3, H5, 3y

Welding Current* AC, OCV 70V or DC+-

Metal Recovery 120%

Hydrogen content / 100g weld metal

<4ml



C Si Mn P S

Typical 0.05 0.6 1.4 0.015 0.010


Typical (as welded) PWHT Typical*



elongation 26% 29%

Impact energy, CVN 60J @ -40°C 40J @ -46°C

130J @ -20°C

*PWHT 620°C 1 hour

Packaging Data

Dia. (mm) 2.5 3.2 4.0 5.0

Part No. 184155 N 184156 N 184157 N 184158

Weight packet (kg) 3.5 3.5 3.5 5.5

Weight carton (kg) 10.5 10.5 10.5 16.5

electrodes pkt (approx) 148 89 64 55

Welding Parameters

Dia. (mm) 2.5 3.2 4.0 5.0

Length (mm) 350 350 350 450

Current (A) 80–110 110–155 140–205 200–285

Voltage (V) 23 24 25 25

Deposition Data

Dia. (mm) 2.5 3.2 4.0 5.0

Kg weld metal / kg electrodes 0.71 0.72 0.74 0.75

No. of electrodes / kg weld metal 60 35 25 13

Kg weld metal / hour arc time 1.0 1.6 2.1 2.9

Burn off time / electrode (sec) 54 57 73 91


Dia. (mm) 2.5 3.2 4.0 5.0

Throat thickness 3.0 4.2 5.0 6.0

Leg length 4.3 6.0 7.0 8.5

Amps 85 125 175 225

Arc time (sec) 61 74 81 104

Bead length / electrode (mm) 163 215 226 287

Weld speed (m / hr) 9.6 10.6 10.1 9.7


MMa electrodes Hydrogen controlled

8



Mild Steel

Ferrocraft 11Cellulose pipe welding electrode

All positional, AC / DC capabilities

High penetration, root pass applications

White flux colour for easy identification

Recommended for root pass welding where the “stovepipe” or “flick” techniques can be used to achieve full root penetration

The root, hot fill and capping pass welding of-pipelines, pressure vessels, storage tanks, workshop and field construction

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Classifications

AS / NZS 1553.1: e4111-2 AWS / ASMe-SFA A5.1: e6011

Typical all weld metal mechanical properties

yield stress 415 MPa


elongation 28%

CVN impact values 90J av @ -20°C

Packaging and operating data AC (minimum 65 OCV) DC+ or DC- polarity

electrode Approx no. rods / kg

Current Range (A) Packet (kg) Carton (kg) Part No.Size (mm) Length (mm)

2.5 300 62 65–85 5 15 (3 x 5) 611132

3.2 380 33 95–125 5 15 (3 x 5) 611133

4.0 380 22 130–160 5 15 (3 x 5) 611134

Typical all weld metal analysis (%)

C Mn Si S P

0.12% 0.47% 0.10% 0.01% 0.01%

Approvals

Lloyds Register of Shipping Grade 3, 3y

American Bureau of Shipping Grade 3


American Bureau of Shipping AWS A5.1 e6011

Pipearc 6010Puser friendly pipe welding electrode

Lower spatter levels and easy slag removal

excellent reverse bead formation on butts

Versatile “out-of-position” capabilities

Batch numbered for on-the-job traceability

used to weld out (root, fill and cap) steel pipes such as API 5L, 5LX grades X42 to-X52

Welding of ‘V’ butt (groove weld) joints in higher strength steels, including 5LX grades X60, X65 and X70. Recommended for root pass welding only

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Classifications





elongation 30%

CVN impact values 65J av @ -20°C 40J av @ -30°C

Packaging and operating data DC+ (Direct Current electrode Positive) polarity

electrode Approx no. (rods / kg)


2.5 300 66 45–85 5 15 (3 x 5) 615602

3.2 350 39 70–125 5 15 (3 x 5) 615603

4.0 350 25 120–190 5 15 (3 x 5) 615604

4.8 350 18 160–250 5 15 (3 x 5) 615605

The results quoted in this data sheet are obtained from the listed Shipping Societies (ABS, DNV, LRS) Conformance Tests and Procedures. Actual weld metal mechanical properties achieved with PipeArc 6010P are influenced by many factors including, base metal analysis, welding parameters / heat input used, number of weld passes and run placement etc. On the job mechanical tests may produce different results. Please consult your nearest BOC branch for welding procedure recommendations.


C Mn Si S P

0.11% 0.46% 0.15% 0.011% 0.012%

Approvals

Lloyds Register of Shipping Grade 3




MMa electrodescellulosic

8



Mild Steel

GP 6012Versatile general purpose electrode

All positional welding capabilities

Ideal for the vertical-down welding of thin steel sections

Wrought iron furniture

Suitable for welding mild steel plate, sheet metal and galvanised iron sheet, ducting, hoppers, tanks, pipes and low pressure pipelines

excellent for welding joints with poor fit-up

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Classifications





elongation 29%

CVN impact values 80J av @ 0°C


electrode Approx No. (rods / kg)


2.5 300 55 55–80 5 15 (3 x 5) 611142

3.2 380 30 90–130 5 15 (3 x 5) 611143

4.0 380 19 130–180 5 15 (3 x 5) 611144


C Mn Si

0.07% 0.45% 0.30%

Approvals




MMa electrodes General Purpose

Ferrocraft 12XPGeneral purpose “XP series” electrode

easy striking – hot or cold

Xtra smooth performance (XP)

Versatile – all positional capabilities

Ideal for vertical-down fillet welding

All positional fillet welding of steel furniture, plates, fences, gates, pipes and-tanks etc

Red flux colour for easy identification

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Classifications





elongation 27%




Current range (A) Packet (kg) Carton (kg)

easyweld Handipack Part No.

Size (mm)

Length (mm)

2.0 300 95 40–70 half pack 2.5 15 (6 x 2.5) – 612231

2.0 300 95 40–70 – – 90 rods 322128

2.5 300 55 60–100 5 15 (3 x 5) – 611232

2.5 300 55 60–100 half pack 2.5 15 (6 x 2.5) – 612232

2.5 300 55 60–100 – – 50 rods 322129

3.2 380 30 90–130 5 15 (3 x 5) – 611233

3.2 380 30 90–130 half pack 2.5 15 (6 x 2.5) – 612233

3.2 380 30 90–130 – – 25 rods 322138

4.0 380 19 130–180 5 15 (3 x 5) – 611234

easyweld Blister pack

10 x 2.5 mm, 5 x 3.2 mm Rod Blister Pack 322213


C Mn Si

0.07 0.60 0.50

Approvals

Lloyds Register of Shipping Grade 2, 2y

American Bureau of Shipping Grade 2, 2y



8



Mild Steel

WeldcraftRutile – basic type electrode

Higher radiographic quality

excellent mechanical properties

Versatile “out-of-position” capabilities

“On-site” and workshop welding where better mechanical properties are required and the work cannot be re-positioned to allow welding in the downhand. The electrode is recommended for welding joints subject to radiographic examination in pressure vessel, ship building, bridge and storage tank fabrications

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Classifications

AS / NZS 1553.1: e4113-2 AWS / ASMe-SFA A5.1: e6013.




elongation 28%



electrode Approx. (rods / kg)

Current range (A) Packet (kg) Carton (kg) Part No.Size (mm) Length (mm)

2.5 300 51 60–95 5 15 (3 x 5) 611202

3.2 380 27 95–135 5 15 (3 x 5) 611203

4.0 380 17 130–185 5 15 (3 x 5) 611204


C Mn Si

0.07 0.60 0.50

Approvals




MMa electrodesGeneral Purpose

Satincraft 13General purpose, rutile type electrode

Outstanding operator appeal


Smooth mitre fillet welds with low spatter

Developed and manufactured in Australia

Blue flux colour for instant identification

General workshop, field and structural welding of mild or galvanised steel components such as pipes, tanks, frames, fences and gates etc

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Classifications





elongation 28%


Packaging and operating data AC (minimum 45 OCV) DC+ or DC- polarity.

electrode Approx no. (rods / kg)

Current Range (A) Packet (kg) Carton (kg)

easyweld Handipack Part No.Size (mm) Length (mm)

2.5 300 53 55–90 5 15 (3 x 5) – 611182

2.5 300 53 55–90 half pack 2.5 15 (6 x 2.5) – 612182

2.5 300 53 55–90 – – 50 rods 322135

3.2 380 29 90–135 5 15 (3 x 5) – 611183

3.2 380 29 90–135 half pack 2.5 15 (6 x 2.5) – 612183

3.2 380 29 90–135 – – 25 rods 322136

4.0 380 20 135–180 5 15 (3 x 5) – 611184




C Mn Si

0.07% 0.60% 0.50%

Approvals





8



Mild Steel

MMa electrodes

Ferrocraft 21Rutile type, medium iron powder electrode

excellent operator appeal


easy striking – hot or cold

Ideal for vertical-down fillet welding

Workshop or “on-site” repair, maintenance and fabrication welding jobs where the iron powder addition gives improved usability over conventional e4112 rutile type electrodes

Ideal vertical-down fillet welding electrode for-thinner steel sections using “touch welding” techniques

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Classifications





elongation 30%




Current range (A)

Packet (kg) Carton (kg)


2.5 300 50 55–100 5 15 (3 x 5) – 611242

2.5 300 50 55–100 – – 20 rods 322130

3.2 380 26 95–140 5 15 (3 x 5) – 611243

4.0 380 17 140–195 5 15 (3 x 5) – 611244

5.0 450 9 200–260 5 15 (3 x 5) – 611245




C Mn Si

0.06 0.65 0.30

Approvals





Iron Powder

Ferrocraft 22Rutile type high iron powder electrode

High productivity fillet and butt welding in all downhand positions

Self releasing slag

Recommended for high production welding where large standing fillet welds are required

Ideal electrode for heavy structural welding – tanks, frames, girders, beams, ship structures, rolling stock and general fabrication in the workshop or “on-site”

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Classifications

AS / NZS 1553.1: e4824-0 AWS / ASMe-SFA A5.1: e7024.




elongation 25%




Current range (A)

Packet (kg) Carton (kg) Part No.Size (mm) Length (mm)

2.5 350 34 85–120 4 12 (3 x 4) 611252

3.2 380 18 130–170 5 15 (3 x 5) 611253

4.0 450 11 185–235 5 15 (3 x 5) 611254

5.0 450 7 260–320 5 15 (3 x 5) 611255

Ferrocraft 22 is formulated to operate with AC (min 45 OCV), DC+ or DC- polarity.

The preferred polarity for DC fillet welding is DC+.


C Mn Si

0.05% 0.75% 0.25%

Approvals

Lloyds Register of Shipping Grade 2y




8



Mild Steel

Ferrocraft 16tXP Now in Hermetically sealed 3kg Cans

“XP series” e4816 / e7016 type electrode

Great operator appeal / hydrogen controlled

Longer 350 mm 2.5 mm size for fewer electrode change-overs and less wastage

easy operation, reliable Grade 3 weld metal properties and low hydrogen status of Ferrocraft 16TXP make the electrode ideal for maintenance welding jobs, including the repair of earth-moving equipment and the “buttering” of steel sections prior to the application of hard surfacing.

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Classifications

AS / NZS 1553.1 e4816-2 H10 AWS / ASMe-SFA A5.1: e7016 H8




elongation 27%



C Mn Si S P

0.07 1.50 0.65 0.010 0.015



Current range (A)


2.5 350 56 50–90 3 12 (4 x 3) 613562

3.2 350 30 85–140 3 12 (4 x 3) 613563

4.0 350 21 135–190 3 12 (4 x 3) 613564

easyweld blister pack

10 x 2.5 mm, 5 x 3.2 mm rod Ferrocraft 16TXP Blister Pack 322214

Ferrocraft 16TXP is formulated to operate with AC (45 OCV min) DC+ or DC- polarity. The preferred polarity for fillet welding and fill and capping passes is DC+.

Typical diffusible hydrogen levels to AS 3752

7.0–7.5 ml of hydrogen / 100 gm of deposited weld metal*

*Reconditioned for 2 hours maximum at 300°C

Approvals

Lloyds Register of Shipping Grade 3, 3y H15

American Bureau of Shipping Grade 3H10, 3y


Ferrocraft 7016Fully basic hydrogen controlled e4816 / e7016 type electrode

excellent operator appeal in all positions

Ideal for fill and capping passes

excellent impact toughness to -30°C

Applications include pressure vessel fabrication, bridge, ship building, equipment repair and maintenance work

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AS / NZS 1553.1: e4816-3 H10 AWS / ASMe-SFA A5.1: e7016 H8 BS eN 499: e42 4 B 12 H10

Typical mechanical properties



elongation 25%


100J av @ -30°C


C Mn Si S P

0.08 1.10 0.65 0.009 0.019



Current range (A)


3.2 380 29 90–130 5 15 (3 x 5) 611743

4.0 380 19 120–180 5 15 (3 x 5) 611744

Ferrocraft 7016 is formulated to operate with AC (55 O.CV), DC+ or DC- polarity. The preferred polarity for fillet welding and fill and capping passes is DC+.


5.0–6.0 mls of hydrogen / 100 gm of deposited weld metal*


Approvals

Lloyds Register of Shipping Grade 3y H10





8



Mild Steel

Ferrocraft 55uBasic, hydrogen controlled e4816 / e7016 type electrode

Thin coated for easier joint access

Purple end tip colour for instant identification

Designed specifically for the all positional (except vertical-down) root pass welding of-steel pipes and plates

Classifications

AS / NZS 1553.1: e4816-2 H10 AWS / ASMe-SFA A5.1: e7016 H8

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elongation 29%



C Mn Si S P

0.07 0.80 0.77 0.007 0.013


electrodeApprox no. (rods / kg)

Current range (A)


2.5 350 53 40–90 5 15 (3 x 5) 611492

3.2 380 31 60–140 5 15 (3 x 5) 611493

4.0 380 19 90–180 5 15 (3 x 5) 611494

Ferrocraft 55u is formulated to operate on low welding current to accommodate poor joint fit up and large root gaps. The electrode is suitable for AC (minimum 70 O.CV), DC+ or DC- polarity. The preferred polarity for ease of use in root pass welding is DC-. Where it is necessary to maximise weld metal toughness fill and capping passes should be deposited with DC+ polarity.




Approvals

Lloyds Register of Shipping

Grade 3, 3y H15

Det Norske Veritas

Grade 3y H10

Ferrocraft 61Basic coated, hydrogen controlled e4818 / e7018 type electrode

excellent out-of-position welding

Reliable impact properties to -30°C

Batch number identification

Designed for all positional (especially vertical-up) fillet and butt welding applications on-heavier steel sections under high restraint such as machinery parts, pressure vessels, mining equipment, pipework, ship construction and all maintenance and-repair-work

Classifications

AS / NZS 1553.1: e4818-3 H10 AWS / ASMe-SFA A5.1: e7018

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Tensile strength

545 MPa

elongation 29%

CVN impact values

160J av @ -20°C 130J av @ -30°C


C Mn Si S P

0.06 1.45 0.45 0.010 0.012


electrodeApprox No. (rods / kg)

Current range (A)


2.5 350 42 65–100 5 15 (3 x 5) 611342

3.2 380 24 95–150 5 15 (3 x 5) 611343

4.0 380 16 145–220 5 15 (3 x 5) 611344

5.0 450 9 195–270 5 15 (3 x 5) 611345

Ferrocraft 61 is formulated to operate with AC (55 O.CV min), DC+ or DC- polarity. The preferred polarity for fillet welding and fill and capping passes is DC+.




Approvals

Lloyds Register of Shipping Grade 3, 3y H15

American Bureau of Shipping

Grade 3H15, 3y



AWS A5.1 e7018


8



Mild Steel

Ferrocraft 61 H4 Hermetically Sealed Cans

Highly Basic, e4818 / e7018 Type Hydrogen controlled electrode

Advanced moisture resistant flux coating

Very low “H5 / H4” diffusible hydrogen class

C-Mn weld deposit for reliable Impact properties to -40°C

Recommended for critical DC welding applications

Batch Number Identification

Classifications

AS / NZS 1553.1: e4818-5 H5R AWS / ASMe-SFA A5.1: e7018-1 H4R

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Typical All Weld Metal Mechanical Properties

yield Stress 450 MPa.

Tensile Strength 545 MPa.

elongation 28%.

CVN impact Values 150J av @ -20°C 100J av @ -40°C 80J av @ -50°C

Typical All Weld Metal Analysis (%)

C Mn Si S P

0.07 1.50 0.35 0.07 0.012

Packaging and Operating Data AC (minimum 55 OCV), DC+ or DC- polarity

electrode Approx no.

rods / kgCurrent Range (A) Can (kg) Carton Part No.Size (mm) Length (mm)

2.5 350 42 65–100 3 12 (4x3) 614342

3.2 380 24 95–150 3 12 (4x3) 614343

4.0 380 16 145–220 3 12 (4x3) 614344

Typical Diffusible Hydrogen Levels To AS 3752

3.0–3.5 mls of hydrogen / 100gms of deposited weld metal

Approvals

Lloyd’s Register of Shipping Grade 3, 3yH5


Det Norske Veritas Grade 3yH5


8



Mild Steel

Fleetweld 5PAll position, deep penetration welding of pipelines and critical refinery work. X-ray quality.

Classification

AS / NZS 1553.1: e4110-2 AWS A5.1: e6010

Size (mm) Weight (kg) Part No.

2.4 22.68 Can eD010211

3.2 22.68 Can eD010203

4.0 22.68 Can eD010216

4.8 22.68 Can eD010207

Fleetweld 5P+Similar to traditional Fleetweld 5P, plus quick striking, easy slag removal and improved final appearance.

Classifications

AS / NZS 1553.1: e4110-2 AWS A5.1: e6010


2.4 22.68 Can eD010283

3.2 22.68 Can eD010278

4.0 22.68 Can eD010285

4.8 22.68 Can eD010281

Jetweld lH-70Controlled hydrogen, semi-iron powder type for X-ray quality all positional welding with mechanical properties in 495–555 MPa (72,000–80,000 psi) range.

Classifications

AS / NZS 1553.1: e4818-4H5, AWS A5.1: e7018


2.4 22.68 Can eD010568

3.2 22.68 Can eD010561

4.0 22.68 Can eD010575

4.8 22.68 Can eD010564

5.6 27.2 Can eD010577

conarc 49cThe offshore electrode if Ni-alloying is not allowed, good CTOD at -10°C. Good pipe welding properties. Reliable impact toughness at -40°C. excellent X-ray soundness. Basic, extremely low hydrogen (HDM <5ml / 100g) coated electrode with 120% recovery.

Classification

AWS. A5.1: e7018-1-H4R

Size (mm) Packet (kg) Product No

3.20 4.40 509243

4.00 4.70 509359

2.50 1.40 511420

3.20 2.00 511437

4.00 1.60 511505

eMR-Sahara product.(Hermetically sealed packaging i.e. requires no pre-baking)

MMa electrodes cellulosic


8



Mild Steel

GMaW Wire

boc Mild Steel MIG Wire

DescriptionBOC Mild Steel MIG Wire is a premium quality copper coated mig wire produced from high quality double deoxidised rod. The higher manganese and silicon levels ensure improved weld metal deoxidation, making BOC Mild Steel MIG Wire an excellent choice for welding on metal with a medium to high presence of mill scale or rust. The higher silicon levels promote a smooth bead surface and a flat fillet bead profile with equal leg length and uniform wetting is easily achieved.

The wire is designed for both single- and multiple-pass welding in all positions.

The wire is copper coated for increased shelf life and to ensure good electrical conductivity with reduced friction during high speed welding.

BOC Mild Steel MIG Wire has excellent, smooth wire feedability and is suitable for welding with dip (short circuit), spray arc and pulsed arc transfer using Ar / CO2 or CO2 shielding gases.

applicationBOC Mild Steel MIG Wire is recommended for welding of mild and medium tensile strength steels and is an excellent choice for general steel construction, sheet metal applications, pressure vessel fabrication, structural welding and pipe welding.

Welding positions

Specifications

Classifications AWS / ASMe-SFA A5.18 eR70S-6

AS / NZS 2717.1 eS6-GC / M-W503AH

Approvals* Lloyds Register of Shipping

Grade 3S, 3yS

*with Ar / CO2 shielding gas.

Recommended Shielding Gases

Argoshield Light

Argoshield universal

Argoshield Heavy

Argoshield 40

Argoshield 52

Argoshield 54

Argoshield 100

Welding Grade CO2

Flow rate 15-20 L/min.

Chemical composition, wt% – Wire

Typical C Si Mn

0.07 0.85 1.45

Mechanical properties – all weld metal

using Argoshield using CO2



elongation 27% 31%

Impact energy, CVN 84J min av @ –30°C 72J min av @ –30°C

Packaging Data – Mini spool (100mm Ø)

Dia. (mm) 0.6 0.8 0.9

Part No. 1061108 1081108 1091108

Winding Random Random Random

Spool weight (kg) 1 1 1

Packaging Data – Handi spool (200mm Ø)

Dia. (mm) 0.6 0.8 0.9

Part No. 1061150 1081150 1091150

Winding Random Random Random

Spool weight (kg) 5 5 5

Packaging Data – Spool (300mm Ø)

Dia. (mm) 0.6 0.8 0.9 1.0 1.2

Part No. 1061155 1081155 1091155 1101155 1121155

Winding Random Precision PLW

Precision PLW

Precision PLW

Precision PLW

Spool weight (kg) 15 15 15 15 15

Pallet weight (kg) 810 810 810 810 810

Packaging Data – Smoothpak Drum

Dia. (mm) 0.9 1.0 1.2

Part No. 1091250 1101250 1121250

Drum weight (kg) 250 250 250

Welding Parameters

Dia. (mm) 0.6 0.8 0.9 1.0 1.2

Current range (A) 40–100 60–150 90-220 100-240 120-320

Voltage (V) 12–22 15–24 16-30 17-30 18-32

8



Mild Steel

GMaW Wire

autocraft Super SteelA low carbon, triple deoxidised steel wire for GMA welding

For use with welding grade CO2 or argon based shielding gases

Triple deoxidised for superior weld deposit quality and resistance to porosity

The ideal choice for the welding of rusty or-mill scaled plates and pipes and the root pass welding of pipes, tanks, and heavy walled joints

Classifications

AS / NZS 2717.1: eS2-GC / M-W503AH AWS / ASMe-SFA A5.18: eR70S-2

■

■

■

■


Argon 20–25% CO2



elongation 34%


Typical wire analysis (%)

C: 0.05 Mn: 1.10 Si: 0.55

Ti: 0.10 Zr: 0.06 Al: 0.08

S: 0.007 P: 0.008 Fe: Balance

Packaging and operating data

Dia. (mm) Voltage (V)Wire feed speed (m / min)

Current Range (A) Pack type*

Pack weight (kg) Part No.

1.2 18–32 3.5–15 120–350 Spool 15 720054

* Spool (ø300 mm)


1.0–2.0 ml of hydrogen / 100 gm of deposited weld metal.

Recommended shielding gas

Argoshield® universal

Argoshield® 52

Argoshield® Heavy

Argoshield® Light

Industrial Grade CO2

autocraft lW1A premium quality low carbon steel wire for GMA welding

Suitable for the all positional multi-pass GMA welding of mild, low alloy and medium strength steels, as used in general fabrication, pressure vessels and structural work.



Argoshield® 52

Argoshield® Heavy

Argoshield® Light


Classifications


■

■


Argon 10–25% CO2


yield stress 420 MPa 390 MPa

Tensile strength

520 MPa 500 MPa

elongation 30% 31%

CVN impact values

110J @ -20°C 100J @ -20°C


C Mn Si S P

0.08 1.16 0.70 0.010 0.015



Current range (A)

Pack type* Pack (kg) Part No.

0.9 15–26 3.5–15 70–230 Spool 15 720115

1.2 18–32 2.5–15 120–350 Spool 15 720116

* Spool (ø300 mm)


1.0–2.0 ml of hydrogen / 100 gm of deposited weld metal

Approvals

CO2 and Argon 10–25% CO2

LRS Grade 3S

ABS Grade 3SA

DNV Grade IIIyMS

8



Mild Steel

GMaW Wire

autocraft lW1-6A higher manganese / silicon steel wire for-GMA welding

use with CO2 and argon based shielding gases

Wide range of minispool, handispool and-autopak packaging options

Suitable for the positional gas metal arc welding (GMAW) of mild and low alloy steels, used in general fabrication and structural work.



Argoshield® 52

Argoshield® Heavy

Argoshield® Light


Classifications


■

■

■

■


Welding Grade CO2

Argon 20–25% CO2


Tensile strength

525 MPa 550 MPa

elongation 32% 29%

CVN impact values

110J @ -20°C 120J @ -20°C


C Mn Si S P

0.07 1.55 0.88 0.012 0.015


Dia. (mm)

Voltage (V)

Wire feed speed (m / min)

Current range (A) Pack type*


0.6 12–14 3.5–14 35–100 Mini Spool – Packs of 4 4 x 0.8 721104

0.6 12–14 3.5–14 35–100 Handi Spool 5 720108

0.6 12–14 3.5–14 35–100 Spool 15 720103

0.8 14–22 3.5–14 50–180 Mini Spool – Packs of 4 4 x 0.8 721105

0.8 14–22 3.5–14 50–180 Handi Spool 5 720109

0.8 14–22 3.5–14 50–180 Spool 15 720114

0.9 15–26 3.5–15 70–230 Handi Spool 5 720161

0.9 15–26 3.5–15 70–230 Spool 15 720090

0.9 15–26 3.5–15 70–230 AutoPak 250 720122A

1.0 16–29 3.5–15 100–280 Spool 15 720094

1.0 16–29 3.5–15 100–280 AutoPak 250 720123A

1.2 18–32 2.5–15 120–350 Spool 15 720096

1.2 18–32 2.5–15 120–350 AutoPak 250 720124A

1.6 18–34 2.5–10 180–390 Spool 15 720095

1.6 18–34 2.5–10 180–390 AutoPak 350 720125A

* Mini Spool (ø100 mm); Handi Spool (ø200 mm); Spool (ø300 mm); AutoPak (ø510 mm x H.770 mm)



Approvals

CO2 and Argon 20–25% CO2

Lloyds Register of Shipping Grade 3S, 3yS

American Bureau of Shipping Grade 3SA, 3ySA

Det Norske Veritas Grade 111yMS

* Approvals do not include 0.6 mm and 0.8 mm Autocraft LW1-6 wires

8



Mild Steel

GMaW Wire

ultramag S4Copper coated, ‘S4’ steel wire for gas metal arc welding. Suitable for use with carbon dioxide or argon based shielding gases for welding mild and medium strength steels.

Classifications

AS 2717.1: eS4; AWS A5.18: eR70S-4


0.9 15 Spool 812855

1.0 15 Spool 812879

1.2 15 Spool 812862

1.6 15 Spool 812809

ultramag S6Premium quality copper coated, ‘S6’ high manganese, high silicon steel wire for gas metal arc welding. Suitable for use with carbon dioxide or argon based shielding gases for welding mild and medium strength steels. Low spatter.

Classifications

AS 2717.1: eS6, AWS A5.18: eR70S-6


0.6 5 Spool 801231

0.8 5 Spool 801248

0.8 15 Spool 8180815

0.9 15 Spool 8180915

1.0 15 Spool 8181015

1.2 15 Spool 8181215

8



Mild Steel

FcaW Wire

Smoothcor™ 711

DescriptionSmoothCor™ 711 is a general purpose, rutile flux cored wire that performs exceptionally well in the downhand, vertical up and overhead positions at the same parameter settings. It is suitable for use with both Ar / CO2 or CO2 shielding gases. Designed for single and multi pass welding, SmoothCor™ 711 produces weld metal that is consistently free of inclusions and porosity for X-ray soundness. The wire has Grade 3 shipping society approval for improved weld deposit impact toughness. SmoothCor™ 711 welds with a very smooth running, low spatter arc and a fine spray type transfer to give excellent weld pool control. Bead surface is extremely smooth with excellent slag detachability. Flat fillet bead profile with equal leg length and uniform wetting is easily achieved. SmoothCor™ 711 has a very wide operating window, excellent feedability and easy arc starting characteristics.

applicationSmoothCor™ 711 is recommended for welding of mild and medium tensile strength steels and is an excellent choice for general steel construction, shipbuilding, pressure vessel fabrication and structural welding.

Welding Positions

Specifications

Flux Type Rutile

Classification AWS / ASMe-SFA A5.20 e71T-1 H8, e71T-1M H8 e71T-9 H8, e71T-9M H8

AS 2203.1 eTP-GMp-W503A.CM1 H10 eTP-GCp-W503A.CM1 H10


Grade 3


,American Bureau Shipping

Grade 3

Welding Current DC+

* With Ar / CO2 and CO2 shielding gas

Recommended Shielding Gases:

Argoshield® 52 or Ar+20–25% CO2 mixtures Welding Grade CO2 Flow rate 15–20 L / min


Typical C Si Mn

Argoshield® 52 0.05 0.60 1.35

CO2 0.04 0.54 1.27


As Welded using Argoshield® 52 using CO2

yield strength 440 MPa min 430 MPa min

Tensile strength 500–620 MPa 490–580 MPa

elongation 25% min 25% min

Impact energy, CVN 95J min av @ -18ºC 65J min av @ -29ºC

90J min av @ -18ºC 60J min av @ -29ºC

Diffusible Hydrogen

1.2 mm, 100% CO2, DC+, 230 amps, 27 volts, 20 mm stick-out: <8ml / 100g (vacuum packed)

1.2 mm, Argoshield® 52, DC+, 230 amps, 27 volts, 20 mm stick-out: <8ml / 100g (vacuum packed)

Packaging Data

Dia. (mm) 1.2 1.6

Part No. 1071112 1071116

Type Spool (vacuum packed) Spool (vacuum packed)

Weight (kg) 15 15

Welding Parameters

Welding Position

Flat, Horizontal Vertical up Overhead

Dia. (mm) 1.2 1.6 1.2 1.6 1.2 1.6

Current Range (A)

150–290

180–400

150–250

180–300

150–250

180–310

Voltage (V) 23–30 25–34 22–26 21–27 23–26 22–27

electrode Stick-out (mm)

15–20 20–25 15–20 20–25 15–20 20–25

Deposition Data

Dia. (mm)Current (A)

Voltage (V)

Approx. Wire Feed Speed (m / min)

Deposition Rate (kg / h)

efficiency (%)

1.2 150 28 5.08 1.91 86

210 29 7.62 2.86 86

250 30 10.16 3.86 87

290 33 12.70 4.85 87

330 34 15.24 5.76 87

1.6 190 27 3.81 2.77 87

300 30 6.35 4.63 87

365 33 7.62 5.58 86

410 33 8.89 6.35 88

Gas assisted General Purpose

8



Mild Steel

Smoothcor™ 715

DescriptionSmoothCor™ 715 is a basic flux cored wire for which the all round operability has been optimised. It is suitable for use with both Ar / CO2 or CO2 shielding gases. using DC-, the wire can be used for welding in all positions. Designed for single and multi pass welding, SmoothCor™ 715 produces low temperature – high toughness, microscopically clean weld metal with very low H4 hydrogen content and superior hot and cold crack resistance. SmoothCor™ 715 welds with particularly stable running characteristics and has a thin easily remelted slag cover which, with its excellent feedability and easy arc starting characteristics, enhances operator appeal and minimises spatter.

applicationSmoothCor™ 715 is an excellent choice for a wide range of critical applications including pressure vessels, offshore oil and gas platforms and heavy earth moving and mining equipment. SmoothCor™ 715 is suitable for welding mild and higher carbon and difficult to weld steels. It combines strength and toughness and is particularly suitable for heavily restrained sections where there can be a risk of cracking due to weld stress.

Welding Positions

Specifications

Flux Type Basic

Classification AWS / ASMe-SFA A5.20 e71T-5 H4, e71T-5MJ H4

AS 2203.1 eTP-GMn-W504A.CM1 H5 eTP-GCn-W504A.CM1 H5


Grade 3



Grade 3

Welding Current DC-

* With Ar / CO2 shielding gas.




Typical C Si Mn

Argoshield® 52 0.07 0.70 1.50

CO2 0.06 0.60 1.35







Diffusible Hydrogen

1.2 mm, 100% CO2, DC-, 230 amps, 27 volts, 20 mm stick-out: <4ml / 100g (vacuum packed)

1.2 mm, Argoshield® 52, DC-, 230 amps, 27 volts, 20 mm stick-out: <4ml / 100g (vacuum packed)

Packaging Data

Dia. (mm) 1.2 1.6

Part No. 1071512 1071516


Weight (kg) 15 15

Welding Parameters

Dia. (mm) 1.2 1.6

Current Range (A) 150–290 180–400

Voltage (V) 23–30 25–34


15–20 20–25

Welding Position Flat, Horizontal

Deposition Data

Dia. (mm)

Current (A)

Voltage (V)



efficiency (%)

1.2 170 29 7.24 3.20 96

250 30 11.91 4.90 91

300 32 15.39 6.44 92

1.6 300 30 5.74 4.45 92

400 32 9.37 7.30 92

450 32 10.72 8.40 93

FcaW Wire Gas assisted Hydrogen controlled

8



Mild Steel

Smoothcor™ 70c6

DescriptionSmoothCor™ 70C6 is a metal cored wire producing 40% less fume than conventional metal cored products. It is suitable for use with both Ar / CO2 or CO2 shielding gas. Designed for single and multi pass welding, the wire can be used in both the flat and horizontal positions. SmoothCor™ 70C6 welds with a very smooth running, low spatter arc. Deposition efficiency is high and slag islands minimal. With its wide range of welding parameters, excellent feedability and easy arc starting characteristics, SmoothCor™ 70C6 has superb welder appeal.

applicationSmoothCor™ 70C6 is ideal for a wide range of high speed fillet and butt welding applications where high productivity is required. SmoothCor™ 70C6 has better wetting action than solid wire, minimising cold lap on heavier sections of steel. SmoothCor™ 70C6 is recommended for general fabrication of mild and medium tensile steels. It is also suitable for use on pressure vessel work and structural welding.

Welding Positions

Specifications

Type Metal cored

Classification AWS / ASMe-SFA A5.18 e70C-6C H8, e70C-6M H8

AS 2203.1 eTD-GMp-W503A.CM1 H10

eTD-GCp-W503A.CM1 H10


Grade 3



Grade 3

Welding Current DC+





Typical C Si Mn

Argoshield® 52 0.03 0.62 1.68

CO2 0.03 0.59 1.66







Diffusible Hydrogen



Packaging Data

Dia. (mm) 1.2 1.6

Part No. 1070C612 1070C616


Weight (kg) 15 15

Welding Parameters

Dia. (mm) 1.2 1.6

Current Range (A) 150–350 300–500

Voltage (V) 24–32 26–34


10–20 10–20

Welding Position Flat, horizontal Flat, horizontal

Deposition Data

Dia. (mm)Current (A)

Voltage (V)



efficiency (%)

1.2 250 28 8.38 3.63 90

275 30 10.92 5.03 94

300 32 11.79 5.26 94

350 32 13.00 5.76 96

1.6 300 30 4.60 3.90 89

350 30 6.12 5.40 94

400 32 7.44 6.62 94

450 34 8.46 7.35 94

FcaW WireMetal cored

8



Mild Steel

FcaW Wire Gas assisted General Purpose

Satin-cor XPA rutile type flux cored wire formulated exclusively for CO2 shielding gas

For high speed, downhand welding applications


Superior fillet shape and slag lift

Recommended for the downhand fillet welding of structural steels of 6 mm thickness or heavier

1.6 mm Satin-Cor XP is now qualified for both CO2 and Mixed Gas

Now Precision Layer Wound

Classifications

AS / NZS 2203.1: eTD-GCp-W502A. CM1 H10 AWS / ASMe-SFA A5.20: e70T-1H8

*1.6 mm only eTD-GMp-W502A CM1H10 and eTD-GCp-W502A CM1 H10


using welding grade CO2



elongation 27%


■

■

■

■

■

■

■

Typical all weld metal analysis (%) using CO2 shielding gas

C Mn Si S P

0.08 1.38 0.55 0.011 0.016.



* for ‘as manufactured’ product using welding grade CO2 shielding gas

Operating data

All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and welding grade CO2 shielding gas with a flow rate of 15–20 L / min.

Dia. (mm)

Current range (A) Voltage (V)

electrode stickout eSO (mm)

Optimum amps Volts

Welding positions

1.6 350–450 28–33 25–30 380 30 Flat

2.4 400–550 28–33 25–35 450 30

1.6 300–400 26–30 25–30 330 29 HV Fillet

2.4 350–450 26–30 25–30 400 29

1.6 270–350 25–29 25–30 300 28 Horizontal

2.4 320–420 25–29 25–30 360 28

Approvals*


Grade 2yS H15

* with welding grade CO2 shielding gas.

Packaging data

Wire dia. (mm) Pack type Pack (kg) Part No.

1.6 Spool 13 720904

2.4 Coil 25 720906

8



Mild Steel

Verti-cor XP Now upgraded to Grade 3 on CO2 and Mixed Gas

A general purpose, rutile type flux cored wire

Versatile, all positional capabilities



Recommended for general steel construction / fabrication

Classifications

AS / NZS 2203.1: eTP-GMp-W503A. CM1 H10

eTP-GCp-W503A. CM1 H10

AWS / ASMe-SFA A5.20: e71T-1H8 / e71T-1M H8

Recommended shielding gases

Argoshield® 52

Welding Grade CO2


Argon CO2


Tensile strength

630 MPa 600 MPa

elongation 26% 26%

CVN impact values

70J av @ 0°C 60J av @ 0°C

■

■

■

■

■

■



* for ‘as manufactured’ product using Argoshield® 52 shielding gas

Approvals*


Grade 3yS H15


Grade 3SA, 3ySA

Det Norske Veritas III yMS

* Argon +20–25% CO2 and CO2 shielding gas combinations

Operating data

All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L / min.

Dia. (mm)



Optimum amps Volts

Welding positions

1.2 250–300 27–31 20–25 280 31 Flat

1.6 350–400 27–31 25–30 360 31

1.2 230–280 26–30 20–25 260 28 HV Fillet

1.6 310–360 26–30 25–30 320 29

1.2 170–220 24–28 15–20 200 24 Vertical up

1.6 200–250 24–28 15–20 240 25

1.2 160–210 24–28 15–20 200 24 Overhead

1.6 190–240 24–28 15–20 220 24


C Mn Si S P

Argon +20–25% CO2

0.07 1.55 0.65 0.007 0.014

using CO2

0.06 1.45 0.60 0.010 0.015

Packaging data

Dia. (mm) Pack type Pack (kg) Part No.

1.2 Spool 15 720915

1.6 Spool 15 720917

1.2 Drum 200 720915A

1.6 Drum 200 720917A

Verti-cor ultraA rutile type flux cored wire formulated exclusively for CO2 shielding gas



Grade 2 shipping society approvals

Low spatter and fume levels

Designed for the single and multi-pass welding of mild and medium strength steels in the downhand, vertical-up and overhead positions

Precision Layer Wound

Classifications

AS / NZS 2203.1:

eTP-GCp-W502A. CM1 H10

AWS / ASMe-SFA A5.20: e71T-1H8


Welding Grade CO2





elongation 28%


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■

■

■

■

Typical all weld metal analysis (%) using

CO2 shielding gas

C: 0.04 Mn: 1.24 Si: 0.70

Ti: 0.035 B: 0.005



* for ‘as manufactured’ product using welding grade CO2 shielding gas

Operating data


Dia. (mm)



Optimum (A) Volts

Welding positions

1.2 250–300 27–31 20–25 250 28 Flat

1.6 350–400 27–31 25–30 300 29

1.2 230–280 26–30 20–25 230 27 HV Fillet

1.6 310–360 26–30 25–30 270 27

1.2 170–220 24–28 15–20 190 24 Vertical up

1.6 200–250 24–28 15–20 210 25

1.2 160–210 24–28 15–20 215 26 Overhead

1.6 190–240 24–28 15–20 250 27

Approvals*


Grade 2yS H15


Grade 2ySA H10

Det Norske Veritas IIyMS H10

*with welding grade CO2 shielding gas

Packaging data

Wire dia.(mm) Pack type

Pack weight / kg Part No.

1.2 Spool 13 720900

1.6 Spool 13 720902

FcaW WireGas assisted General Purpose

8



Mild Steel

Verti-cor 3XPA microalloyed, rutile type flux cored wire




Formulated to give smooth (low spatter) arc transfer, flat mitre fillet welds and excellent slag lift in all positions (except vertical-down), on a wide range of mild and medium strength steels


Classifications

AS / NZS 2203.1 eTP-GMp-W503A. CM1 H10 eTP-GCp-W503A. CM1 H10

AWS / ASMe-SFA A5.20: e71T-1 H8 , e71T-12M H8


using Argoshield® 52

using CO2


Tensile strength

560 MPa 530 MPa

elongation 28% 30%

CVN impact values

110J av @ 0°C 90J av @ 0°C

90J av @ -20°C 75J av @ -20°C


using Argon +20–25% CO2

C: 0.07 Mn: 1.16 Si: 0.52

Ti: 0.035 B: 0.008

using CO2

C: 0.06 Mn: 1.05 Si: 0.42

Ti: 0.035 B: 0.007

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■

■

■

■

■



* For ‘as manufactured’ product using Argoshield® 52 shielding gas

Approvals*


Grade 3S, 3yS H


Grade 3SA, 3ySA H

Det Norske Veritas IIIyMS H

* With Argon +20–25% CO2 shielding gas combinations

Operating data

All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L / min.

Dia. (mm)



Optimum (A) Volts

Welding positions

1.2 250–300 27–31 20–25 280 31 Flat

1.6 350–400 27–31 25–30 360 31

1.2 230–280 26–30 20–25 260 28 HV Fillet

1.6 310–360 26–30 25–30 320 29

1.2 170–220 24–28 15–20 200 24 Vertical up

1.6 200–250 24–28 15–20 240 25

1.2 160–210 24–28 15–20 200 24 Overhead

1.6 190–240 24–28 15–20 220 24



Argoshield® 52

Argoshield® Heavy

Welding Grade CO2

Packaging data


1.2 Spool 13 720919

1.6 Spool 13 720921

FcaW Wire Gas assisted General Purpose

8



Mild Steel

Verti-cor 3XP H4Next generation technology flux cored wire.

Copper coated for smooth consistent feedability and current pick up.

Rutile, all positional capabilities producing a flat mitre fillet bead shape.

ultra low splatter and fume levels.

H4 diffusible hydrogen class with a typical weldmetal of 2.2 mls of hydrogen/100 gms.

excellent Operator Appeal.

Grade 3 Shipping Society Approvals.

Classifications

AS/NZS 2203.1: eTP-GMp-W503A. CM1 H5.

AWS/ASMe-SFA A5.20: e71T-12M H4.


using Argon + 20–25% CO2 :

yield Stress 510 MPa

Tensile Strength 570 MPa

elongation 30%

CVN, Impact Values 105J av @ -20°C



C Mn Si P S

0.05 1.25 0.43 0.009 0.007

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■

■

■

■

■

Typical Diffusible Hydrogen Levels to AS3752:

2.2 mls of hydrogen / 100gms of deposited weld metal *.

* - for ‘as manufactured’ product using Argon + 20–25% CO2 shielding gas.

Approvals*

Lloyds Register of Shipping 3S, 3yS H5

American Bureau of Shipping S3A, 3ySA H5

* - with Argon +20–25% CO2 shielding gas combinations.

Operating Data

All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L/min

Wire Dia. (mm)

Current Range (A)

Voltage Range (V)

CTWD Optimum Amps

Volts Welding Positions

1.2 250–300 27–31 20–25 280 31 Flat

1.6 350–400 27–31 25–30 360 31 Flat

1.2 230–280 26–30 20–25 260 28 HV Fillet

1.6 310–360 26–30 25–30 320 29 HV Fillet

1.2 170–220 24–28 15–20 200 24 Vertical up

1.6 200–250 24–28 15–20 240 25 Vertical up

1.2 160–210 24–28 15–20 200 24 Overhead

1.6 190–240 24–28 15–20 220 24 Overhead

These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.


Argon + 20–25% CO2 . ISO14175:

M21,M24, M21 (1)

Packaging Data

Wire Dia. (mm)

Pack Type Weight (kg)

Part No.

1.2 Spool 12.5 722919

1.6 Spool 12.5 722921


8



Mild Steel

Supre-cor XP H4Fully basic Seamless tubular flux cored wire

Low temperature impact toughness to -20°C

Available in 2.4 mm size only


Recommended for the fillet and butt welding of heavy earthmoving and mining equipment

Suitable for use with CO2 and Argon + 20–25% CO2 or equivalent shielding gases

Classifications

AS / NZS 2203.1:

eTD-GCn / p-W503A. CM1 H5 and eTD-GMn / p-W503A. CM1 H5

AWS / ASMe-SFA A5.20:

e70T-5 H4, e70T-5M H4





elongation 29%


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C: 0.08 Mn: 1.34 Si: 0.63

P: 0.20 S: 0.015


1.5–2.0 ml of hydrogen / 100 gm of deposited weld metal *

* For ‘as manufactured’ product using Argon +20–25% CO2

Approvals*

Lloyds Register Grade 3S, 3yS H15 of Shipping

*With Argon +20 –25% CO2

Operating data

All welding conditions recommended below are for use with semi-automatic operation and DC electrode positive. Argon +20-25% CO2 shielding gas with a flow rate of 15–20 L / min was used.

Dia. (mm)



Optimum (A) Volts

Welding positions

2.4 350–500 27–33 25–30 450 31 Flat

2.4 350–500 27–33 25–30 400 30 HV Fillet

Recommended shielding glasses

Argoshield® 52

Welding Grade CO2

Packaging data

Dia. (mm)Pack type Pack (kg) Part No.

2.4 Coil 25 720911

FcaW Wire Gas assisted Hydrogen controlled

8



Mild Steel

Supre-cor 5Second generation, fully basic flux cored-wire

Improved low temperature impact toughness to -50°C

Improved positional capabilities of 1.2 mm and 1.6 mm sizes

DC electrode negative operation

Suitable for a wide range of critical applications including the fillet and butt welding of pressure vessels, offshore oil and-gas platform structures and heavy earthmoving equipment


Classifications

AS/NZS 2203.1: eTP-GCn/p-W505A. CM1 H5 eTP-GMn/p-W505A. CM1 H5

AWS/ASMe-SFA A5.20: e71T-5 H4, e71T-5MJ H4


using Argon +20-25% CO



elongation 29%


100J av @ -40°C

90J av @ -60°C

using CO2



elongation 30%


90J av @ -40°C

80J av @ -60°C

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C Mn Si P S

0.10 1.45 0.42 0.012 0.015

using CO2

C Mn Si P S

0.09 1.25 0.32 0.012 0.015



* For ‘as manufactured’ product using Argoshield® Argon +20–25% CO2

Approvals*


Grade 3S, 3yS H5


Grade 3SA,3ySA H5

Det Norske Veritas IIIyMS H5

* With Argon +20 -25% CO2 and CO2 shielding gas combinations

Operating data

All welding conditions recommended below are for use with semi-automatic operation, DC electrode negative and Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L/min.

Dia. (mm)Current range (A)

Voltage range (V)


Optimum Amps Volts

Welding positions

1.2 250 – 300 27 – 31 20 – 25 280 29 Flat

1.6 350 – 400 27 – 31 25 – 30 320 31

1.2 230 – 280 26 – 30 20 – 25 250 27 HV Fillet

1.6 310 – 360 26 – 30 25–30 315 30

1.2 170 – 220 24 – 28 15 – 20 140 21 Vertical up

1.6 200 – 250 24 – 28 15 – 20 N/A N/A

1.2 160 – 210 24 – 28 15 – 20 120 20 Overhead

1.6 190 – 240 24 – 28 15 – 20 N/A N/A


Argoshield® 52

Welding Grade CO2

Packaging data

Dia. (mm) Pack typeWeight (kg) Part No.

1.2 Spool 13 720982

1.6 Spool 13 720983

FcaW WireGas assisted Hydrogen controlled

8



Mild Steel

Metal-cor XPLow slag, metal cored wire


High deposition efficiency = 95%

High deposition rates

For the high productivity fillet and butt welding of mild and medium strength steels in all downhand positions


Classifications

AS / NZS 2203.1: eTD-GMn / p-W503A. CM1 H5 eTP*-GMn / p-W503A. CM1 H5 (*1.2 mm only )

AWS / ASMe-SFA A5.18: e70C-6M*

* The Classifications of metal cored wires to the American Welding Society (AWS) has changed. Detailed information regarding these changes are available in the technical section of pocket guide.

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elongation 28%

CVN impact values 100J av @ 0°C 85J av @ -20°C

40J av @ -30°C

Typical all weld metal analysis (%)*

C: 0.05% Mn: 1.42% Si: 0.75%

S: 0.012% P: 0.014%

* using Argon +20–25% CO2 shielding gas

Operating data

All welding conditions recommended below are for use with semi-automatic operation, DC electrode negative and Argon +20 –25% CO2 shielding gas with a flow rate of 15–20 L / min.

Wire Dia. (mm)

Current range (A)

Voltage Range (V)


Optimum (A) Volts

Welding positions

1.2 280–350 28–33 20–25 330 32 Flat

1.6 350–450 29–33 25–30 420 31

1.2 250–300 27–31 20–25 280 30 HV Fillet

1.6 300–380 27–31 25–30 360 28

1.2 250–300 27–31 20–25 250 30 Horizontal

1.6 300–380 27–31 25–30 280 26

Approvals*


Grade 3yS H5

ABS Grade 3SA, 3ySA H5

Det Norske Veritas IIIyMS H5

*With Argon +20–25% CO2 shielding gas combinations


Argoshield® 52


Packaging data

Dia. (mm)Pack type Pack (kg) Part No.

1.2 Spool 13 720912

1.6 Spool 13 720913

FcaW Wire Metal cored

8



Mild Steel

Metal-cor 5High efficiency Metal Cored Wire with excellent Operator Appeal.

Grade 4 Shipping Society Approvals.

Very Low Slag Formation.

Outstanding Low Temperature Impact Properties.

High Deposition efficiency.

High Deposition Rates.

Precision Layer Wound.

Classifications

AS 2203.1: eTD-GMp-W505A. CM1 H5.

eTP*-GMp-W505A. CM1 H5. ( *1.2mm only )

AWS/ASMe-SFA A5.18: e70C-6M H4



yield Stress. 460 MPa.


elongation 32%

CVN Impact Values 135J av @ -20°C.

135J av @ -40°C

80J av @ -60°C.

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Typical All Weld Metal Analysis*:


C Mn Si S

0.07 0.9 0.56 0.014

P Ni Cr

0.013 0.04 0.03

Approvals*:


Grade 3S, 4yS H5


Grade 4SA, 4ySA H5

Det Norske Veritas IV yMS H5

*with Argon + 20–25% CO2 shielding gas or equivalent.

Operating Data

All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive using Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L/min.

Wire Dia. (mm) Current Range (A) Voltage Range (V) electrode stickout eSO (mm)

Welding Positions

1.2 280–350 28–33 20–25 Flat

1.6 350–450 29–33 25–30 Flat

1.2 250–300 27–31 20–25 HV Fillet

1.6 300–380 27–31 25–30 HV Fillet

1.2 250–300 27–31 20–25 Horizontal

1.6 300–380 27–31 25–30 Horizontal



<3.5 mls of hydrogen / 100gms of deposited weld metal.


Argon + 20–25% CO2 or equivalent ISO14175: M21, M24

Packaging Data

Wire Dia. (mm)


Part No.

1.2 Spool 15 720552

1.6 Spool 15 720553

1.2 Autopak 230kg 720552A

1.6 Autopak 230kg 720553A


8



Mild Steel

Shield-cor 11Self-shielded flux cored wire


excellent tolerance to joint misalignment or-poor joint fit-up

Smooth rippled fillets with good edge wetting

Ideal for welding thin section mild and galvanised steels

Classifications

AS / NZS 2203.1: eTP-GNn-W500A. CM2

AWS / ASMe-SFA A5.20: e71T-11




elongation 22%

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C: 0.25 Mn: 0.70 Si: 0.40

Al: 1.65 S: 0.004 P: 0.007


15.0–20.0 ml of hydrogen / 100gm of deposited weld metal*

* For ‘as manufactured’ product using the recommended eSO lengths

Operating dataAll welding conditions recommended below are for use with semi-automatic operation and DC electrode negative only.

Dia. (mm)Current range (A) Voltage (V)

electrode stickout eSO (mm) Welding positions

1.2 150–200 16–18 15–20 Flat

1.2 130–180 16–18 15–20 HV Fillet

1.2 130–180 16–18 15–20 Vertical up

1.2 180–230 16–18 15–20 Overhead


Not required

Packaging data


1.2 Spool 15 720923

Shield-cor 15Self-shielded flux cored wire

For single pass applications only


excellent tolerance to joint misalignment or-poor joint fit-up

Smooth rippled fillets with good edge wetting

Ideal for welding thin section mild and galvanised steels

Classifications

AS / NZS 2203.1:eTPS-GNn-W500A. CM2 AWS / ASMe-SFA A5.20: e71T-14




elongation 21%

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C: 0.25

Mn: 0.70

Si: 0.40

Al: 2.10

S: 0.004

P: 0.007


15.0–20.0 ml of hydrogen / 100gm of deposited weld metal*

* For ‘as manufactured’ product using the recommended eSO lengths


Not required

Operating dataAll welding conditions recommended below are for use with semi-automatic operation and DC electrode negative only.

Dia. (mm) Current range (A) Voltage (V)electrode stickout eSO (mm) Welding positions

0.8 90–150 14–16 10–12 Flat

0.8 80–140 14–16 10–12 HV Fillet

0.8 60–120 14–16 10–12 Vertical up

0.8 60–120 14–16 10–12 Overhead

0.9 110–180 15–17 12–15 Flat

0.9 100–175 15–17 12–15 HV Fillet

0.9 80–150 15–17 12–15 Vertical up

0.9 80–150 15–17 12–15 Overhead

1.2 180–230 16–18 15–20 Flat

1.2 150–200 16–18 15–20 H-V Fillet

1.2 130–180 16–18 15–20 Vertical

1.2 130–180 16–18 15–20 Overhead

Packaging data


0.8 100 spool 0.45 x (4 / ctn)

721956

0.8 200 handispool 4.5 721923

0.9 100 minispool 0.45 x (4 / ctn)

721976

0.9 200 handispool 4.5 721924

1.2 200 handispool 4.5 720302

FcaW Wire Self Shielded

8



Mild Steel

outershield 70A wire with excellent bead wetting, low spatter and fast follow. especially recommended for applications requiring deep penetration. For use in the down-hand and horizontal positions.

Classifications

AS 2203.1: eTD-GCp-W502A. CM1.H10, AWS A5.20: e70T-1


1.6 22.68 Coil eD012782

2.0 22.68 Coil eD012785

outershield 71MXDesigned and manufactured in Australia, Outershield 71MX is an all positional Rutile based Microalloyed electrode, providing excellent operator appeal, producing sound welds, with a clean surface finish under mixed gas.

Classifications

AWS. A5.20 e71T-1M H8, e71T-9M-H8 & e71T-12M H8


1.2 13 033502

1.6 13 033506

outershield 71cXDesigned and manufactured in Australia, Outershield 71CX is an all positional rutile based micro-alloyed electrode. 71CX provides an extremely smooth arc transfer, with excellent “ease of use” making good out of position welds with a clean surface finish under 100% CO2 shielding gas.

Classifications

AWS. A5.20 e71T-1 H8, e71T-9 H8 & e71T-12 H8

Size (mm) Weight (kg) Product No

1.2 13 033602

1.6 13 033606


outershield Mc710Metal cored wire having good deposition rate, excellent operator appeal with minimal slag and spatter. Dip transfer mode can be used for positional welding. Suitable for automatic applications including robotic welding.

Classifications

AS 2203.1: eTP-GMp-W503A.CM1.H10; AWS A5.20: e71T-1


1.2 15 Readi reel 033101

1.6 15 Coil 033102

outershield Mc710-HFor welding with high efficiency in all positions. excellent arc characteristics give outstanding operator appeal. Little slag and spatter, fast travel speed and excellent wire feeding “robotic” quality. Superior on scale plate, good resistance to porosity. Very good mechanical properties (CVN >47J @ -30°C). Superior product consistancy with optimal alloy control

Classification

AWS. A5.18: e70C-6M H4


1.6 200 941937

outershield Mc460VD-HMetal Cored wire for welding with high efficiency. especially for vertical down welding in thin plate. excellent Arc characteristics give outstanding operator appeal. Little slag and spatter, fast travel speed, good wire feeding. Superior Product consistency with optional alloy control.

Classification

AWS. A5.18: e70C-6M H4


1.2 15 941859


8



Mild Steel


nR-152Designed primarily for single pass welds on carbon steel up to 5 mm maximum thickness. especially suited for the welding of galvanised and zinc coated steels.

Classifications

AS 2203.1: eTPS-GNn-W500A.CM2; AWS A5.20: e71T-GS


1.7 22.68 Coil eD012186

nR-211-MPGeneral purpose all position wire. Smooth spray arc is easy to control with good visibility, low heat and glare. Suitable for sheetmetal, mild steel, galvanised and zinc coated steels up to 12 mm thickness (8 mm for 0.9 and 1.2 mm sizes).

Classifications

AS 2203.1: eTP-GNn-W500A.CM2.H15; AWS A5.20: 71T-11


0.9 4.54 Spool eD016354

1.2 4.54 Spool eD016363

1.2 11.34 Readi reel eD030638

1.7 6.0* Coil KC211176MP

1.7 12.5 Spool KC2111712MP

2.0 6.0* Coil KC211206MP

2.0 25 Coil KC211205MP

2.0 12.5 Spool KC2112012MP

*4 per box

nR-212The operating characteristics of NR 212 are similar to those of NR 211MP. It has the ability to handle poor fit up with very little tendency for burn through on sheetmetal and can be used on galvanised and mild steel over 12 mm thickness.

Classifications

AS2203.1; eTP-GNn-W500A. G.H10: AWS A5.20; e71TG-G

Size (mm) Carton (kg) Part No.

1.2 11.34 eD030639

1.7 11.34 eD030642

2.0 11.34 eD030646

nR-232General purpose smooth running wire producing high deposition rates in all positions. excellent choice for out of position welding requiring high productivity and good impact properties.

Classifications

AS 2203.1: eTP-GNn-W503A.CM1.H15; AWS A5.20: e71T-8


1.7 6.0* Coil eD012518

1.7 11.34 Coil eD030634

1.7 22.68 Coil eD012519

2.0 6.0* Coil eD012525

2.0 11.34 Coil eD030647

2.0 22.68 Coil eD012526

*4 per box

nR-233NR-233 is an advanced technology, self-shielded flux-cored electrode designed for high deposition rate welding - even when welding out-of-position in seismic and non-seismic structural steel applications. It is also great for fillet welding for ship and barge fabrication. The electrode is welder-friendly, making it easier to pass tough qualification tests and deposit great looking beads.

Classification AWS. e71T-8


1.6 11.34 eD030934

1.8 11.34 eD031030

nR-311General purpose wire for high deposition rates, fast travel speeds and good penetration in the flat and horizontal positions.

Classifications

AS 2203.1: eTD-GNn-W500A. CM2; AWS A5.20: e70T-7


2.0 6 Coil KC311206

2.4 25 Coil KC3112425

2.8 25 Coil KC3112825

*4 per box

nS-3Mextremely high deposition rates. Has low penetration which makes it particularly useful for poor fit up. Can be used for both single and multiple pass welds.

Classifications

AS 2203.1: eTD-GNp-W500A.CM2.H15; AWS A5.20: e70T-4


2.0 12.5 Coil KCNS32012

2.0 25 Coil KCNS32025

2.4 25 Coil KCNS32425

3.0 25 Coil KCNS33025

8



Mild Steel

comweld lW1Copper coated, low carbon steel rod for gas tungsten arc welding applications

Green end tip for instant identification

Ideal for root pass welding applications where tough and ductile welds are produced

Classifications

AS / NZS 1167.2: R4 AWS / ASMe-SFA A5.18: eR70S-4

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Typical rod analysis (%)

C: 0.08 Mn: 1.16 Si: 0.75

S: 0.010 P: 0.015 Fe: Balance

Packaging data

Rod Size (mm) Weight (kg), Pack type Approx No. (rods / kg) Part No.

1.6 x 750 5 plastic pack 84 321411

2.4 x 750 5 plastic pack 34 321412

Joining process

Gas (fusion) and gas tungsten arc (TIG) welding


Argon Welding Grade

tIG

comweld Super SteelLow carbon steel filler rod for gas tungsten arc (TIG) welding

Triple deoxidised for superior weld deposit quality and resistance to porosity

end stamped with AWS class ‘eR70S-2’

Ideal for TIG welding rusty or mill scaled plates and pipes and the root pass welding of pipes, tanks and heavy walled joints

Classifications


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C: 0.06% Mn: 1.08% Si: 0.52%

Ti: 0.08% Zr: 0.07% Al: 0.08%

S: 0.007% P: 0.008% Fe: Balance

Packaging data


1.6 x 915 5 cardboard tube* 70 321370

2.4 x 915 5 cardboard tube* 31 321373

*Resealable

Joining process

Gas tungsten arc (TIG) welding


Argon Welding Grade

comweld lW1-3Copper Coated, Low Carbon Steel Rod for Gas TIG & Oxy Welding Applications.

end stamped with ‘eR70S-3’ for easy I.D.

Resealable 5kg cardboard tube.

Classifications

AS 1167.2: R3.

AWS/ASMe-SFA A5.18: eR70S-3.

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Joining Process

Gas (Fusion) and Gas Tungsten Arc (TIG) welding.

Typical Rod Analysis

C Mn Si S P Fe

0.07 1.1 0.5 0.012 0.015 bal

Packaging Data

Rod Size (mm) Pack Weight/Type Approx. Rods/kg Part No.

1.6 x 1000 5kg Pack 64 321423

2.4 x 1000 5kg Pack 29 321424




elongation 30%

CVN Impact Values 100 J av @ -20°C

8



Mild Steel

tIG

comweld lW1-6Copper coated, low carbon steel rod for gas TIG and oxy welding applications

end stamped with ‘eR70S-6’ for easy ID

Recommended for the TIG welding of steel pipes, plates and castings with a tensile strength in the 500 MPa class

Classifications


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C: 0.07 Mn: 1.55 Si: 0.88

S: 0.012 P: 0.015 Fe: Balance

Packaging data


1.6 x 1000 cardboard pack 64 321417

2.4 x 1000 cardboard pack 29 321418

Joining process



Argon Welding Grade

8



Mild Steel

Submerged arc Wire

l-50Recommended for high speed, single pass welding on mild steel 12 mm or thinner because it gives better wetting action, straighter bead edges and better slag removal. Resists porosity due to rust or mill scale.

Classifications

AS 1858.1: eM13K; AWS A5.17: eM13K


2.0 27.2 Coil eD011335

2.4 27.2 Coil eD011328

3.2 27.2 Coil eD011323

l-60Primarily for multiple pass welding on steel under 25 mm thick using Lincoln 700 series fluxes.

Classifications

AS 1858.1: eL12; AWS A5.17: eL12


2.0 30 Coil KC602030

2.4 30 Coil KC602430

3.2 30 Coil KC603230

4.0 30 Coil KC604030

2.4 600 Bulk reel KC6024600

3.2 600 Bulk reel KC6032600

4.0 600 Bulk reel KC6040600

l-61General purpose wire recommended for both single pass welding with Lincoln 700 series fluxes and multiple pass welding with most Lincoln 800 series fluxes.

Classifications

AS 1858.1: eM12K; AWS A5.17: eM12K


2.0 30 Coil KC612030

2.4 30 Coil KC612430

3.2 30 Coil KC613230

4.0 30 Coil KC614030

4.8 30 Coil KC614830

2.4 600 Bulk reel KC6124600

3.2 600 Bulk reel KC6132600

4.0 600 Bulk reel KC6140600

l-S3Designed for use with 880M or 8500 flux. Produces 480 MPa minimum tensile strength and good low temperature impacts at higher deposition rate procedures and after stress relief. Typically used for off-shore drilling platform leg fabrication and similar.

Classifications

AS 1858.1: eMH12K; AWS A5.17: eH12K


2.4 30 Coil 030401

3.2 30 Coil 030402

4.0 30 Coil 030403

8



Mild Steel

860 For multiple pass welding. Has excellent operating characteristics and produces good impact properties when used with L60 and L61 wires.

Classifications AS 1858.1: FMM

Weight (kg) Part No.

Bags 25 KC860025

Drums 260 KC860260

880 For multi-pass welding with stainless steel electrodes, solid low alloy steel electrodes containing a min. 0.20% Si and Lincoln’s LAC series of low alloy flux cored electrodes. Not recommended for single arc AC welding or as a general purpose flux.

Classifications AS 1858.1: FBL


Bags 25 KC880025

Drums 260 KC880260

880MSuitable for multi-pass welding with solid carbon steel and low alloy steel electrodes. Produces excellent mechanical properties, including CTODs and low temperature impacts.



Bags 25 KC880025M

Drums 220 KC880220M

882For multiple pass welding with solid carbon and low alloy steel wires. Produces excellent low temperature impact properties when used with L61 wire.



Bags 25 KC882025

Drums 250 KC882250

8500Basic flux recommended for single and multiple pass welding with LS3 wire when excellent mechanical properties including low temperature impacts and CTODs are required.



Drums 220 KC8500220

960A low cost general purpose flux for full and semi-automatic single and multiple pass butt and fillet welding. Welds have good impact strength and good slag removal.

Classifications AS 1858.1: FMM


Drums 25 KC960025

Submerged arc Flux

761Recommended for single and some multiple pass welding. Provides excellent resistance to cracking. Slower freezing slag gives good appearance on large, flat fillet welds. excellent impact properties can be produced when used with L61 wire.

Classifications AS 1858.1: FGH


Bags 45 KC761045

Drums 250 KC761250

780excellent performance characteristics, including very good slag removal make this flux suitable for all general purpose single run and some multiple pass applications. The faster freezing slag of 780 minimises spilling in circumferential welding applications.

Classifications AS 1858.1: FGH


Bags 25 KC780025

Drums 280 KC780280

781Recommended for high speed single pass welding on clean plate and sheet steel. The ‘fast-follow’ characteristics of 781 allow uniform welds to be made at high speeds without undercut or voids.

Classifications AS 1858.1: FSH


Bags 25 KC781025

Drums 280 KC781280

St-100ST-100 is an alloy flux specifically for use with solid stainless steel wires. Contains chromium additions to compensate for chromium lost from the wire during transfer through the welding arc.

Classifications

AS 1858.1: FMMA (2Cr)


Bags 25 KCST100025

8Consumables



Ferrocraft 61ni H4 Now in Hermetically sealed 3kg cans

Highly basic, e4818-G / e7018-G type hydrogen controlled electrode

Very low “H5 / H4” diffusible hydrogen class

C-Mn-Ni weld deposit for reliable impact properties to -50°C

Batch number identification

Recommended for the critical welding of-C-Mn, microalloyed and low alloy structural steels in the 350–450 MPa yield strength class

Applications include the all positional (except vertical-down) fillet and butt welding of pressure vessels, offshore platforms, pipes, earth-moving equipment

Classifications

AS / NZS 1553.2: e4818-G AWS / ASMe-SFA A5.5: e7018-G

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elongation 27%

CVN impact values 130J av @ -20°C 80J av @ -40°C 60J av @ -50°C


C Mn Si Ni S P

0.07 1.20 0.25 0.9 0.007 0.012


electrode Approx. (rods / kg)

Current Range (A)


2.5 350 53 80–110 3 12 (4 x 3) 611812

3.2 350 26 110–145 3 12 (4 x 3) 611813

4.0 350 17 140–200 3 12 (4 x 3) 611814

Ferrocraft 61Ni H4i is formulated to operate with AC (min 70 OCV), DC+ or DC- polarity. The preferred polarity for fillet welding and fill and capping passes is DC+.




Approvals

Lloyds Register of Shipping Grade 3, 3yH5



Low Alloy

MMa electrodes

8



Low Alloy

alloycraft 80-b2Improved high strength, low alloy steel electrode

Advanced flux coating

Very low “H5” diffusible hydrogen class

550 MPa tensile class


Recommended for the all positional (except vertical-down) welding of chromium and chromium – molybdenum bearing steels as-used in elevated temperature applications

Hermetically sealed cans

Classifications

AS / NZS 1553.2: e5518-B2 AWS / ASMe-SFA A5.5: e8018-B2 H4

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0.2% Proof stress 570 MPa


elongation 24%


C: 0.08 Mn: 0.82 Si: 0.39 P: 0.015

Mo: 0.65 Cr: 1.40 S: 0.013

Packaging and operating data — AC (min. 70 OCV) DCeP (DC+) or DCeN (DC-) polarity


Current range (A)

Packet (kg)

Carton (kg)

Part No.Size (mm) Length (mm)

2.5 350 22 65–100 3 12 (3 x 4) 611922

3.2 350 15 105–150 3 12 (3 x 4) 611923

4.0 350 8 145–200 3 12 (3 x 4) 611924




MMa electrodes

alloycraft 70-a1Hermetically sealed cans

Improved high strength, low alloy steel electrode

Advanced moisture resistant flux coating

Very low ‘H5’ diffusible hydrogen class


Recommended for DC welding applications

Batch Numbered for identification

Classifications

AS /NZS 1553.2: e4818-A1. H5R AWS/ASMe-SFA A5.5: e7018-A1 H4R.

All positional - except vertical down

■

■

■

■

■

■

■




elongation 25%.


C Mn Si Mo S P

0.03 0.77 0.37 0.53 0.013 0.015

Packaging and Operating Data — AC (min 75 OCV), DC+ or DC- polarity.

electrodeApprox. Rods/kg

Current Range (A) Can

Carton (kg) Part No.Size (mm) Length (mm)

*2.5 350 42 65–100 3kg 12 (3 x 4) 611842

*3.2 350 26 95–150 3kg 12 (3 x 4) 611843

*4.0 350 17 145–220 3kg 12 (3 x 4) 611844

# -Alloycraft 70-A1 is formulated to operate with AC (min 70 OCV), DC+ or DC- polarity. The preferred polarity for DC welding is DC+.

*Non-stock item available on indent only.


3.0–3.5 mls of hydrogen / 100gms of deposited weld metal .

Approvals

Lloyd’s Register of Shipping Grade 3, 3yH5.

American Bureau of Shipping Grade 3H5, 3y.

Det Norske Veritas Grade 3yH5.

8



Low Alloy

MMa electrodes

alloycraft 80-c1Hermetically sealed cans



550 MPa tensile class, reliable impact toughness to -60°C


Suitable for the full or under matching strength welding of high strength nickel bearing steels as used for low temperature applications

Classifications

AS / NZS 1553.2: e5518-C1 AWS / ASMe-SFA A5.5: e8018-C1 H4

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■

■

■

■


0.2% Proof Stress 550 MPa


elongation 26%


Packaging and operating data — AC (minimum 70 OCV) DC+ or DC- polarity


Current range (A)

Packet (kg)

Carton (kg)


3.2 350 22 110–145 3 12 (3 x 4) 611833

4.0 350 15 140–200 3 12 (3 x 4) 611834

5.0 350 8 190–270 3 12 (3 x 4) 611835

Alloycraft 80-C1 is formulated to operate with AC (min 70 OCV), DC+ or DC- polarity. The preferred polarity for DC welding is DC+.


C: 0.05 Mn: 1.1 Si: 0.38

Ni: 2.46 S: 0.013 P: 0.015

Typical Diffusible hydrogen levels to AS 3752



alloycraft 90-b3Hermetically sealed cans





Recommended for the all positional (except vertical-down) welding of Cr-Mo and Cr-Mo-V bearing steels as used for high temperature applications

Classifications

AS / NZS 1553.2: e6218-B3 AWS / ASMe-SFA A5.5: e9018-B3 H4

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■

■

■

■

■




elongation 20%


C: 0.08 Mn: 0.85 Si: 0.35

Mo: 1.05 Cr: 2.20 S: 0.013

P: 0.015

Packaging and operating data AC (min. 70 OCV) DCeP (DC+) or DCeN (DC-) polarity


Current range (A)

Packet (kg)

Carton (kg)


3.2 350 15 105–150 3 12 (3 x 4) 611963

4.0 350 8 145–200 3 12 (3 x 4) 611964

Typical Diffusible hydrogen levels to AS 3752

3.0–3.5 ml of / 100 gm of deposited weld metal*


8



Low Alloy

alloycraft 110Hermetically sealed cans


Low “H5” diffusible hydrogen class



Applications include the full strength welding of high strength steels, including Bisalloy 80, uSST1 and T1A, welten 80, Hy80, AS2074 Grade L6A and ASTM A533 type A, A514 and A517 grades used in structural transport, mining and earthmoving applications

Classifications

AS / NZS 1553.2: e7618-M AWS / ASMe-SFA A5.5: e11018M H4

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■

■

■




elongation 22%




rods / (kg)Current range (A)

Packet (kg)

Carton (kg)


3.2 350 22 110–145 3 12 (3 x 4) 611893

4.0 350 15 140–200 3 12 (3 x 4) 611894

Alloycraft 110 is formulated to operate with AC (min 70 OCV), DC+ or DC- polarity. The preferred polarity for DC welding is DC+.


C Mn Si Ni Mo Cr

0.07 1.5 0.45 2.1 0.4 0.2




alloycraft 90Hermetically sealed cans





Applications include the full or under matching strength welding of high strength steels, including Bisalloy 60, 70 and 80, Welten 60 and 80, AS2074 Gr L6, Comsteel 023 / 026. ASTM A514 and A517 used in structural, transport, mining and earthmoving applications

Classifications

AS / NZS 1553.2: e6218M AWS / ASMe-SFA A5.5: e9018M H4

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■

■

■

■

■




elongation 26%




rods / kgCurrent range (A)

Packet (kg)

Carton (kg)


3.2 350 22 110–145 3 12 (3 x 4) 611873

4.0 350 15 140–200 3 12 (3 x 4) 611874

5.0 350 10 190–270 3 12 (3 x 4) 611875

Alloycraft 90 is formulated to operate with AC (min 70 OCV), DC+ or DC- polarity. The preferred polarity for DC welding is DC+.





C Mn Si Ni Mo

0.07 1.0 0.40 1.6 0.3

MMa electrodes

8



Low Alloy

autocraft Mn-MoA manganese molybdenum steel wire for the GMA welding of higher strength steels


550 MPa tensile class weld deposits

Suitable for the all positional fillet and butt welding of a wide range of higher strength steels, particularly those used in the fabrication of pressure vessels, boilers and pipelines

Classifications

AWS / ASMe-SFA A5.28: eR80S-D2

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■

■

■


Argon20–25% CO2



elongation 24%

CVN impact values 80J av @ +20°C


C Mn Si Mo S P

0.08 1.73 0.65 0.45 0.011 0.017





0.9 16–28 3.5–15 70–230 Spool 15 720049

1.2 18–32 3.5–15 120–350 Spool 15 720052

* Spool (ø300 mm)




Argoshield® 52

Argoshield® 54

Stainshield®

Welding Grade CO2

GMaW Wire

autocraft nicrMoA low alloy steel wire for the GMA welding of high strength steels


760 MPa tensile class weld deposits

Suitable for the all positional fillet and butt welding of a wide range of high strength steels, particularly quenched and tempered types such as Bisalloy 80, uSS-T1 types and Welten 80C etc.

Classifications

AS / NZS 2717.1: eSMG-GC / M-W769AH AWS / ASMe-SFA A5.28: eR110S-G

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■

■

■


Argon 1–3% O2

Argon 20–25% CO2


Tensile strength

790 MPa 770 MPa

elongation 17% 21%

CVN impact values

130J @ -29°C

80J @ -51°C

72J @ -29°C

50J @ -51°C


C: 0.08 Mn: 1.40 Si: 0.60

Ni: 1.40 Cr: 0.40 Mo: 0.25

V: 0.10%





1.2 18–32 3.5–15 120–350 Spool 15 720053

* Spool (ø300 mm)




Argoshield® 52

Argoshield® 54

Stainshield®

Welding Grade CO2

8



Low Alloy

autocraft crMo1A low alloy steel wire for the GMA welding of matching Cr-Mo-steels

Recommended for the GMA welding of-1 / 2Cr-1⁄2Mo, 1Cr-1⁄2Mo and 1 1⁄4Cr-1⁄2Mo steel pipes, plates and castings

Classifications

AS / NZS 2717.1: eSB2-GM-W559AH AWS / ASMe-SFA A5.28: eR80S-B2


Argon 1–3% O2



elongation 20%


Post weld heat treated at 620°C as required by AWS A5.28

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■


C: 0.09 Mn: 0.60 Si: 0.60

Cr: 1.30 Mo: 0.50 P: 0.015

S: 0.010 Fe: Balance


Dia. (mm) Voltage (V) Wire feed speed (m / min)

Current Range (A)

Pack type* Pack weight (kg)

Part No.

1.2 18–32 3.5–15 120–350 Spool 15 720029

* Spool (ø300 mm)




Argoshield® 52

Stainshield®

GMaW Wire

8



Low Alloy

FcaW Wire

Smoothcor™ 811K2

DescriptionSmoothCor™ 811K2 is a rutile type flux cored wire designed to provide excellent low temperature impact toughness. It is suitable for use with both Ar / CO2 or CO2 shielding gas and can be used in all positions including downhand, vertical up and overhead. Designed for single and multi pass welding, SmoothCor™ 811K2 deposits a weld metal containing approximately 1.5% nickel. The nickel content of the weld metal ensures excellent impact properties at temperatures below -60ºC with radiographic quality which is consistently high. The very low H4 hydrogen class ensures superior crack resistance. A rutile based wire, SmoothCor™ 811K2 welds with a very smooth running, low spatter arc and a fine spray type transfer to give excellent weld pool control. With its excellent feedability and easy arc starting characteristics, SmoothCor™ 811K2 has excellent operator appeal.

applicationSmoothCor™ 811K2 is recommended for welding fine-grained low alloy steels intended for service at low temperatures and for matching strength on 490 MPa yield strength steels. It is also eminently suitable for welding fine-grained and quench and tempered steels where undermatching strength weld metal is desirable.

Welding Positions

Specifications

Flux Type Rutile

Classification AWS / ASMe-SFA A5.29 e81T1-K2 H4, e81T1-K2M H4

AS 2203.1 eTP-GCp-W559A.K2 H5

eTP-GMp-W559A.K2 H5


Grade 5y 40S H5

Det Norske Veritas Grade 4ySA H5


Grade 5yMS H5

Welding Current DC+



Argoshield® 52 or Ar+20–25% CO2 mixtures

Welding Grade CO2

Flow rate 15–20 L / min


Typical C Si Mn Ni

Argoshield® 52 0.05 0.45 1.15 1.54

CO2 0.04 0.38 1.07 1.54






Impact energy, CVN 125J av @ -29ºC 85J av @ -40ºC 76J av @ -60ºC

120J av @ -29ºC 80J av @ -40ºC 73J av @ -60ºC

PWHT*

using Argoshield® 52 using CO2




Impact energy, CVN 75J av @ -29ºC 65J av @ -40ºC 50J av @ -60ºC

70J av @ -29ºC 60J av @ -40ºC 45J av @ -60ºC

* PWHT 625ºC 2 hours

Diffusible Hydrogen



Packaging Data

Dia. (mm) 1.2 1.6

Part No. 10811K212 10811K216


Weight (kg) 15 15

Welding Parameters


Vertical up Overhead

Dia. (mm) 1.2 1.6 1.2 1.6 1.2 1.6

Current Range (A) 150–290

180–400

150–250

180–300

150–250

180–310

Voltage (V) 23–30 25–34 22–26 21–27 23–26 22–27


15–20 20–25 15–20 20–25 15–20 20–25

Deposition Data

Dia. (mm)

Current (A)

Voltage (V)

Wire Feed Speed (m / min) Approx.


efficiency (%)

1.2 150 28 5.08 1.91 86

210 29 7.62 2.86 86

250 30 10.16 3.86 87

290 33 12.70 4.85 87

330 34 15.24 5.76 87

1.6 190 27 3.81 2.77 87

300 30 6.35 4.63 87

365 33 7.62 5.58 86

410 33 8.89 6.35 88

Gas assisted

8



Low Alloy

FcaW Wire

Smoothcor™ 115

DescriptionSmoothCor™ 115 is a basic type flux cored wire designed for the welding of high tensile low alloy steels. It is suitable for use with both Ar / CO2 or CO2 shielding gas and can be used in both the flat and horizontal position. Designed for single and multi pass welding, SmoothCor™ 115 deposits a weld metal containing approximately 2.25% nickel, 0.5% molybdenum and 0.3% chromium which, apart from having good tensile properties, is extremely tough and ductile. The very low H4 hydrogen class ensures superior crack resistance. The wire produces weld metal of the highest radiographic and metallurgical quality. SmoothCor™ 115 welds with particularly stable running characteristics, a minimum amount of spatter and easy slag removal for this class of wire. Feedability is excellent.

applicationSmoothCor™ 115 is recommended for welding a range of high strength fine-grained structural steels, low temperature steels and quench and tempered steels. Produces matching strength and hardness on 690 MPa yield strength and 230 HB steels e.g. AS 3597 grade 700, ASTM A514. Weld deposits are resistant to cracking in heavy sections or under high restraint.

Welding Positions

Specifications

Flux Type Basic

Classification AWS / ASMe-SFA A5.29 e110T5-K4 H4 e110T5-K4M H4

AS 2203.1 eTD-GMp-W769A.K4 H5 eTD-GCp-W769A.K4 H5

Approvals* American Bureau Shipping

AWS A5.29 e110T5-K4M

Welding Current DC+

* With Ar / CO2 shielding gas

Recommended Shielding Gases

Argoshield® 52 or Ar+20–25% CO2 mixtures

Welding Grade CO2

Flow rate 15–20 L / min


Typical C Si Mn Ni Mo Cr

Argoshield® 52 0.07 0.38 1.55 2.29 0.44 0.27

CO2 0.06 0.30 1.40 2.29 0.44 0.22







Diffusible Hydrogen



Packaging Data

Dia. (mm) 1.2 1.6

Part No. 1011512 1011516


Weight (kg) 15 15

Welding Parameters

Dia. (mm) 1.2 1.6

Current Range (A) 150–290 180–400

Voltage (V) 23–30 25–34


15–20 20–25


Deposition Data

Dia. (mm)

Current (A)

Voltage (V)



efficiency (%)

1.2 170 29 7.24 3.20 96

250 30 11.91 4.90 91

300 32 15.39 6.44 92

300 30 5.74 4.45 92

1.6 400 32 9.37 7.30 92

450 32 10.72 8.40 93

Gas assisted

8



Low Alloy

FcaW Wire

Verti-cor 81ni1A higher strength low alloy steel, rutile type flux cored wire

Formulated for use with argon +20 –25% CO2 shielding gases




A nominal 1% nickel steel deposit of the 550 MPa tensile class

Typical applications include the under matching strength fillet welding of Bisalloy 60, 70 and 80 quenched and tempered steels

Classifications

AS / NZS 2203.1: eTP-GMp-W554A. Ni1 H10

AWS / ASMe-SFA A5.29: e81T1-Ni1MH8





elongation 26%


■

■

■

■

■

■

■


C: 0.06 Mn: 1.35 Si: 0.35

Ni: 0.90 Ti: 0.035 B: 0.007

*using Argon +20–25% CO2




Operating data




Optimum amps Volts

Welding positions

1.2 250–300 27–31 20–25 280 31 Flat

1.6 350–400 27–31 25–30 360 31

1.2 230–280 26–30 20–25 260 28 HV Fillet

1.6 310–360 26–30 25–30 320 29

1.2 170–220 24–28 15–20 200 24 Vertical up

1.6 200–250 24–28 15–20 240 25

1.2 160–210 24–28 15–20 200 24 Overhead

1.6 190–240 24–28 15–20 220 24


Argoshield® 52

Packaging data

Dia. (mm) Pack type

Pack weight (kg)

Part No.

1.2 Spool 13 720390

1.6 Spool 13 720391

Gas assisted

8



Low Alloy

FcaW Wire Gas assisted

Verti-cor 81 ni1 H4Higher Strength Copper coated seamless Low Alloy, Rutile Type Flux Cored Wire.

Formulated for use with either Argon + 20–25% CO2 or CO2 shielding gases.

Versatile, All Positional Capabilities.

Outstanding Operator Appeal.

Low Fume Levels.

Precision Layer Wound.

Classifications

AS 2203.1: eTP-GC/Mp-W554A. Ni1 H5

AWS/ASMe-SFA A5.29: e81T1-Ni1M H4; e81T1-Ni1 H4


using Argon + 20–25% CO2

CO2

yield Stress 540 MPa 500 MPa

Tensile Strength

600 MPa 560 MPa

elongation 22% 23%

CVN Impact Values

85J av @ -40°C

75J av @ -50°C

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Approvals*


Grade 4y, 4yS H10.


Grade 4ySA H5.

Det Norske Veritas IV yMS H10.

*with Argon + 20–25% CO2 or CO2 shielding gases

Typical All Weld Metal Analysis

C Mn Si Ni


0.06 1.4 0.5 1.00%

using CO2

0.05 1.1 0.38 1.16%

Operating Data

All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L/min.

Wire Dia. (mm) Current Range (A) Voltage Range (V) CTWD Welding Positions

1.2 250–300 27–31 20–25 Flat

1.6 350–400 27–31 25–30 Flat

1.2 230–280 26–30 20–25 HV Fillet

1.6 310–360 26–30 25–30 HV Fillet

1.2 170–220 24–28 15–20 Vertical up

1.6 200–250 24–28 15–20 Vertical up

1.2 160–210 24–28 15–20 Overhead

1.6 190–240 24–28 15–20 Overhead


Typical Diffusible Hydrogen Levels to AS 3752

<3 mls of hydrogen / 100gms of deposited weld metal for as manufactured product using Argon +20–25% CO2 or CO2 .

Recommended Shielding Gas

Ar + 20–25% CO2 or equivalent

ISO14175: M21, M24

Welding Grade CO2 ISO14175: C1

Packaging Data

Wire Dia. (mm)


Part No.

1.2 Spool 15 720550

1.6 Spool 15 720551

8



Low Alloy

FcaW WireGas assisted

Verti-cor 91 K2A higher strength low alloy steel, rutile type flux cored wire formulated for use with argon +20–25% CO2 shielding gases



A nominal 1.5% nickel steel deposit of the 620 MPa tensile class

Typical applications include the full strength butt welding of Bisalloy 60 or the under matching strength fillet welding of Bisalloy 70 and 80 steels

Classifications

AS / NZS 2203.1: eTP-GMp-W629A. K2 H10

AWS / ASMe-SFA A5.29: e91T1-K2MH8


using Argon +20 –25% CO2



elongation 23%


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■

■

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■


C: 0.06 Mn: 1.30 Si: 0.50

Ni: 1.60 Ti: 0.035 B: 0.007

* using Argon +20–25% CO2




Operating data



Optimum amps Volts

Welding positions

1.2 250–300 27–31 20–25 280 31 Flat

1.6 350–400 27–31 25–30 360 31

1.2 230–280 26–30 20–25 260 28 HV Fillet

1.6 310–360 26–30 25–30 320 29

1.2 170–220 24–28 15–20 200 24 Vertical up

1.6 200–250 24–28 15–20 240 25

1.2 160–210 24–28 15–20 200 24 Overhead

1.6 190–240 24–28 15–20 220 24


Argoshield® 52

Packaging data

Dia. (mm)Pack type


1.2 Spool 13 720394

1.6 Spool 13 720396

8



Low Alloy

FcaW Wire

Verti-cor 91 K2 H4Copper coated seamless wire delivering very low H4 class hydrogen levels.

Higher Strength Low Alloy, Rutile Type Flux Cored Wire

Formulated for use with Argon + 20–25% CO2 .

Very low hydrogen status.

Low fume levels.

Classifications

AS 2203.1: eTP-GMp-W629A. K2 H5.

AWS/ASMe-SFA A5.29: e91T1-K2M H4



yield Stress 560 MPa


elongation 22%

CVN Impact Values >40J av @ -40°C

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■

Typical All Weld Metal Analysis*

C Mn Si Ni

0.05 1.3 0.3 1.2

*using Argon + 20–25% CO2 shielding gas

Typical Diffusible Hydrogen Levels to AS 3752:

<3.5 mls of hydrogen / 100gms of deposited weld metal *.

* for ‘as manufactured’ product using Argon + 20–25% CO2 shielding gas.

Operating Data

All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L/min.

Wire Dia. (mm) Current Range (A) Voltage Range (V) electrode stickout eSO (mm)

Welding Positions

1.2 250–300 27–31 20–25 Flat

1.6 350–400 27–31 25–30 Flat

1.2 230–280 26–30 20–25 HV Fillet

1.6 310–360 26–30 25–30 HV Fillet

1.2 170–220 24–28 15–20 Vertical up

1.6 200–250 24–28 15–20 Vertical up

1.2 160–210 24–28 15–20 Overhead

1.6 190–240 24–28 15–20 Overhead



Argon + 20–25% CO2 or equivalent ISO14175: M21, M24

Packaging Data

Wire Dia. (mm)


Part No.

1.2 Spool 15 720554

1.6 Spool 15 720555

Gas assisted

8



Low Alloy

FcaW Wire

Verti-cor 111 K3A high strength low alloy steel, rutile type flux cored wire

Formulated for use with argon + 20–25% CO2 shielding gases


A nickel molybdenum steel deposit of the 760 MPa tensile class

Typical applications include the full strength butt welding and fillet welding of Bisalloy 80 and similar quenched and tempered steels


Classifications

AS / NZS 2203.1: eTP-GMp-W768A. K3 H10

AWS / ASMe-SFA A5.29: e111T1-K3M H8





elongation 18%


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Typical all weld metal (AWM) analysis* (Wt%)

C: 0.06 Mn: 1.65 Si: 0.36

Ni: 2.05 Mo: 0.46 B: 0.004.

*using Argon +20–25% CO2



* For ‘as manufactured’ product using and electrode stickout eSO of 20 mm with 1.2 mm wire and 25 mm with 1.6 mm wire and mid-range current and Voltage (V) settings.

Operating data

All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argoshield® 52 shielding gas with a flow rate of 15–20 L / min.



Optimum amps Volts

Welding positions

1.2 250–300 27–31 20–25 280 31 Flat

1.6 350–400 27–31 25–30 360 31

1.2 230–280 26–30 20–25 260 28 HV Fillet

1.6 310–360 26–30 25–30 320 29

1.2 170–220 24–28 15–20 200 24 Vertical up

1.6 200–250 24–28 15–20 240 25

1.2 160–210 24–28 15–20 200 24 Overhead

1.6 190–240 24–28 15–20 220 24


Argoshield® 52

Packaging data

Dia. (mm) Pack

type

Pack weight (kg)

Part No.

1.2 PLW 15 721381

1.6 PLW 15 721382

Gas assisted

tensi-cor 110tXP H4Fully basic, high strength low alloy steel, Seamless Flux cored wire

Formulated for use with CO2 and Argon + 20–25% CO2

Premium quality weld deposits

“Very low H5” hydrogen status

For the crack free full strength butt welding of Bisalloy 80 and similar quenched and tempered steels

Seamless Copper Coated


Classifications

AS / NZS 2203.1:

eTD-GCn / p-W769A. K4 H5

eTD-GMn / p-W769A. K4 H5

AWS / ASMe-SFA A5.29: e110T5-K4





elongation 22%


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■

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Typical all weld metal (%)*

C Mn Si Ni Mo: Cr

0.08 1.50 0.40 1.90 0.4 0.3

*using CO2 shielding gas

Typical diffusible hydrogen levels to AS3752

1.5–2.0 ml of hydrogen / 100 gm of deposited

weld metal*

*For ‘as manufactured’ product using welding grade CO2 shielding gas

Operating data




Optimum amps Volts

Welding positions

1.6 300–350 28–32 25–30 320 29 Flat

2.4 400–450 28–32 25–35 450 32

1.6 280–330 27–31 25–30 300 28 HV Fillet

2.4 380–430 27–31 25–30 400 28

1.6 220–270 25–30 25–30 280 26 Vertical up

1.6 260–310 27–31 25–30 N / A N / A Horizontal

2.4 360–410 27–31 25–30 N / A N / A


Welding Grade CO2 and Argon + 20–25% CO2 or equivalent.

Packaging data

Dia. (mm)

Pack type Pack weight (kg)

Part No.

1.6 Spool 15 720387

2.4 Coil 25 720389

8



Low Alloy

outershield 81ni1-HProduces weld deposits exhibiting excellent low temperature impacts and CTOD values. Ideally suited to applications requiring superior mechanical properties in the as welded condition.

Classifications

AS 2203.1: eTP-GMp-W554. Ni1.H5; AWS A5.29: e81T1-Ni1


1.2 15 Readireel 941357

1.6 15 Readireel 942750*

*No spool adaptor required

outershield 91K2-HFor Hy-80, HSLA-80 and similar steels. Produces weld deposits exhibiting excellent low temperature impact values.

Classifications

AS 2203.1: eTP-GMp-W629A.K2.H5; AWS A5.29: e91T1-K2


1.2 11.34 Readireel

eD017708

1.6 11.34 Readireel

eD017709

outershield 690-HFor high strength steel grades like grade S690.Outstanding operators appeal. exceptional mechanical properties (CVN >50J @ -40°C). Good wire feeding. Superior product consistency with optimal alloy control.

Classifications

AWS. A5.29: e111T1-K3 MJ H4


1.2 15 942422

1.6 15 942828



Pipeliner nR-207Primarily used for hot, fill and cap pass welding on cross-country pipelines. It is designed to produce weld deposits exceeding 490 MPa tensile strength with excellent low temperature impact properties.

Classifications

AS 2203.1:eTP-GNn-W509A.Ni1.H15; AWS A5.29: e71T8-K6


2.0 6.0* Coil KC207206

*4 per box

Pipeliner nR-208P Similar to NR-207-H, but with higher strength. Produces weld deposits exceeding 80,000 psi yield strength with excellent low temperature impacts. Recommended for API Pipe Grade X80.

Classification

AWS. e91T8-G


2.0 6.0 KC208206

*4 per box

8



Low Alloy

tIG

comweld crMo 1Nominal 1.25% Cr 0.5% Mo steel TIG rod

end stamped with AWS class ‘eR80S-B2’ for-easy identification

For the gas tungsten arc (TIG) welding of matching Cr-Mo creep resistant steels for elevated temperature and corrosive service

Classifications

AS / NZS 1167.2: RB2 AWS / ASMe-SFA A5.28: eR80S-B2

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■

■


C: 0.09% Mn: 0.60% Si: 0.60%

Cr: 1.30% Mo: 0.50% P: 0.015%

S: 0.010% Fe: Balance

Packaging data

Rod Size (mm) Weight (kg), Pack type Approx. (rods / kg) Part No.

2.4 x 1,000 5 cardboard tube* 29 321379

*Resealable


Argon Welding Grade

Alushield® Light

comweld crMo 2Nominal 2.5% CR 1% Mo steel TIG rod

end stamped with AWS class ‘eR90S-B3’ for-easy identification

For the gas tungsten arc (TIG) welding of Cr-Mo and Cr-Mo-V creep resistant steels for elevated temperature and corrosive service

Classifications

AS / NZS 1167.2: RB3 AWS / ASMe-SFA A5.28: eR90S-B3

■

■

■


C: 0.08% Mn: 0.70% Si: 0.60%

Cr: 2.50% Mo: 1.00% P: 0.015%

S: 0.010% Fe: Balance

Packaging data

Rod Size (mm) Weight (kg) Pack type Approx. (rods / kg) Part No.

2.4 x 1,000 5 Cardboard tube*

29 321383

*Resealable


Argon Welding Grade

8



Low Alloy

Submerged arc Wire

l-70 Special purpose 0.5% Mo electrode recommended for multiple pass welding with 860 flux on 480 MPa tensile (stress relieved) applications when the use of Mo is not restricted. Also suitable for single pass welding with Lincoln 700 series fluxes.

Classification:

AS 1858.2: eA1; AWS A5.23: eA1


2.0 30 Coil KC702030

3.2 30 Coil KC703230

4.0 27.2 Coil eD012053

4.0 30 coil KC704030

4.0 600 Bulk reel spool

KC7040600

lac-b2Alloy cored wire designed for welding chromium-molybdenum steels having 1.25% Cr – 0.5% Mo or less.

Classifications

AS 1858.2: eCB2; AWS A5.23: eCB2


2.4 22.68 Coil eD010954

4.0 22.68 Coil eD010955

lac-M2Alloy cored wire designed to weld steels requiring 690 MPa yield strength (as welded or stress relieved) and 20 J minimum Charpy V-notch at -45°C.

Classifications

AS 1858.2: eCM2; AWS A5.23: eCM2


2.4 22.68 Coil eD010981

4.0 22.68 Coil eD010982

lac-ni2Alloy cored wire designed to weld weathering steels, 2.5% Ni steels, 3.5% Ni steels, and other steels requiring 480 MPa tensile strength (as welded or stress relieved) and excellent low temperature impact properties.

Classifications

AS 1858.2: eCNi2; AWS A5.23: eCNi2


2.4 22.68 Coil eD010986

Submerged arc Flux

Refer to page 376 for a listing of Submerged Arc Flux

8Consumables



Weldability of Stainless Steel

Stainless Steel

IntroductionStainless steels are a group of high alloy steels which contain at least 12% chromium. In general these steels are alloyed with a number of other elements which make them resistant to a variety of different environments.

In addition these elements modify the microstructure of the alloy which in turn has a distinct influence on their mechanical properties and weldability. Stainless steels can be broadly classified into five groups as detailed below:

Austenitic stainless steels which contain 12–27% chromium and 7–25% nickel.

Ferritic stainless steels which contain 12–30% chromium with a carbon content below 0.1%.

Martensitic stainless steels which have chromium content between 12–18% with 0.15–0.30% carbon.

Ferritic-austenitic (Duplex) stainless steels which contain 18–25% Chromium, 3–5% nickel and up to 3% molybdenum.

Martensitic-austenitic steels which have 13–16% chromium, 5–6% nickel and 1–2% molybdenum. The first three of these groups will be discussed in greater detail below.

austenitic stainless steelsThis is by far the largest and most important group in the stainless steel range. These steels which exhibit a high level of weldability are available in a wide range of compositions such as the 19/9 AISI 304 types, 25/20 AlSI 310 types and 19/12/2 AISl 316 types, etc which are used for general stainless steel fabrications, elevated temperature applications and resistance to pitting corrosion respectively.

As the name implies the microstructure of austenitic stainless steel consists entirely of fine grains of austenite in the wrought condition. When subjected to welding however, a secondary ferrite phase may be formed on the austenite grain boundaries, in the heat affected zone and in the weld metal. The extent of the formation of this secondary phase maybe dependent on the composition of the steel or filler material and the heat input during welding.

While delta ferrite formation can have negative effects on the resistance to corrosion and formation of sigma phase at operating

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■

■

■

■

temperatures between 500–900°C, delta ferrite in weld metal is necessary to overcome the possibility of hot cracking (tearing).

In general austenitic welding consumables deposit a weldment containing 4–12% delta ferrite. For special applications, i.e. when dissimilar steels are welded under conditions of high restraint, austenitic consumables having weld metal delta ferrite contents as high as 40% may be required. The delta ferrite content can be calculated using the procedure given at the end of this section with the aid of the Schaeffler diagram.

The carbon content of austenitic stainless steels is kept at very low levels to overcome any possibility of carbide precipitation, where chromium combines with available carbon in the vicinity of the grain boundaries to produce an area depleted in chromium and thus becomes susceptible to intergranular corrosion.

The titanium and niobium stabilised AISI 321 and 347 steels together with eLC (extra low carbon) grades are available to further overcome this problem.

Ferritic stainless steelsThese steels which contain 12–30% chromium with a carbon content below 0.10% do not exhibit the good weldability of the austenitic types. The steels which become fully ferritic at high temperatures and undergo rapid grain growth, leads to brittle heat affected zones in the fabricated product. No refinement of this coarse structure is possible without cold working and recrystallization. In addition, austenite formed at elevated temperatures may form martensite upon transformation which can cause cracking problems. The brittleness and poor ductility of these materials have limited their applications in the welded condition.

Ferritic stainless steels are also subject to intergranular corrosion as a result of chromium depletion from carbide precipitation. Titanium and niobium stabilised ferritic steels and steels with extra low interstitials (i.e. C,N) are available to overcome this problem.

As this material has a coefficient of expansion lower than that of carbon manganese steels, warpage and distortion during welding is considerably less. They are magnetic, however, and therefore subject to magnetic arc blow. Ferritic stainless steels cannot be hardened by conventional heat treatment processes.

8



Stainless Steel

Martensitic stainless steelsMartensitic stainless steels contain between 12–18% chromium with 0.15–0.30% carbon. Because of their composition these steels are capable of air hardening and thus special precautions should be taken during welding to overcome possible cracking. Cold cracking, as a result of hydrogen, which is experienced with low alloy steels can also occur in martensitic stainless steels and thus hydrogen-controlled consumables should be used.

Martensitic steels, because of their lower chromium content and responsiveness to heat treatment, have limited applications for corrosion resistance but are successfully used where their high strength and increased hardness can be utilised, e.g turbine blades, cutlery, shafts etc.

As in the case of ferritic stainless steels the martensitic types have a lower coefficient of expansion than mild steels and are magnetic.

Procedure for welding stainless steelsThe procedure for welding stainless steel does not differ greatly from that of welding mild steel. The material being handled, however, is expensive and exacting conditions of service are usually required which necessitate extra precautions and attention to detail.

Stainless steel can be welded using either AC or DC, using as short an arc as possible, to overcome any possibility of alloy loss across the arc. When using AC a slightly higher current setting may be required.

When welding in the flat position stringer beads should be used and if weaving is required this should be limited to 2 times the electrode diameter. The heat input, which can adversely affect corrosion resistance and lead to excessive distortion, should be limited by using the correct electrode diameter to give the required bead profile and properties at the maximum travel speed In all cases the heat input should be limited to 1.5 kJ/mm.

Specific points to be noted for the different stainless steel types are given below.

austenitic steels

As austenitic stainless steels have a coefficient of expansion 50% greater than carbon manganese steels, distortion and warping can be a problem. Welding currents should therefore be kept as low as possible with high travel speeds, tacking should be carried out at approximately half the pitch used for mild steel and welding should be balanced and properly distributed. Preheating should not be applied and post-weld heat treatment of this material is seldom required after welding.

Austenitic stainless steels are normally welded with electrodes of matching composition to the base material. See table at the end of this section for specific recommendations.

Ferritic steels

The need for preheating is determined to a large extent by composition, desired mechanical properties, thickness and conditions of restraint. Preheat, when employed, is normally no more than 200°C.

Some ferritic stainless steels can form chromium carbides at the ferrite grain boundaries during welding. For these types a post-weld heat treatment of 700–800°C will restore the corrosion properties of the material.

For mildly corrosive applications, and where the presence of nickel bearing weld metal can be tolerated, an austenitic stainless steel

electrode is recommended. This would tend to alleviate many of the toughness problems of ferritic stainless steel weld metal and could obviate the need for post-weld heal treatment (i.e. in many cases the narrow notch sensitive heat affected zone could be tolerated).

Martensitic steels

These steels require a preheat of 200–300°C followed by slow cooling after welding. This should be followed if possible by a post-weld heat treatment.

Austenitic stainless steel electrodes are normally used for welding this material.

Procedure for welding clad steelsThe use of a clad-material, consisting of a mild or low alloy steel backing faced with stainless steel, usually from 10–20% of the total thickness, combines the mechanical properties of an economic backing material with the corrosion resistance of the more expensive stainless steel facing. This facing usually consists of austenitic stainless steel of the 18% chromium 8% nickel or 18% chromium 10% nickel type, with or without additions of molybdenum, titanium and niobium, or a martensitic stainless steel of the 13% chromium type.

The backing should be welded first at the same time making sure that the root run of the mild steel electrode does not come into contact with the alloyed cladding. This can be achieved in two ways, either by cutting the cladding away from both sides of the root, or welding with a closed butt preparation and a sufficiently large root-face.

After welding the mild steel side the root run should be back grooved and the stainless clad side welded with a stainless electrode of matching composition. The use of a more highly alloyed electrode (e.g. Smootharc S309) for the initial root run on the clad side is first advisable. This applies particularly to preparations in which the back-cutting of the cladding makes pick-up from the mild steel difficult to avoid. For the best resistance to corrosion, at least two layers of stainless weld metal on the clad side are recommended.

The welding of material which is clad or lined with 13% chromium (martensitic) steels usually requires a preheat of 250°C and the use of austenitic electrodes of appropriate type. Welding should be followed by a post-weld heat treatment, though satisfactory results can be obtained without these precautions if, during welding, heat dissipation is kept to a minimum. This will help to temper the heat-affected zone by utilising the heat build-up from adjacent weld runs.

Procedure for welding stainless steels to mild or low alloy steelsSituations frequently arise when it becomes necessary to weld an austenitic stainless steel to a mild or low alloy ferritic steel. In selecting a suitable electrode, the effect of dilution of the weld metal by the base material must be considered.

The weld metal may be diluted from 20–50% depending on the welding technique used, root runs in butt joints being the most greatly affected since all subsequent runs are only in partial contact with the base material and share dilution with neighbouring runs.

If a mild or low alloy steel electrode is used to weld stainless to mild steel, the pick up of chromium and nickel from the stainless steel side to the joint could enrich the weld metal by up to 5% chromium and 4% nickel. This would result in a hardenable crack-sensitive weld.

8



Stainless Steel

Austenitic stainless steel electrodes are therefore used for joining dissimilar metal combinations of stainless materials to mild and low alloy ferritic steels. However, the correct type, which has sufficient alloying to overcome the effects of dilution from the mild or low alloy steel side of the joint, must be selected since if the weld metal does not start with an adequate alloy content the final weld may contain less than 17% chromium and 7% nickel. Weld metal with lower chromium and nickel contents are crack sensitive. Also if as a result of dilution the weld metal is incorrectly balanced with nickel and chromium, there may not be sufficient ferrite present in the weld metal to prevent fissuring and subsequent cracking.

For these reasons the austenitic stainless steel electrodes such as Smootharc S319, etc should be used as their composition has been specially balanced to ensure that the total alloy content is adequate to accommodate dilution effects and their ferrite content is sufficient to provide high resistance to hot cracking.

effects of alloying elements and impurities in stainless steels

carbon (c)A strong austenite former.

Added to some high-strength alloys for hardening and strengthening effects.

Manganese (Mn)Austenite former.

Silicon (Si)A ferite former.

used to increase the corrosion resistance of austenitic steels.

used to improve high-temperature scaling resistance.

used to improve resistance of high-temperature steels to carburization.

Promotes wetting by weld metal at 0.8–1.0%.

chromium (cr)A ferrite former.

Primary contributor to resistance to scaling and corrosion.

12% chromium minimum essential for passivation.

nickel (ni)An austenite former.

Provides good low temperature toughness

used to improve the general corrosion resistance against non-oxidizing liquids.

Sometimes added in small amounts to straight chromium grades to improve the mechanical properties.

Molybdenum (Mo)A ferrite former.

used to improve high-temperature strength and creep resistance

used to improve general corrosion resistance of steels in non- oxidizing media, and the resistance to pitting corrosion in all media.

copper (cu) used to improve corrosion resistance of stainless steel in environments which are reducing rather than oxidizing.

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niobium (nb) A strong carbide former. used to stabilize austenitic stainless steels against the harmful precipitation of chromium carbides in the range 480–820°C

A strong ferrite former.

Added to some high strength alloys for hardening and strengthening effects.

Added to some martensitic straight chromium stainless steels to tie up the carbon and hence reduce the hardening tendency of the steels.

titanium (ti) A strong carbide former. used to stabilize austenitic stainless steels against the harmful precipitation of chromium carbides in the range 480–820°C.

A strong ferrite former.

Added to some high-strength heat resisting alloys for its hardening and strengthening effects.

cobalt (co) Added to various alloys to impart strength and creep resistance at high temperatures.

tungsten (W) Improves the high-temperature strength and creep resistance of some high-temperature alloys.

nitrogen (n)A strong austenite former.

used to minimize grain grown in high chromium straight chromium steels at high temperatures.

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8



Stainless Steel

uniform surface corrosion

This occurs when the general corrosion resistance of a steel is inadequate to withstand the attack of the corrosive medium. It is then necessary to choose another steel having higher corrosive resistance, i.e. usually one of higher alloy content.

Pitting corrosion

Certain chemicals, such as chlorides and some organic acids, cause localised pitting of the steel surface. The presence of molybdenum in the stainless steel has been found to reduce this tendency.

Stress corrosion

Some stainless steels having high residual stresses remaining after fabrication will, in certain cases, fail very rapidly due to stress-corrosion The most satisfactory method of preventing this is to solution treat the fabrication. Another method involves redesigning to reduce the stress concentration. If neither of these methods is possible or economical a change to a higher alloy material may provide the solution. The use of duplex austenitic-ferritic stainless steels can also be effective in preventing stress corrosion cracking.

Weld decay

If unstabilised Cr-Ni steels are heated to 500–900°C and allowed to cool slowly they become more easily prone to corrosion. Such a condition may occur in the heat affected zone to a weld when a band is formed parallel to the weld where corrosion resistance is greatly reduced. This is due to the chromium in the grain boundary areas combining with the carbon. The subsequent precipitation of chromium carbides leaves a chromium depleted alloy in the grain boundaries of much lower corrosion resistance. When the steel is immersed in a corrosive medium, these depleted areas are eaten out and the grains of metal simply fall apart.

Titanium or niobium additions are frequently made to stainless steels to act as ‘stabilisers’. These elements have a greater affinity for carbon than has chromium and combine with it to form harmless titanium or niobium carbides. In this way the grain boundaries are not depleted of chromium and retain their corrosion resistance.

unstabilised steel which has been welded may have corrosion resistance restored by quenching from 1100°C. This method is limited by size considerations and the tendency to distort during the heat treatment

An even better method of avoiding carbide precipitation is to reduce the carbon content in the steel of such a low level that negligible carbide formation is possible at any temperature. A carbon level of less than 0.03% is effective in achieving this. Such extra low carbon steels are not subject to harmful carbide precipitation during welding and also display superior impact properties at low temperatures.

Welding electrodes are available with either extra low carbon content (L grade, i.e. 308L, 316L) or containing niobium to stabilise the higher carbon weld deposit against weld decay. Titanium, used to stabilise wrought material, i.e. AISI 321, is not suitable for stabilising weld metal since much of it is oxidized during transfer across the arc and is lost to the slag and is replaced by niobium as a stabiliser in electrodes.

oxidation

Steels for heat resistance must possess one or both of two properties - resistance to oxidation or scaling, and the retention of correct shape under stress at elevated temperatures, i.e. AISI 310.

The scaling or oxidation resistance of these steels is deprived primarily from chromium which is increasingly effective from 8% upwards. Nickel also improves oxidation resistance but only when present in large amounts. It is, however, more effective in promoting dimensional stability under stress at elevated temperatures, that is, it imparts creep resistance. Other elements contributing to creep resistance are titanium, niobium, molybdenum, cobalt and tungsten.

Sigma phase embrittlement

A feature which occurs when some stainless steels are exposed to temperatures in the range to 450–900°C is the formation of sigma phase. This is a brittle constituent which develops from the ferrite in the ‘duplex’ austenitic type of stainless steels, and results in loss of ductility and toughness in steel.

Sulphur attack

Sulphidation may occur in nickel-bearing steel exposed to high-temperature atmospheres containing sulphurous gases. The nickel is attacked and forms nickel sulphide causing cracking of the steel. under such conditions plain chromium steels must be used.

Schaeffler and Delong diagramsA useful method of assessing the general metallurgical characteristics of any stainless steel weld metal is by means of the Schaelflar and Delong diagrams. The various alloying elements are expressed in terms of nickel or chromium equivalents i.e. elements which, like nickel, tend to form austenite and elements like chromium which tend to form ferrite. By plotting the total values for the nickel and chromium equivalents on these diagrams a point can be found indicating the main phases present in the stainless steel in terms of % ferrite and ferrite number, respectively. This provides certain information as to its behavior during welding.

The Schaeffler diagram indicates that the comparatively low alloyed steels are hardenable since they contain the martensitic phase in the as-welded state. As the alloying elements increase, the austenite and ferrite phases become more stable and the alloy ceases to be quench hardenable. Steels with a relatively high level of carbon, nickel and manganese become fully austenitic (‘austenitic’ area), while those with more chromium, molybdenum, etc. tend to be fully ferritic (‘ferritic’ area).

There is also an important intermediate region of ‘duplex’ compositions indicated as A + F on the diagram. In this region the welds contain both austenite and ferrite. This leads to the general classification of stainless steel into austenitic, ferritic and martensitic, according to which phase is pre-dominant.

types of corrosion

8



Stainless Steel

Schaeffler diagram

28

24

20

16

12

8

4

00 4 8 12 16 20 24 28 32 36 40

28

24

20

16

12

8

4

00 4 8 12 16 20 24 28 32 36 40

AUSTENITE

MARTENSITE

FERRITE

F + M

M + F

904L

308L316L

309L

317L318

310

A + M + F

A + M

A + F

0% Fe

rrite

5%

10%

40%20%

904L

308L316L

309L

317L318

3100%

Ferri

te

5%

10%

40%20%

80%

100%

AUSTENITE

MARTENSITE

Chromium equivalent = %Cr + %Mo + (1.5 x %Si) + (0.5 x %Nb)

Nic

kel e

quiv

alen

t =

%N

i + (

30 x

%C

) +

(0.

5 x

%M

n)Chromium equivalent = %Cr + %Mo + (1.5 x %Si) + (0.5 x %Nb)

Nic

kel e

quiv

alen

t =

%N

i + (

30 x

%C

) +

(0.

5 x

%M

n)

FERRITE

F + MM + F

A + M + F

A + M

A + F80%

100%

Delong diagram

21

19

17

15

20

18

16

14

13

12

11

1016 17 18 19 20 21 22 23 24 25 2726

21

19

17

15

20

18

16

14

13

12

11

1016 17 18 19 20 21 22 23 24 25 2726

AUSTENITE

AUSTENITE + FERRITE

SchaefflerA + M Line



Nic

kel e

quiv

alen

t =

%N

i + (

30 x

%C

) +

(30

x %

N)

+ (

0.5

x %

Mn)

Nic

kel e

quiv

alen

t =

%N

i + (

30 x

%C

) +

(30

x %

N)

+ (

0.5

x %

Mn)

AUSTENITE

AUSTENITE + FERRITE

SchaefflerA + M Line

0%Ferrite

2%

4%

6%

7.6%

9.2%

10.7%

12.3%

13.8%

0Fer

rite nu

mber

2

46

810

1214

16

18

0%Ferrite

2%

4%

6%

7.6%

9.2%

10.7%

12.3%

13.8%

0Fer

rite nu

mber

2

46

810

1214

16

18

8



Stainless Steel

The Schaeffler diagram also lets us forecast the composition of heterogenous welds (different materials).

Suppose we want to weld 410 plate (13% chromium; 0.8% manganese; 0.5% silicon; 0.08% carbon) point B, to a carbon-steel (0.2% carbon; 1.0% manganese) point D, using (23% chromium; 12% nickel; 1.0% manganese; 0.5% silicon and 0.4% carbon) point A. We assume that both plates (410 and carbon steel) play equal parts in the weld and the dilution is 30%. Point e is the resultant of both plates and point F, the resultant of applying 30% dilution to the Ae section. Therefore the resulting weld will have 4% ferrite.This weld is also possible without the danger of hot cracking.

28

24

20

16

12

8

4

00 4 8 12 16 20 24 28 32 36 40

28

24

20

16

12

8

4

00 4 8 12 16 20 24 28 32 36 40

AUSTENITE

MARTENSITE

Chromium equivalent = %Cr + %Mo + 1.5 x %Si + 0.5 x %Nb

Nic

kel e

quiv

alen

t =

%N

i + 3

0 x

%C

+ 0

.5 x

%M

n

FERRITE

F + M M + F

E B

D

F

A

A + M + F

A + M

A + F

0% Fe

rrite

5%

10%

40%20%

80%

100%

AUSTENITE

MARTENSITE


Nic

kel e

quiv

alen

t =

%N

i + 3

0 x

%C

+ 0

.5 x

%M

n

FERRITE

F + MM + F

E B

D

F

A

A + M + F

A + M

A + F

0% Fe

rrite

5%

10%

40%20%

80%

100%

Welding of 11-14% manganese steel

Owing to its great ductility, toughness and work hardening properties, 11-14% manganese steel is extensively used for the wearing parts of stone-breaking and ore-crushing machinery, tumblers, buckets, digger teeth, rail points and crossings and similar applications subject to high impact service.

The inherent toughness of 11-14% manganese steel can be seriously reduced if the material is excessively heated during welding; the degree of embrittlement which occurs being greater as the temperature and heating period is increased.

For this reason, very careful control over the amount of reheating must be exercised during welding.

Points to note when welding manganese steelNeVeR use preheating or stress relieving

use minimum currents consistent with a stable arc

Weld beads should be of high build-up to avoid dilution of the weld by the base material

Prior to welding care should be taken to remove work hardened areas

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Minimise heat build-up in the component so that the temperature is below 200 degrees Celsius by:

a) Sequence of staggered welding

b) Direct cooling of the welded area by an air blast

c) Indirect cooling with water

Any surfaces prepared by thermal cutting should be ground prior to welding

For strength welding of 11-14% manganese the use of the following BOC electrodes are recommended: BOC Smootharc S 309 MoL

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types of corrosion (cont)

8



Stainless Steel

coating types a WS a5.4-2000

usability Designation -15The electrodes are usable with DCeP (electrode positive) only. While use with alternating current is sometimes accomplished, they are not intended to qualify for use with this type of current. electrode sizes 5/32 in. (4.0 mm) and smaller may be used in all positions of welding.

usability Designation -16The covering for these electrodes generally contains readily ionizing elements, such as potassium, in order to stabilize the arc for welding with AC. electrode sizes 5/32 in. (4.0 mm) and smaller may be used in all positions of welding.

usability Designation -17The covering of these electrodes is a modification of the -16 covering in that considerable silica replaces some of the titania of the -16 covering. Since both the -16 and the -17 electrode coverings permit AC operation, both covering types were classified as -16 in the past because there was no classification alternative until this revision of ANSI/AWS A5.4. However, the operational differences between the two types have become significant enough to warrant a separate classification.

On horizontal fillet welds, electrodes with a -17 covering tend to produce more of a spray arc and a finer rippled weld-bead surface than do those with the -16 coverings. A slower freezing slag of the -17 covering also permits improved handling characteristics when employing a drag technique. The bead shape on horizontal fillets is typically flat to concave with -17 covered electrodes as compared to flat to slightly convex with -16 covered electrodes. When making fillet welds in the vertical position with upward progression, the slower freezing slag of the -17 covered electrodes requires a slight weave technique to produce the proper bead shape. For this reason, the minimum leg-size fillet that can be properly made with a -17 covered electrode is larger than that for a -16 covered electrode. While these electrodes are designed for all-position operation, electrode sizes 3/16 in. (4.8 mm) and larger are not recommended for vertical or overhead welding.

8



Stainless Steel

IntroductionSteels containing carbon in excess of 0.25%, chromium and molybdenum over 1.5% and manganese over 1.5%, exhibit, increased strength and hardenability and decreased weldability.

Additional elements such as vanadium, silicon, nickel, boron, niobium and titanium also influence hardenability and weldability. Steels of increased hardenability tend to form brittle microstructures in the heat-affected zone which may result in cracking. Steels featuring reduced weldability are commonly referred to as ‘problem steels’ as a result of the problem areas which are directly caused by shrinkage stresses, rapid cooling rates and the presence of hydrogen.

electrodes for welding problem steels are chromium nickel austenitic types containing delta ferrite in the range of 10–80%. The weld metal is insensitive to hot cracking above 1200°C. At ambient temperatures, the weld metal is strong and tough and is capable of withstanding heavy impact and shock loading in service.

Problem steels fall into two categories, i.e. ferritic types which require preheat and austenitic steels such as 11–14% manganese steels which require minimum heat input.

When hardenable ferritic steel types are to be welded, reference should be made to the section on mild and medium tensile steels for the calculation of the carbon equivalent and pre-heat temperatures.

Problem steel electrodes are suitable for welding combinations of dissimilar steels such as chromium, molybdenum. creep-resistant steels and stainless steels to mild and low alloy steels. Care should be taken when welding such combinations to ensure that excessive dilution between the base and weld metal does nor occur.

the welding of dissimilar steelsWhen welding dissimilar steels a number of factors must be taken into account. i.e:

The weld metal must be capable of accepting dilution from both dissimilar base materials without forming crack-sensitive microstructures. These structures must remain stable at the desired operating temperatures.

The mechanical properties of the weld metal should be superior to the weaker of the two base materials.

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■

The coefficients of expansion should preferably be between those of the base materials in order to reduce possible stress concentrations.

The corrosion resistance of the weld metal should be superior to at least one of the base materials to avoid preferential attack of the weld metal.

In many instances it is not possible to satisfy all of the foregoing points and a compromise has to be made. BOC Smootharc S 309 and 312 problem steel electrodes have been specially designed to weld a large number of dissimilar materials such as stainless steels to carbon manganese steels and low alloy steels, and low alloy steels to 11–14% manganese steels, high carbon and tool steels, etc.

calculation of final weld metal structuresThe final weld metal chemistry and therefore properties, depends on the amount of dilution that occurs during welding.

Weld metal dilution is normally expressed as a percentage of the final weld metal composition, the effect being dependent on a number of factors such as the joint configuration, the welding technique and the welding process. With the manual metal arc process, dilution in the vicinity of ±25% can occur. This will obviously be greatest in the root pass and least in fill-in passes where two or more runs per layer are used.

The Schaeffler diagram is a useful tool in that it allows us to determine the microstructures after dilution theoretically. This is illustrated by means of the following example:

Suppose we want to weld 410 steel (13% Cr; 0.8% Mn;

0.5% Si and 0.08% C) with BOC Smootharc S 309 MoL (23% Cr; 12% Ni; 1.0% Mn; 0.5% Si and 0.03% C), and we assume 30% dilution (the base metal contributes 30% of the union and the electrode the other 70%).What is the composition of the resultant weld metal?

The 410 plate is represented by point B (Cr equivalent 13.75%; Ni equivalent 2.8%) and the BOC Smootharc S 309 MoL electrode by point A (Cr equivalent 23.75%; Ni equivalent 14.5%). Any resultant weld metal from this mixture of A and B will be on the line that joins them. As we have assumed 30% dilution, point C will give the resultant microstructure. i.e. austenite with 10% ferrite. This weld is therefore possible without any danger of hot cracking.

■

■

Problem Steels

28

24

20

16

12

8

4

00 4 8 12 16 20 24 28 32 36 40

28

24

20

16

12

8

4

00 4 8 12 16 20 24 28 32 36 40

AUSTENITE

MARTENSITE


Nic

kel e

quiv

alen

t =

%N

i + 3

0 x

%C

+ 0

.5 x

%M

n

FERRITE

F + M M + F

B

C

C

A

A + M + F

A + M

A + F

0% Fe

rrite

5%

10%

40%20%

80%

100%

AUSTENITE

MARTENSITE


Nic

kel e

quiv

alen

t =

%N

i + 3

0 x

%C

+ 0

.5 x

%M

n

FERRITE

F + MM + F

B

A

A + M + F

A + M

A + F

0% Fe

rrite

5%

10%

40%20%

80%

100%

8



Stainless Steel

Stainless Steels (BOC Smootharc S)

Base Metal ASTM, AISI, uNS

201, 202

304, 304L

309, 309S

310, 310S

317, 316

317L, 316L, 316Ti

321, 347

S30815, (253MA), 904L, (N08904)

409, 430, 446, 5CR12

410, 420

Duplex S31500 S31803 S32304

Carbon and Low Alloy Steels

201, 202

347

308L

347

308L

347

309MoL

347

310

309MoL

318

347

308L

316L

347

347 347

309MoL

309MoL

309L

309MoL

309L

Duplex

309MoL

309MoL

304, 304l

347

308L

347

309MoL

308L

309L

347

310

308L

347

318

308L

347

318

308L

347

308L

347

308L

309MoL

309L

309MoL Duplex

309MoL

309L

309MoL

309L

309, 309S

309MoL

309L

309MoL

309L

310

309MoL

318

316

309L

309L

316L

318

347

309MoL

Match above

309MoL

347

309MoL

309L

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

310, 310S

310 316L

318

310

316L

318

310

347

310

Match above

309L

310

309MoL

309L

316L

309MoL

309L

310

Duplex

309MoL

309L

309L

309MoL

310

317, 316

318

316L

316L

318

347

316L

Match above

309MoL

316L

309MoL

309L

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

317l, 316l, 316ti

316L 347

316L

Match above

309MoL

309L

309MoL

309L

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

321, 347

347 Match above

309MoL

347

309MoL

309L

309MoL

309L

Duplex

309MoL

347

309MoL

309L

S30815, (253Ma), 904l, (n08904)

Matching 309MoL

309L

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

409, 430, 446, 5cR12

309L

309MoL

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

410, 420

Matching or

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

Duplex, S31500, S31803, S32304

Matching Duplex

309MoL

309L

carbon and low alloy Steels

Matching

NOTeS (1) Consumables listed against a steel may not achieve matching corrosion resistance or mechanical properties. (2) Welding procedure qualification should be carried out prior to welding in critical applications. (3) Consult you BOC welding process specialist or visit BOC’s Inform website (subscription required) for more detailed information.

This table can also be found on page 643 of this manual.

8



Stainless Steel

Smootharc™ S 308l

DescriptionSmootharc S 308L is a rutile coated, low carbon grade, AC / DC electrode for the high quality welding of austenitic stainless steel of the 19Cr / 9Ni type. The electrode is very easy to strike and restrike. Welding performance is excellent with a very smooth, low spatter arc producing a finely rippled bead surface with excellent slag detachability.

applicationSmootharc S 308L is recommended for single and multi-pass welding of austenitic stainless steel 302, 304 and 304L grades. Austenitic stainless steel of the 19Cr / 9Ni type may be used in the following applications: brewing equipment, steam piping, vacuum pump parts, dairy equipment, textile drying equipment, chemical handling equipment, pharmaceutical and food handling equipment.

techniqueStainless steel can be welded using either AC or DC, using as short an arc as possible to minimise alloy loss across the arc and control ferrite level. When using AC a slightly higher current setting may be required.

When welding in the flat position stringer beads should be used and if weaving is required this should be limited to 2 times the electrode diameter. The heat input, which can adversely affect corrosion resistance and lead to excessive distortion, should be limited by using the correct electrode diameter to give the required bead profile and properties at the maximum travel speed.

StorageSmootharc S 308L electrodes are packaged in hermetically sealed containers. For critical applications in damp environments, once the seal is broken electrodes should be stored in heated cabinets at 70–120°C.

Re-Drying / conditioningAll electrode coatings are hydroscopic and when left in the opened state for a period of time will absorb moisture. Austenitic materials are generally insensitive to the presence of hydrogen. However, moisture in the electrode coating can lead to porosity in the weld metal. Start porosity is generally indicative of damp electrodes and is more common in fillet welds than in butt welds where pores only occur at high moisture contents.

electrodes which have been stored outside of their hermetically sealed cans and have become damaged by moisture pick-up can be redried at temperatures of 300–350°C for 1–2 hours. Redrying should be restricted to a maximum of 3 cycles.

Welding Positions

Specifications

Coating Type Rutile

Classification AWS / ASMe-SFA A5.4 e308L-17

AS / NZS 1553.3 e308L-17

Welding current AC, OCV 50V or DC+

Scaling temperature Approx. 850°C in air


C Si Mn Cr Ni

Typical 0.02 0.8 0.7 20.0 10.2

Ferrite content FN 5 (WRC-92)


Typical (as welded)



elongation 39% min

Impact energy, CVN 60J @ –20°C

35J @ –196°C

Packaging Data

Dia. (mm) 2.5 3.2 4.0

Part No. 188082 188083 188084

Length (mm) 300 350 350

Weight can (kg) 2.5 3.0 3.0



Welding Parameters

Dia. (mm) 2.5 3.2 4.0

Current (A) 40–80 80–120 100–160


Deposition Data

Dia. (mm) 2.5 3.2 4.0

Kg weld metal / kg electrode

0.62 0.64 0.64

No. of electrodes / kg weld metal

91 45 31

Kg weld metal / hour arc time

1.0 1.5 2.0

Burn off time / electrode (sec)

33 45 55

MMa electrodes

8



Stainless Steel

Smootharc™ S 316l

DescriptionSmootharc S 316L is a rutile coated, low carbon, 19% Cr, 12% Ni, 3% Mo, AC / DC electrode for the high quality welding of molybdenum alloyed, acid resisting austenitic stainless steels of the 316 / 316L type. The electrode is very easy to strike and restrike. Welding performance is excellent with a very smooth, low spatter arc producing a finely rippled bead surface with excellent slag detachability. Fillet welds have slightly concave profile with excellent toe line blend-in.

applicationSmootharc S 316L is recommended for single and multi-pass welding of molybdenum alloyed austenitic stainless steels 316 and 316L. It is also suitable for welding the Nb or Ti stabilised steels, provided service temperatures are below 4000C. Austenitic stainless steels of the 316 / 316L type may be used for applications such as food handling equipment, structures in marine environments, heat exchangers, chemical storage and transportation tanks, oil refining equipment and pharmaceutical equipment.

techniqueStainless steel can be welded using either AC or DC, using as short an arc as possible to overcome any possibility of alloy loss across the arc. When using AC a slightly higher current setting may be required.





Welding Positions

Specifications

Coating Type Rutile


AS / NZS 1553.3 e316L-17

Approvals American Bureau of Shipping




C Si Mn Cr Ni Mo

Typical 0.02 0.8 0.7 18.5 12.0 2.7



Typical (as welded)



elongation 32% min


45J @ –120°C

Packaging Data

Dia. (mm) 2.5 3.2 4.0 5.0

Part No. 188162 188163 188164 188165

Length (mm) 300 350 350 450

Weight can (kg) 2.5 3.0 3.0 5.0

Weight carton (kg) 7.5 9.0 9.0 15.0

electrodes pkt (approx) 136 84 58 45

Welding Parameters

Dia. (mm) 2.5 3.2 4.0 5.0

Current (A) 40–80 80–120 100–160 170–230

Voltage (V) 29 29 30 30

Deposition Data

Dia. (mm) 2.5 3.2 4.0 5.0

Kg weld metal / kg electrodes

0.64 0.64 0.65 0.65


85 44 30 14


1.1 1.5 2.1 2.8


35 43 56 89

MMa electrodes

8



Stainless Steel

Smootharc™ S 347

DescriptionSmootharc S 347 is a rutile coated, niobium stabilised, AC / DC electrode of the 19% Cr, 10%Ni type. The electrode is very easy to strike and restrike. Welding performance is excellent with a very smooth, low spatter arc producing a finely rippled bead surface with excellent slag detachability. The electrode has good positional welding characteristics.

applicationSmootharc S 347 has been especially designed for the welding of 321 and 347 stabilised steels. The electrode is also suitable for the unstabilised grades 304 and 304L. Smootharc S 347 is primarily intended for use where resistance to weld metal sensitisation and intergranular corrosion is required. Stabilised 321 and 347 austenitic stainless steel grades may be used for applications such as aircraft exhaust manifolds, fire walls, pressure vessels and elevated temperature chemical handling equipment.



StorageSmootharc S 347 electrodes are packaged in hermetically sealed containers. For critical applications in damp environments, once the seal is broken electrodes should be stored in heated cabinets at 70–120°C.



Welding Positions

Specifications

Coating Type Rutile

Classification AWS / ASMe-SFA A5.4 e347-17

AS / NZS 1553.3 e347-17




C Si Mn Cr Ni Nb

Typical 0.02 0.9 0.6 19.0 10.2 0.5



Typical (as welded)



elongation 35% min


Packaging Data

Dia. (mm) 2.5 3.2 4.0

Part No. 188472 188473 184164

Length (mm) 300 350 350




Welding Parameters

Dia. (mm) 2.5 3.2 4.0

Current (A) 50–80 80–110 130–170


Deposition Data

Dia. (mm) 2.5 3.2 4.0


0.62 0.64 0.63


90 46 31


1.0 1.3 1.9


34 55 62

MMa electrodes

8



Stainless Steel

Smootharc™ S 309l

DescriptionSmootharc S 309L is a rutile coated, AC / DC electrode which deposits a low carbon, 23% Cr, 13% Ni austenitic stainless steel weld metal. The electrode is very easy to strike and restrike. Welding performance is excellent with a very smooth, low spatter arc producing a finely rippled bead surface with excellent slag detachability.

applicationSmootharc S 309L is recommended for welding corrosion resistant and heat resistant steels of the 309 type, which are often used for furnace parts, aircraft and jet engine parts, heat exchangers and chemical processing equipment.

Smootharc S 309L can also be used for welding dissimilar carbon manganese steels and low alloy steels, welding stainless steels to mild steels and as a buffer for hardfacing applications.






Welding Positions

Specifications

Coating Type Rutile


AS / NZS 1553.3 e309L-17




C Si Mn Cr Ni

Typical 0.02 0.8 0.8 23.0 13.0



Typical (as welded)



elongation 34% min


45J @ –60°C

Packaging Data

Dia. (mm) 2.5 3.2 4.0

Part No. 188092 188093 188094

Length (mm) 300 350 350




Welding Parameters

Dia. (mm) 2.5 3.2 4.0

Current (A) 40–80 80–120 100–160


Deposition Data

Dia. (mm) 2.5 3.2 4.0


0.67 0.67 0.67


83 42 28


0.9 1.4 1.9


42 53 59

MMa electrodes

8



Stainless Steel

Smootharc™ S 309Mol

DescriptionSmootharc S 309MoL is a rutile coated, AC / DC electrode which deposits a low carbon, 23% Cr, 12% Ni, 2.5% Mo austenitic stainless steel weld metal with a ferrite content of FN 20. The high alloy content and ferrite level enable the weld metal to tolerate dilution from dissimilar and difficult-to-weld materials without hot cracking.

The electrode is very easy to strike and restrike. Welding performance is excellent with a very smooth, low spatter arc producing a finely rippled bead surface with excellent slag detachability.

applicationSmootharc S 309MoL is recommended for welding corrosion-resistant CrNiMo steels to themselves and to mild and low alloy steels without hot cracking. The electrode is suitable for welding armour plate, austenitic manganese steel, medium and high carbon hardenable steels, tools, dies, springs, etc. which may be of unknown composition.

Smootharc S 309MoL is also recommended for welding dissimilar steels such as stainless steels to carbon manganese or low alloy steels and for welding austenitic manganese steel to carbon manganese and low alloy steel.

techniqueStainless steel electrodes can be welded using either AC or DC, using as short an arc as possible to minimise alloy loss across the arc and control ferrite level. When using AC a slightly higher current setting may be required. When welding in the flat position stringer beads should be used and if weaving is required this should be limited to 2 times the electrode diameter.

StorageSmootharc S 309MoL electrodes are packaged in hermetically sealed containers. For critical applications in damp environments, once the seal is broken electrodes should be stored in heated cabinets at 70–120°C.



Welding Positions

Specifications

Coating Type Rutile

Classification AWS / ASMe-SFA A5.4 e309MoL-17

AS / NZS 1553.3 e309MoL-17




C Si Mn Cr Ni Mo

Typical 0.02 0.8 0.8 22.8 12.8 2.4



Typical (as welded)



elongation 33% min


Packaging Data

Dia. (mm) 2.5 3.2 4.0

Part No. 188096 188097 188098

Length (mm) 300 350 350




Welding Parameters

Dia. (mm) 2.5 3.2 4.0

Current (A) 40–80 80–120 100–160


Deposition Data

Dia. (mm) 2.5 3.2 4.0


0.64 0.65 0.65


84 43 29


1.1 1.5 2.1


38 55 59

MMa electrodes

8



Stainless Steel

Smootharc™ S 312

DescriptionSmootharc S 312 is a rutile coated, AC / DC electrode which deposits a 29%Cr / 9%Ni austenitic / ferritic stainless steel weld metal with a ferrite content of FN 50. The resultant weld metal is high strength with high ductility and the structure is highly resistant to hot cracking and extremely tolerant of dilution from medium and high carbon steels.

The electrode is very easy to strike and restrike. Welding performance is excellent with a very smooth, low spatter arc producing a finely rippled bead surface with excellent slag detachability.

applicationSmootharc S 312 is a universal electrode specifically designed for welding steels of poor weldability. The electrode is suitable for welding armour plate, austenitic manganese steel, medium and high carbon hardenable steels, tools, dies, springs etc which may be of unknown composition. It is also suitable for welding dissimilar steels eg. stainless to mild steel.

techniqueStainless steel electrodes can be welded using either AC or DC, using as short an arc as possible to minimise alloy loss across the arc and control ferrite level. When using AC a slightly higher current setting may be required. When welding in the flat position stringer beads should be used and if weaving is required this should be limited to 2 times the electrode diameter.

StorageSmootharc S 312 electrodes are packaged in hermetically sealed containers. For critical applications in damp environments, once the seal is broken electrodes should be stored in heated cabinets at 70–120°C.



Welding Positions

Specifications

Coating Type Rutile

Classification AWS / ASMe-SFA A5.4 e312-17 AS / NZS 1553.3 e312-17




C Si Mn Cr Ni

Typical 0.10 1.2 0.8 28.8 9.7



Typical (as welded)



elongation 25% min

Packaging Data

Dia. (mm) 2.5 3.2 4.0

Part No. 188122 188123 188124

Length (mm) 300 350 350




Welding Parameters

Dia. (mm) 2.5 3.2 4.0

Current (A) 40–80 80–120 100–160


Deposition Data

Dia. (mm) 2.5 3.2 4.0


0.64 0.64 0.65


90 47 31


1.1 1.5 2.1


36 51 55

MMa electrodes

8



Stainless Steel

Satincrome 316l-17Rutile type, stainless steel electrode

Outstanding operator appeal, improved slag lift

All positional (except vertical-down) welding capabilities

Applications include the single and multi-pass welding of matching Molybdenum bearing stainless steels, 316 and 316L. Also suitable for the general purpose welding of other “300 series” austenitic stainless steels including 301, 302, 303 and 304 / 304L, 305, 3CR12-types

Classifications

AS / NZS 1553.3: e316L-17 AWS / ASMe-SFA A5.4: e316L-17

■

■

■

■




elongation 40%


Packaging and operating data — AC (minimum 45 OCV) DC+ polarity


Current range (A)


2.0 300 87 35–55 2.5 15 (6 x 2.5) 611661

2.5 300 46 40–70 2.5 15 (6 x 2.5) 611662

3.2 350 28 75–110 2.5 15 (6 x 2.5) 611663

4.0 350 18 110–150 2.5 15 (6 x 2.5) 611664


C: 0.025 Mn: 0.8 Si: 0.85

Cr: 19.4 Ni: 11.5 Mo: 2.5

S: 0.011 P: 0.017

Ferrite number

3.0–10.0 FN (using Severn Gauge)

Approvals


AWS A5.4: e316L-17

Satincrome 308l-17Rutile type, stainless steel electrode



Applications include the single and multi-pass welding of 19Cr / 10Ni type stainless steel grades including 201, 202, 301, 302, 303, 304, 304L, 305, 308 etc,

Classifications

AS / NZS 1553.3: e308L-17 AWS / ASMe-SFA A5.4: e308L-17

■

■

■

■




elongation 40%



electrode Size (mm)

Length (mm)Approx No. (rods / kg)

Current range (A) Packet (kg) Carton (kg) Part No.

2.5 300 47 40–70 2.5 15 (6 x 2.5) 611602

3.2 350 28 75–110 2.5 15 (6 x 2.5) 611603

4.0 350 18 110–150 2.5 15 (6 x 2.5) 611604


C: 0.025 Mn: 0.76 Si: 0.87

Cr: 20.4 Ni: 9.8 S: 0.010

P: 0.017

Ferrite number

3.0–10.0 FN (using Severn Gauge)

Approvals


AWS A5.4: e308L-17

MMa electrodes

8



Stainless Steel

Weldalleasy-to-use rutile type, high alloy electrode

Outstanding operator appeal

Welds all steels

Ideal for repair and maintenance jobs

easy arc starting and excellent stability on low OCV welding machines

Not recommended for welding cast irons

Classifications

AS / NZS 1553.3 312-17 AWS / ASMe-SFA A5.4: e312-17

■

■

■

■

■

■


0.2% proof stress 630 MPa


elongation 25%


Packaging and operating data AC (minimum 45 OCV) DC+ polarity


Current range (A)



2.5 300 57 40–80 2.5 15 (6 x 2.5) – 611702

2.5 300 – – – – 20 rods 322101

3.2 350 30 75–110 2.5 15 (6 x 2.5) – 611703

3.2 350 – – – – 15 rods 322102

4.0 350 20 110–150 2.5 15 (6 x 2.5) – 611704


C: 0.11 Mn: 0.60 Si: 0.88

Cr: 27.0 Ni: 9.10 S: 0.011

P: 0.020

MMa electrodes

Satincrome 318-17(Supersedes Satincraft 318-16)

Rutile Type, Stainless Steel electrode.

Outstanding Operator Appeal!

Now with Improved Slag Lift!

All Positional (except vertical down) Welding Capabilities.

Advanced Moisture Resistant Flux Coating.

Classifications

AS/NZS 1553.3: e318-17. AWS/ASMe-SFA A5.4: e318-17.

All positional - except vertical down

■

■

■

■

■




elongation 36%

Packaging and Operating Data

AC (min 45 OCV), DC+ polarity.

electrode Approx No.

Rods/kg

Current Range (A)

PacketCarton (kg)

easyweld

Handipaks

Part No.

Size (mm) Length (mm)

2.5 300 46 40–70 2.5kg 15 (6 x 2.5) 611652

2.5 300 46 40–70 20 rod 322105

3.2 350 28 75–110 2.5kg 15 (6 x 2.5) 611653


C Mn Si Cr Ni

0.04 0.8 0.90 19 12

Mo Nb S P

2.30 0.35 0.017 0.02

Ferrite number

5.0 – 10.0 FN (using Severn Gauge)

Satincrome 309Mo-17Rutile type, stainless steel electrode



Applications include the single and multi-pass welding of matching 309 and 309L stainless steels. Also suitable for the dissimilar welding of other “300 series” austenitic stainless steels and selected “400 series” ferritic grades to mild or low alloy steels

Classifications

AS / NZS 1553.3: e309Mo-17 AWS / ASMe-SFA A5.4: e309Mo-17

■

■

■

■




elongation 35%



electrode Size (mm)

Length (mm)Approx No. (rods / kg)

Current range (A)

Packet (kg) Carton (kg) Part No.

2.5 300 52 40–70 2.5 15 (6 x 2.5) 611692

3.2 350 30 75–110 2.5 15 (6 x 2.5) 611693

4.0 350 19 110–150 2.5 15 (6 x 2.5) 611694


C: 0.05 Mn: 0.75 Si: 0.9

Cr: 23.0 Ni: 13.0 Mo: 2.2

S: 0.012 P: 0.017

Ferrite number

15.0 – 20.0 FN (using Severn Gauge)

Approvals


AWS A5.4: e309Mo-17

8



Stainless Steel

MMa electrodes

limarosta 304lA rutile-basic all position stainless steel electrode for 304L or equivalent steels. Mirror like bead appearance. Self releasing slag. excellent side wall wetting, no undercut. Highly resistant to porosity.

Nearest classification

AWS e308L-16

Size (mm) Carton(kg) Part No

2.50 2.7 557329

3.20 4.7 557367

4.00 5.8 557398

limarosta 316lA rutile-basic all position stainless steel electrode for 316L or equivalent steels. Molybdenum level min 2.7%. Mirror like bead appearance. Self release slag. Good side wall fusion, no undercut. High resistance to porosity. Weldable on AC and DC+ polarity.


AWS e16L-16


2.50 2.7 557442

3.20 4.8 557466

4.00 5.9 557497

limarosta 309SA rutile-basic all position CrNi over alloyed buffer electrode. Developed for welding stainless steel to mild steel and for clad steel. Self releasing slag. excellent side wall wetting, no undercut, mirror like bead appearance. High resistance to porosity. Weldable on AC and DC+ polarity.


AWS e309L-16


2.50 2.8 556534

3.20 4.9 557565

4.00 5.9 557589

limarosta 312A rutile-basic high CrNi alloyed all position electrode. excellent for repair welding. Specially developed for welding steels difficult to weld such as: armour plate, austenitic Mn-steel, high C-steel. excellent weldability and self releasing slag.


AWS e312-16


2.50 2.6 557640

3.20 5.0 557664

4.00 5.0 557671

arosta 304lRutile basic all position stainless steel electrode for 304L or equivalent steels. excellent corrosion resistance to intergranular corrosion and in oxidising environments such as nitric acid. Smooth bead appearance and easy slag release. AC/DC+

Classification AWS e308L-16


2.60 2.6 527537

3.20 4.8 527834

4.00 4.5 527940

arosta 309A high CrNiMo alloyed all position rutile basic electrode. High corrosion resistant deposit. Specially developed for welding stainless steel to mild steel and root runs in cladding. max plate thickness in butt welds - 12mm. Suitable for repair welding in dissimilar joints and steels difficult to weld. AC/DC+

Classification AWS e309Mo-16

Size (mm) Carton (kg) Part No

2.50 2.6 528633

3.20 4.7 528824

4.00 4.8 528930

arosta 316lRutile basic all position stainless steel electrode for 316L or equivalent steels. Molybdenum level minimum 2.7%. High resistance to general and intergranular corrosion. Smooth weld appearance and easy slag release. AC/DC+.

Classification AWS e316L-16


2.50 2.7 529180

3.20 4.9 529487

4.00 4.8 529593

Limarosta electrodes are predominantly used for welding downhand fillets, although out of position welds are possible. On the other hand, Arosta electrodes have superior out of position capabilities.

8



Stainless Steel

boc Stainless Steel MIG Wire 308lSi

Welding characteristicsHigh silicon levels improve arc characteristics, weld pool fluidity and flatten weld bead profile

Low carbon increases resistance to corrosion and maintains mechanical properties

applicationsWelding of 18% Cr 8% Ni type Stainless Steels i.e. 301, 302, 321, 347, 409 and 444-type alloys

Welding of 304 and 304L in cryogenic applications

Welding positions

■

■

■

■

Classifications

AS / NZS 2717.3, eS308LSi, AWS / ASMe-SFA, A5-9, eR308LSi

Approvals: TÜV X2 CrNi 19 9 DIN 8556

DB (Ü-Sign) SG-X2 CrNi 19 9


Typical as welded

yield strength ( MPa) 415

Tensile strength ( MPa) 570

elongation (%) 35

Reduction of area 40

Impact LevelsJ @ 20ºC 140

J @ -110ºC 84

J @ -196ºC 52

Ferrite No. FN 14

Welding current DC+

Welding data

Dip Transfer Spray Transfer

Dia. (mm) 0.9 1.2 0.9 1.2

Wire Feed 4–8 3–7 7–14 5–9

Current (A) 50–130 90–160 130–220 180–260

Voltage (V) 15–19 17–21 22–25 24–29

Shielding Gas Stainshield® Stainshield® Heavy Stainshield® 66

Packing data

Dia. (mm) 0.9 1.2

Part No. 109308 112308

Spool Weight (kg) 15 15

Chemical Composition, wt% – all weld metal

C Mn Si S P Cr Ni Mo Co Cu N

Min. 1.50 0.65 0.005 19.5 10.00

Typical as welded 0.014 1.78 0.85 0.001 0.015 19.67 10.4

Max. 0.02 2.00 1.00 0.015 0.020 20.50 10.75 0.30 0.20 0.20 0.060

GMaW Wire

8



Stainless Steel




applicationsWelding of 23% Cr / 12% Ni type Stainless steels

For welding mild or low alloy steels to 300 and selected 400 series stainless steels

Ideal for buttering layer on carbon for hardfacing consumables

A stainless overlay on mild steels

Welding positions

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Classifications

AS / NZS 2717.3 eS309LSi AWS / ASMe – SFA A5 – 9 eR309LSi


Typical as welded



elongation (%) 40

Impact levelsJ @ 20°C 160

Ferrite No. FN 15

Welding current DC+

Packaging

Dia. (mm) 0.9 1.2

Part No. 112309 112309


Welding data


Dia. (mm) 0.9 1.2 0.9 1.2

Wire Feed 4–8 3–7 7–14 5–9

Current (A) 50–130 90–160 130–220 180–260

Voltage (V) 15–19 17–21 22–25 24–29


Chemical composition, wt% – all weld metal


Min. 1.50 0.65 0.005 23.0 13.00

Typical as welded 0.015 1.79 0.80 0.012 0.014 23.4 13.63

Max. 0.02 2.00 1.00 0.015 0.020 24.0 14.00 0.30 0.20 0.20 0.060

GMaW Wire

8



Stainless Steel




applicationsWelding of 18% Cr / 8% Ni and 18%Cr / 8%Ni / 3%Mo type Stainless Steels

Most suitable for the welding of 316, 318, and-316l alloys

Suitable for 301, 302, 304, 321, 347, 410, and-430 alloys

Welding positions

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Classification

AS / NZS 2717.3, eS316LSi, AWS / ASMe – SFA, A5 – 9, eR316LSi

Approvals:

TÜV X 2 CrNiMo 1912 DIN 8556 DB SG – X2 CrNiMo 19 12


Typical as welded



elongation (%) 32

Reduction of area 46

Impact levelsJ @ 20°C 152

J @ – 110°C 110

J @ – 196°C 53

Ferrite content FN 13

Welding current DC+

Packaging

Dia. (mm) 0.9 1.2

Part No. 109316 112316


Welding data


Dia. (mm) 0.9 1.2 0.9 1.2

Wire Feed 4–8 3–7 7–14 5–9

Current (A) 50–130 90–160 130–220 180–260

Voltage (V) 15–19 17–21 22–25 24–29




Min. 1.50 0.65 0.005 18.00 12.00 2.50

Typical as welded 0.012 1.70 0.93 0.008 0.016 18.58 12.2 2.63

Max. 0.02 2.00 1.00 0.015 0.020 19.00 13.00 3.300 0.30 0.20 0.060

GMaW Wire

8



Stainless Steel

autocraft 307SiFor the GMAW Welding of hardenable steels, 13% Mn steels & difficult to weld steels.

extra Low Carbon ( < 0.07% ) Weld Deposits for Resistance to Intergranular Corrosion.

High Silicon level for Improved Arc Stability and Increased Weld Pool Fluidity and edge Wetting.

New ultrafeed matt finish.

Classifications

AS 2717.3: eS307Si.

AWS/ASMe-SFA A5.9: eS307Si.


Stainshield



elongation 40%

CVN Impact Values 150 J av @ 20°C

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Typical Wire Analysis

C Mn Si Cr

0.07 8.9 0.8 18.5

Ni P S Fe

8.5 0.03 0.015 Balance

Ferrite Number

10 – 15 FN


These machine settings are a guide only. Actual voltage and welding current used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.

Wire Dia. (mm)

Voltage Range (V)

Wire Feed Speed

(m/min)Current Range (A) Pack Type* Weight (kg) Part No.

0.9 16–24 4.5–15.0 70–200 Spool 15kg 721300

1.2 20–28 3.0–10.0 150–280 Spool 15kg 721301

* Spool (ø300mm).

Comparable Cigweld Products:

Coabalarc Austex

AS/NZS 2576 1315-A4


Stainshield®

Stainshield® Heavy

autocraft 308lSiA steel wire for the GMA welding of 304 and 304L type stainless steels

Recommended for the general welding of-201, 302, 321, 347, 409 and 444 type stainless steels

Classifications

AS / NZS 2717.3: eS308LSi AWS / ASMe-SFA A5.9: eR308LSi


Argon 1–3% CO2


Tensile strength 620 MP

elongation 36%


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C: 0.02 Mn: 2.05 Si: 0.80

Cr: 19.95 Ni: 10.25 P: 0.020


Ferrite number

5–10 FN


Dia. (mm) Voltage (V)

Wire feed speed m / min



0.9 16–24 4.5–15.0 70–200 Spool 15 721271

1.2 20–28 3.0–10.0 150–280 Spool 15 721272


Stainshield®

Stainshield® Heavy

GMaW Wire

8



Stainless Steel

autocraft 309lSiA stainless steel wire for the GMA welding of 309 and 309L type stainless steels

Also suitable for a wide range of other welding applications including: the dissimilar joining of “300 series” and stainless steel grades to mild or low alloy steels, an intermediate or buttering layer in the butt welding of clad steel

Classifications



Argon 1–3% CO2



elongation 36%


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C: 0.02 Mn: 2.10 Si: 0.75

Cr: 23.75 Ni: 13.75 P: 0.020


Ferrite Number

10–15 FN






0.9 16–24 4.5–15.0 70–200 Spool 15 721276

1.2 20–28 3.0–10.0 150–280 Spool 15 721277


Stainshield®

Stainshield® 66

Stainshield® Heavy

autocraft 316lSiA stainless steel wire for the GMA welding of 316 and 316L type stainless steels

Also suitable for the general welding of other 300 and 400 series stainless steels including 301, 302, 304 / 304L, 321, 347, 410 and 430

Classifications



Argon 1–3% CO2



elongation 36%


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C: 0.02 Mn: 2.05 Si: 0.80

Cr: 19.95 Ni: 10.25 P: 0.020


Ferrite number

5–10 FN






0.8 16–20 5.0–15.0 60–150

Mini spool –

Pack of 4 4 x 1 721285

0.9 16–24 4.5–15.0 70–200 Handi spool

Spool

5

15

720283

721286

1.2 20–28 3.0–10.0 150–280 Spool 15 721287

0.9 16–24 4.5–15.0 70–200 Drum 150 722286


Stainshield®

Stainshield® 66

Stainshield® Heavy

GMaW Wire

8



Stainless Steel

autocraft 2209For the GMAW welding of 22%Cr/5%Ni/3%Mo duplex type stainless steels.

extra low carbon (<0.03%) corrosion resistance weld deposits.

Precision layer wound for improved feedability and performance.

New ultrafeed matt finish.

Classifications

AS 2717.3: eS2209

AWS/ASMe-SFA A5.9: eR2209.

Werkstoffe No: 1.4462


Welding grade Argon



elongation 28%

CVN Impact Value 60J av @ -40°C

80J av @ -20°C

100J av @ +20°C

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Typical Wire Analysis

C Mn Si Cr Ni Mo

0.012 1.6 0.44 22.8 8.63 3.1

N P S Cu Fe

0.14 0.018 0.007 0.06 bal

Ferrite Number

30- 50 FN (Procedure dependent)


These machine settings are a guide only. Actual voltage and welding current used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.

Wire Dia. (mm)

Voltage Range (V)

Wire Feed Speed

(m/min)

Current Range (A)

Pack Type* Weight (kg) Part No.

0.9 16–24 4.5–15.0 65–165 Spool 15kg 721261

1.2 20–26 3.0–10.0 180–280 Spool 15kg 721262


Comweld 2209 TIG rod

AWS A5.9: eR 2209


Stainshield®

Some nitrogen bearing shielding gases assist in maintaining an optimum Austenite/Ferrite ratio. Consult your gas supplier for specific details.

GMaW Wire

8



Stainless Steel

GMaW Wire

lincoln 308 lSiFor joining common austenitic stainless steel grades referred to as “18-8” steels.

Classifications AWS eR308LSi


0.80 15.0 331088

0.90 15.0 331089

1.20 15.0 331082

1.60 15.0 331086

lincoln 309 lSiFor joining higher alloyed austenitic stainless steels. Can also be used on “18-8” steels since it over matches the corrosion resistance, if the weldment will not be exposed to temperatures of 535–927°C.

Classifications AWS eR309LSi


0.80 15.0 331098

0.90 15.0 331099

1.20 15.0 331092

1.60 15.0 331096

lincoln 316 lSiThe undiluted weld metal is designed to contain considerable ferrite for high crack resistance in 316L joining and cladding. Should not be used on 316L joints or overlay for service in urea manufacture, as this environment will attack the ferrite. Can also be used on “18-8” steels.

Classifications AWS eR 316LSi


0.80 15.0 331068

0.90 15.0 331069

1.20 15.0 331062

1.60 15.0 331066

8



Stainless Steel


Shieldcrome 308ltGas shielded stainless steel flux cored wire

Formulated for CO2 or Argon+20–25% CO2 shielding gases

Vacuum sealed in aluminised plastic packs

All positional capabilities

High deposition rate welding of stainless steels

For a wide range of positional and downhand welding applications on 19Cr / 9Ni stainless steel grades including AISI types 301, 302, 304 and 304L etc

Classifications

Shieldcrome 308LT AWS / ASMe-SFA A5.22: e308LT1-1(CO2) e308LT1-4 (Ar + 20–25%CO2)


using CO2 using Argon +20–25% CO2

0.2% Proof stress

390 MPa 400 MPa


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elongation 43% 40%



C: 0.03 Mn: 1.30 Si: 0.70

Cr: 19.5 Ni: 9.9 P: 0.020

S: 0.003

Operating data

All welding conditions recommended below are for use with semi-automatic operation and DC electrode positive and welding grade CO2 shielding gas with a flow rate of 15–20 L / min.

Dia. (mm) Current range (A) Voltage (V)electrode stickout eSO (mm)

Welding positions

1.2 150–250 23–28 15–20 Flat

1.2 150–200 23–28 15–20 HV Fillet

1.2 120–180 22–27 15–20 Vertical up

1.2 140–180 22–27 15–20 Overhead


Argoshield® 52

Welding Grade CO2

Packaging data

Dia. (mm)

Pack type Pack weight (kg)

Part No.

1.2 Spool 12.5 720889

Shieldcrome 309lt / 309ltD

Gas shielded stainless steel flux cored wires

309LT- all positional capabilities

309LTD – fast downhand capabilities


Formulated for CO2 or argon +20–25% CO2 shielding gases


For a wide range of positional and downhand welding applications on matching 309 and 309L stainless steels.

Classifications

Shieldcrome 309LT AWS / ASMe-SFA A5.22: e309LT1-1 (CO2) / e309LT1-4 (Ar + 20–25%CO2)

Shieldcrome 309LTD AWS / ASMe-SFA A5.22: e309LT0-1 (CO2) / e309LT0-4 (Ar + 20–25%CO2)

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using CO2


0.2% Proof stress 410 MPa 430 MPa


elongation 40 % 38 %



C: 0.03 Mn: 1.12 Si: 0.60

Cr: 23.6 Ni: 13.0 P: 0.023

S: 0.003

Operating data


Dia. (mm) Current range (A) Voltage (V)electrode stickout eSO (mm)

Welding positions

1.2 / 309LT 150–250 23–28 15–20 Flat

1.6 / 309LTD 300–400 28–35 25–30

1.2 / 309LT 150–200 23–28 15–20 HV Fillet

1.6 / 309LTD 250–350 28–35 25–30

1.2 / 309LT 120–180 22–27 15–20 Vertical up

1.2 / 309LT 140–180 22–27 15–20 Overhead


Argoshield® 52

Welding Grade CO2

Packaging data

Dia. (mm) Pack type

Pack weight (kg)

Part No.

1.2 / 309LT Spool 12.5 720881

1.6 / 309LTD Spool 12.5 720882

8



Stainless Steel

Shieldcrome 316ltGas shielded stainless steel flux cored wires, all positional capabilities


Formulated for CO2 or argon +20–25% CO2 shielding gases


For a wide range of positional and downhand welding applications on matching molybdenum bearing 316 and 316L stainless steels

Classifications

Shieldcrome 316LT AWS / ASMe-SFA A5.22: e316LT1-1 (CO2) / e316LT1-4 (Ar + 20–25%CO2)

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using CO2 using Argon +20–25% CO2

0.2% Proof stress

400 MPa 410 MPa

Tensile strength

555 MPa 580 MPa

elongation 42% 39%



C: 0.03 Mn: 1.10 Si: 0.60

Cr: 18.8 Ni: 12.0 Mo: 2.5

P: 0.024 S: 0.002

Operating data


Dia. (mm) Current range (A) Voltage (V)electrode stickout eSO (mm) Welding positions

1.2 150–200 23–28 15–20 HV Fillet

1.2 120–180 22–27 15–20 Vertical up

1.2 140–180 22–27 15–20 Overhead

These machine settings are a guide only. Actual Voltage (V), welding current and eSO used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.


Argoshield® 52

Welding Grade CO2

Packaging data

Dia. (mm) Pack type mm

Pack weight (kg)

Part No.

1.2 Spool 12.5 720885

FcaW WireGas assisted

8



Stainless Steel

ProFill 308l

ProFill 308L stainless steel is a high quality low carbon rod for the Gas or Gas Tungsten Arc (TIG) welding of a wide range of low carbon and stabilised 300 series stainless steels. It is recommended for the critical welding of 304 and 304L stainless steels in corrosion resistant and cryogenic applications.

Resealable 5 kg tube

Suitable for gas and GTA (TIG) welding

Classification

AS1167.2:308LSi

AWS / ASMe-SFA A5.9:eR308LSi

Dia. (mm) Weight (kg) Part No.

1.2 mm 5 kg BTGS308L12





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Weld Deposit Properties

Typical weld metal 0.2% proof stress 450 MPa

Typical weld metal tensile strength 600 MPa

Approx. melting point 1,400ºC

Weld metal density 7.95 g / cm3

All weld metal microstructure Austenite with 5–8% ferrite

Procedure for Gas tungsten arc (tIG) WeldingThoroughly clean all areas to be joined.

For the butt welding of thick plates, bevel edges to 60–70° included angle.

use a Thoriated or Ceriated tungsten electrode, ground to a sharp needle point making sure the grinding lines run with the length (longitudinally) of the electrode’s axis. The length of the needle point should be approximately 2–3 times the diameter of the tungsten electrode.

use Direct current electrode negative (DC-) and welding grade-argon.

Preheat surfaces to be welded. Heat a spot on the base metal until it shows signs of melting and progressively add the filler rod to the weld-pool.

For the best cleaning and finishing results use BOC Weld-Guard™ Pickling-Paste.

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tIG

ProFill 309l

ProFill 309L stainless steel is a high quality low carbon rod for the Gas or Gas Tungsten Arc (TIG) welding of highly alloyed 309 or 309L type stainless steels. ProFill 309L is also suitable for the dissimilar joining of other 300 series austenitic stainless steels ferritic steels.



Classification

AS1167.2:309LSi ASMe-SFA A5.9: eR309LSi






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Weld deposit properties



Approx. melting point 1400ºC





use a Thoriated or Ceriated tungsten electrode, ground to a sharp needle point making sure the grinding lines run with the length (longitudinally) of the electrode’s axis. The length of the needle point should be approximately 2 to 3 times the diameter of the tungsten electrode.




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8



Stainless Steel

ProFill 347

ProFill 347 stainless steel is a high quality Gas or Gas Tungsten Arc (TIG) welding rod. Niobium stabilised for improved resistance to intergranular corrosion, ProFill 347 is recommended for the TIG welding of 347, 348 and 321 type stainless steels stabilised with either Niobium or Titanium.

ProFill 347 is also suitable for the general purpose welding of other 300 series stainless steels including 301, 302, 304 and 304L etc.



Classification

AS1167.2:347 AWS / ASMe-SFA A5.9:eR347


1.6 mm 5 kg BTGS34716

2.0 mm 5 kg BTGS34720

3.2 mm 5 kg BTGS34732

2.4 mm 5 kg BTGS34724

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tIG

ProFill 316l

ProFill 316L stainless steel is a high quality low carbon rod for the Gas or Gas Tungsten Arc (TIG) welding of Molybdenum bearing stainless steels; in particular matching 316 and 316L alloys. ProFill 316L is also suitable for the general welding of 304 and 304 stainless steels and ferritic stainless steels including 409, 444 and 3Cr12.



Classification

AS1167.2:316LSi AWS / ASMe-SFA A5.9:eR316LSi








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8



Stainless Steel

comweld 308lResealable 5 kg plastic tube


end stamped with AS / AWS Class ‘308L’

Dark blue colour coded label for instant identification

Classifications

AS / NZS 1167.2: R308L AWS / ASMe-SFA A5.9: eR308L

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C: 0.015 Mn: 1.90 Si: 0.50

Cr: 19.90 Ni: 9.75 P: 0.020


Packaging data


1.6 x 914 5 plastic tube* 69 321406

2.4 x 914 5 plastic tube* 30 321407

*Resealable


Argon Welding Grade


Suitable for Gas and GTA (TIG) welding of highly alloyed 309 or 309L type stainless steel

end stamped with AS / AWS class ‘309L’

Red colour coded pack label for instant identification

Also suitable for the dissimilar joining of other 300 series austenitic stainless steels to ferritic steels

Classifications


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C: 0.015 Mn: 1.90 Si: 0.45

Cr: 23.5 Ni: 13.5 P: 0.020


Packaging data


1.6 x 914 5 plastic tube* 69 321403

2.4 x 914 5 plastic tube* 30 321404

*Resealable


Argon Welding Grade

tIG

8



Stainless Steel

comweld 2209 For the GTA (TIG) welding of 22%Cr/5%Ni/3%Mo duplex type stainless steels.

Resealable 5kg cardboard tube.

Suitable for GTA (TIG) welding.

end stamped with AWS Class ‘eR2209’ for easy identification.

Classifications

AWS/ASMe-SFA A5.9: eR2209.

Werkstoffe No: 1.4462

Joining Process

Gas Tungsten Arc (TIG) welding.

Typical All Weld Deposit Mechanical Properties

0.2% Proof Stress 600 MPa.


Metal Density 7.95 gms / cm3

Microstructure Austenite & ferrite (≈ 50:50)

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Ferrite Number

30-50 FN (Procedure dependent)

Typical Rod Analysis

C Mn Si Cr Ni Mo

0.012 1.06 0.44 22.8 8.63 3.1

N P S Cu Fe

0.14 0.018 0.007 0.06 Bal.

Packaging Data

Rod Size (mm) Weight (kg), Pack Type Approx. Rods/kg Part No.

1.6 x 1,000 5 Cardboard Tube* 69 321393

2.4 x 1,000 5 Cardboard Tube* 30 321394

* Resealable


Autocraft 2209 GMAW wire

AWS A5.9: e2209


Argon Welding Grade


Suitable for gas and GTA (TIG) welding of-molybdenum bearing stainless steels; in particular matching 316 and 316L alloys

end stamped with AS / AWS class ‘316L’

Gold colour coded pack label for instant identification

Also suitable for the general welding of other 300 series stainless steels including 302 and 304; as well as ferritic stainless steels grades such as 409, 444 and 3Cr12

Classifications


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C: 0.012 Mn: 1.57 Si: 0.50

Cr: 19.00 Ni: 12.6 Mo: 2.50

P: 0.015 S: 0.001 Fe: Balance

Packaging data


1.6 x 914 5 plastic tube* 69 321400

25 rod Handipack – 322054

2.4 x 914 5 plastic tube* 30 321401

*Resealable


Argon Welding Grade

tIG

8



Stainless Steel

Submerged arc Flux

lincoln 308lFor joining the more common austenitic stainless steel grades referred to as "18-8" steels.

Classification AWS eR308L


2.40 25.0 330082

3.20 25.0 330083

lincoln 309lFor joining more high alloyed austenitic stainless steels. Can also be used on "18-8" steels since it over matches the corrosion resistance, if the weldment will not be exposed to temperatures of 540–925°C.



2.40 25.0 330092

3.20 25.0 330093

lincoln 316lundiluted weld metal is designed to contain considerable ferrite for maximum crack resistance. Should not be used on 316L joints in service for urea manufacture, as this environment will attack the ferrite.



2.40 25.0 330062

2.40 25.0 330063

lincoln 2209Solid wire for welding duplex stainless steels. High resistance to general corrosion, pitting and stress corrosion conditions.

Classification AWS eR2209


2.40 25.0 330222

Refer to page xx for a listing of Submerged Arc Flux

8Consumables



Aluminium

aluminium WeldingAluminium is a light, ductile, readily worked metal, with good thermal and electrical properties. It has a tenacious oxide film on the surface that gives it good corrosion resistance. It is also the most abundant metal on earth.

Aluminium alloys may be sub-divided into two main groups, cast alloys and wrought alloys. Wrought materials also come in a wide variety of product forms.

Wrought alloys are further sub-divided into heat-treatable and non-heat-treatable alloys.

Heat-treatable alloys are based on aluminium-copper, aluminium-silicon-magnesium and aluminium-zinc-magnesium alloy systems. They can develop high strength by solution treatment followed by age hardening at elevated temperature.

Non-heat-treatable alloys include pure aluminium, and those based on aluminium-manganese, aluminium-silicon, and aluminium-magnesium. They can be strengthened only by cold work.

typesAluminium and aluminium alloys can be divided into two main groups that refer to the form in which they are used and these are “Cast Alloys” and “Wrought Alloys”. each of these two groups may then be further sub-divided into alloy type by composition.

cast alloysAluminium alloy castings may be produced in sand moulds, metal moulds, and by gravity or pressure die-casting. The castings possess rigidity and good corrosion resistance, with strength and ductility generally being of secondary importance.

Alloying elements frequently used in aluminium castings are copper, silicon, magnesium, zinc, iron, manganese and nickel. Cast alloys are of two main types,

those which rely solely on alloying for their properties, such as Al-Mg and Al-Si alloys

those where heat-treatment can be used to enhance properties, like the Al-Cu alloys

As yet there is no agreed international standard numbering system for castings and each country uses its own identification method. In uK, casting alloys are prefixed by the letters ‘LM’, followed by a one

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or two digit number; in uS, casting alloys are given a two or three digit number, some being prefixed with a letter. Similar systems are also used in Australia and New Zealand.

Many aluminium casting alloys are based on the Al-Si or Al-Cu systems. The Al-Si system has good fluidity and can be used for intricately shaped cast sections. Silicon reduces hot shortness and the tendency for castings to crack on solidification. These alloys have good corrosion properties and often have copper as a second element to enhance their strength.

There are only a few Al-Mg casting alloys, for while they have good corrosion properties in marine environments, and good strength, they are somewhat more difficult to cast than Al-Si alloys.

Wrought alloysWrought alloys consist of cast material that has been worked by processes such as forging, extrusion, drawing, or rolling, thereby improving the homogeneity and enhancing the mechanical properties of the material. This renders many forms of wrought alloys more suitable for welded construction.

Wrought alloys may be:

Hot or cold rolled, to produce plate, sheet, strip, or foil

extruded, to give bars, sections, or tube

Drawn, to make wire, bolts, screws, rivets, or tube

Forged, to give a variety of shapes

Wrought aluminium alloys are of two main types:

heat treatable, those which can be strengthened by heat treatment

non-heat treatable, those which can only be strengthened by cold working

Wrought aluminium alloys are also further classified into groups, according to the main alloying element or elements. each group, or ‘series’, has a four-digit designation conferred by the International Standards Organisation (ISO). The first number relates to the main alloying element(s), the second number to the alloy modification (zero being the original alloy) and the next two numbers indicate the order in which the alloys were developed and subsequent variations. A letter following the four-digit number indicates a national variation in composition, for instance alloy 1200A is a compositional variation of alloy 1200.

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8



Aluminium

Wrought aluminium alloys, in numerical series order, are described briefly below. Some of the alloys in each series, and their approximate compositions, are given in tables in each section. elements are only quoted if included as a deliberate addition, with a minimum requirement, or as a maximum and minimum range in specifications. Other elements may be present as impurities with a maximum limit.

Mechanical PropertiesAluminium is ductile and malleable, enabling it to be manufactured in many different forms by such methods as hot rolling, cold rolling, extrusion, forging, drawing, stamping, spinning, pressing or bending.

Aluminium has good toughness, even down to cryogenic temperatures (below –100˚C), because no ductile to brittle phase transition takes place, even with rapid cooling.

Although the strength of pure aluminium is low compared with steel and other common engineering materials, it can be improved by cold working or by alloying with different elements, and these alloys can be further improved with heat treatment or cold working. The elements most commonly used to form alloys with aluminium are copper, magnesium, silicon, manganese and zinc, singly or in combinations.

Alloying with these elements can strengthen aluminium by one of two mechanisms:

Strength may be increased by the presence of alloying elements that become entrapped in solid solution within the aluminium by a process called solid solution hardening. Alloys which are solid solution hardened can be cold worked to further increase strength and this is called work hardening. Work hardening the material involves cold rolling, extrusion, pressing, drawing, etc. and the strength achieved depends on the amount of cold work applied, and may be described as the ‘temper’ of the alloy. Alloys of this type include Al-Mn and Al-Mg, and they are known as non-heat-treatable alloys.

The properties of some aluminium alloys may be improved by heat treatment, a process in which precipitation of constituents held in solid solution is allowed to take place by holding at a suitable temperature. The process is usually described as ageing or age hardening. If age hardening takes place at room temperature it is referred to as natural ageing, but if elevated temperatures are used this is called artificial ageing. Alloys of this type include Al-Cu, Al-Mg-Si, and Al-Zn-Mg, and they are known as heat-treatable alloys.

■

■

WeldingAlthough at first sight it appears to be a relatively simple alloy system to weld compared with steel, because no solid state phase change occurs, there are several important factors influencing the weldability of aluminium and its alloys to be considered. There are some general factors, covering all alloys, and some individual alloy characteristics, the latter making some alloys more difficult to weld than others.

The main factors to be taken into consideration, and dealt with in detail in Welding Aluminium, are:

The presence of a tenacious, refractory, surface oxide film, which if not removed before welding, can cause lack of fusion or porosity

The high solubility of hydrogen in liquid aluminium compared with its solubility in solid aluminium can lead to porosity in weld metal

The tendency for some alloys, notably 2XXX, 6XXX and 7XXX series alloys, to suffer hot cracking or HAZ liquation cracking

The reduction in mechanical properties that occurs across the weld zone when aluminium alloys are welded

Welding ProcessesAluminium and many of its alloys can be readily welded, most frequently using inert gas shielded processes, such as MIG and TIG. MMA is still used occasionally, particularly for site repair work, but it is difficult to obtain good quality welds with the consumables available.

MIG welding of aluminium is always carried out with a completely inert gas shield, traditionally argon, but now increasingly helium / argon mixtures, such as the BOC Alushield range, which help to increase penetration and to reduce the incidence of porosity.

It must be remembered that aluminium and its alloys must not be MIG welded using active gases like carbon dioxide, or Ar-CO2 mixtures, since these will lead to severe oxidation and failure to produce a weld.

TIG welding must also be carried out using inert gas shield, argon or argon / helium mixtures, not only to prevent oxidation of the weld but also to prevent the tungsten electrode being consumed.

High power density processes, like Laser and electron Beam, and the more recently developed Friction Stir Welding Process are

■

■

■

■

Alloy elements

Not recommendedfor welding

Non heat treatable

Heat treatable

Filler wire

Aluminium

Cu Mn Si Mg Zn Other

2xxx2014A

3xxx3103

4xxx4043/4047

518353561080

5xxx5063

8xxx8090

1xxx1050A

7xxx7020

6xxx6082

8



Aluminium

also suitable for welding all alloys. Brazing and Resistance Welding techniques are applicable to some alloys.

The Submerged Arc and Flux Cored Wire processes are not used for welding aluminium alloy systems.

Welding casting alloysAluminium castings find limited use in welded construction, principally because of their low ductility and high porosity content, but re-instatement and repair of castings by welding is often required. Many casting alloys, notably those containing copper, are not recommended for welding, as they are very crack sensitive. Pure aluminium, and alloys based on Al-Si and Al-Mg, may be welded with appropriate filler metals.

Welding Wrought alloysA brief resume of the welding characteristics of each group of alloys is given below.

1XXX series: non-alloyed aluminium

The 1XXX alloys are readily welded using filler metals of matching composition. It is also possible to use Al-Si or Al-Mg filler metals for some applications. They may be welded using all main processes, including MIG, TIG, MMA, gas welding and brazing, resistance and friction welding methods.

2XXX series: copper as Main alloying element

These alloys are virtually unweldable because the formation of aluminium-copper intermetallics in weld metal renders them brittle. They tend to crack if attempts are made to weld them using fusion welding processes, although use of Al-12%Si filler may sometimes give reasonable results. Non-fusion techniques, such as friction welding and friction stir welding may give some success.

3XXX series: Manganese as Main alloying element

The 3XXX series alloys are weldable alloys, welded with matching filler metals, but are welded infrequently, the main joining method being brazing. Furnace brazing and gas torch brazing are suitable methods.

4XXX series: Silicon as Main alloying element

These alloys are weldable by all processes using Al-Si filler metals where appropriate. However, as stated before a major use for these alloys is as welding wire containing 5%Si or 12%Si.

5XXX series: Magnesium as Main alloying element

Alloys with magnesium contents under about 3%, such as 5251 and 5454, are susceptible to cracking and it is usual to use higher magnesium fillers to overcome this tendency. Alloys with more than 4.5%Mg are readily welded.

MIG and TIG are the most frequently used welding processes for these alloys, and they tend not to respond well to MMA or to gas welding and brazing.

6XXX series: Magnesium and Silicon as Main alloying elements

These alloys can be welded with care, since with less than 1%Si and 1%Mg they have a tendency to crack in the HAZ, by a mechanism called liquation cracking, if high heat inputs are used. To avoid weld metal cracking they require a MIG or TIG filler metal containing 5%Mg or 5%Si to be used. Care must be taken not to mix the two filler compositions or cracking will result.

7XXX series: Zinc as Main alloying element

The series includes both weldable and unweldable grades, although even the weldable alloys are prone to suffer HAZ liquation cracking. It is usual to use filler metals containing zinc and magnesium,

Non-heat treatable Heat treatable

Transport, Engineering, Building and Construction

MilitaryPack

agin

g an

d El

ectr

ical

DuctilityStre

ngth

Aero and Space

Alloy Element

Prop

erty

1xxx

Al

3xxx

Al-Mn

5xxx

Al-Mg

6xxx

Al-Mg-Si

2xxx

Al-Cu-Mg-Si

7xxx

Al-Zn-Mg

8xxx

Al-Zn-Mg-Cu

8



Aluminium

although it is possible to use Al-5.5%Mg fillers in some instances. MIG and TIG tend to be the main processes used on these alloys.

8XXX series: Miscellaneous alloys

Most of the alloys in this series are not commonly welded, and some are not weldable. However, there have been developments in aluminium-lithium alloys for aerospace applications that have led to weldable grades becoming available.

cuttingCutting processes that use an electric arc in a stream of inert gas may be used to cut all aluminium alloys. The cut surfaces are generally quite smooth and clean, but the plate retains narrow, melted and partially melted, zones, which with heat-treatable alloys may lead to intergranular cracking. Corrosion properties may also be adversely affected in the immediate HAZ of the cut. It is, therefore, advisable to trim back by about 3mm from the cut surface to give a sound welding surface, free from possible stress raisers.

It should be noted that some standards call for levels of up to 6mm to be removed after cutting.

Relevant standards should be consulted to establish requirements.

cutting Processes

There are several different thermal processes for cutting aluminium and its alloys, but the most frequently used is Plasma Cutting, with Laser Cutting also finding some applications.

For most industrial fabricators today, plasma cutting is probably the first choice as a cutting technique for aluminium from 3mm to 50mm and above in thickness. Plasma cutting gives a smooth cut surface, free from major contamination, but should be trimmed prior to welding, as described above.

Preheating of aluminium and aluminium alloys

When to Preheat

Preheat is needed when there is a risk that if a welding operation is carried out ‘cold’ an unsound weld could be produced. Whilst it is not possible here to cover all eventualities, there are certain guidelines that can be followed in making the decision whether to preheat or not, and these are outlined here, categorised for convenience, by alloy type.

aluminium alloys

Aluminium Alloys have a high thermal conductivity and preheat is used to provide additional heat to the weld area in order to help ensure full fusion of the weld. Application of preheat is also used to drive off any moisture in the surface oxide. Preheating may not be necessary when welding thin sheet, but becomes increasingly important as thickness, and therefore thermal conduction away from the weld increases.

How much Preheat to apply

The actual preheat temperature required for a specific welding operation depends not only on the material or materials being welded, but also the combined thickness of the joint, the heat input from the welding process being used, and the amount of restraint imposed upon the components. There are no hard and fast rules regarding how much preheat to apply, but there are many publications available giving helpful guidance. These publications include national and international standards or codes of practice, guides from steel and aluminium alloy producers, and from consumable manufacturers. Some guidelines are included here, and as in the previous section, categorised for convenience by alloy type.

aluminium alloys

As a rule, aluminium alloys are only preheated to temperatures between 80˚C and 120˚C. Certain heat treatable aluminium alloys (Al-Si-Mg) are sensitive to HAZ liquation cracking if overheated, and preheat must be carefully controlled within this range. With less sensitive alloys preheat may be increased up to a maximum of 180-200˚C. Remember that aluminium alloys have relatively low melting points and care must be taken to avoid overheating which can result in poor weld quality and cracking in some alloys.

8



Aluminium

aluminium and aluminium alloys

Base Metal

1060, 1100, (1050), 3003 3004

5005, 5050 5052 5083 5086

5154, 5354 5454 5456

6005, 6061 7005

356,0 443,0

1060, 1100, (1050), 3003

1100 (1050) (b)(e)

4043 (d)(e)

4043 (d)(e)

4043 (d)(e)

5356 (b)(d)

5356 (b)(d)

4043 (d)(e)

4043 (d)(e)

5356 (b)(d)

4043 (e) 5356 (b)(d)

4043 (e)

3004 4043 (d)(e)

4043 (d)(e)

4043 (d)(e)

5356 (d) 5356 (d) 5356 (a) 5356 (a) 5356 (d) 4043 (d)(e)

5356 (b)(e)

4043 (e)

5005, 5050

4043 (d)(e)

4043 (d)(e)

5356 (d) 5356 (d) 5356 (a) 5356 (a) 5356 (d) 4043 (d)(e)

5356 (b)(d)

4043 (e)

5052 5356 (a)(b)

5356 (d) 5356 (d) 5356 (a) 5356 (a) 5356 (d) 5356 (a)(b)

5356 (a) 4043 (a)(e)

5083 5183 (d) 5356 (d) 5356 (d) 5356 (d) 5183 (d) 5356 (d) 5183 (d) 5356 (b)(d)

5086 5356 (d) 5356 (d) 5356 (d) 5356 (d) 5356 (d) 5356 (d) 5356 (b)(d)

5154, 5254

5356 (a) 5356 (a) 5356 (a) 5356 (a) 5356 (d) 4043 (a)

5454 5554 (b)(d)

5356 (d) 5356 (a)(b)

5356 (a) 4043 (a)(e)

5456 5556 (d) 5356 (d) 5556 (d) 5356 (b)(d)

6005, 6061, 6063, 6351

4043 (a)(e)

5356 (a)(b)

4043 (a)(e)

7005 5356 (d) 4043 (a)(e)

356,0 443,0

4043 (c)(e)

NOTeS (1) The filler metal that is shown for each combination of base metals is that most commonly

used. However, the specific filler metal depends upon usage and type of joint and, in a number of cases, acceptable alternates is recommended (footnotes a to c).

(2) Filler metals conform to requirements of AWS specification A5.10-80. (3) exposure to specific chemicals or a sustained high temperature (over 150°F) may limit

the choice of the metals. Filler alloys 5183, 5356, 5556 and 5654 should not be used in sustained elevated-temperature service.

a) 5813, 5356, 5554, 5556 and 5654 may be used. In some cases they provide: improved colour match after anodising treatment, higher weld ductility, higher weld strength. 5554 is suitable for elevated-temperature service. Castings welded with these filler metals should not be subjected to post-weld artificial aging.

b) 4043 may be used for some applications.c) filler metal with the same analysis as the base metal is sometimes used.d) 5183, 5356 or 5556 may be used.e) 4047 may be used for some applications.

8



Aluminium

boc aluminium MIG Wire 1080

Welding characteristicsTriple shaved for smoother feeding and consistent contact

applicationsFor welding of 99.9% pure aluminium


Welding grade argon

Alushield® Light

Alushield® Heavy

Classifications

AS 2717.2 No equivalent

AWS / ASTM A5.10 No equivalent

DIN 1732 SG. Al Mg 4.5 Mn Werks. 3.3548 BS 2901 Pt.4 5183

Welding positions


Typical as welded

yield strength (Rm) 22


elongation (%) 40%


Si Fe Cu Mn Mg Zn Ti

Min.

Typical <0.15 <0.15 <0.02 <0.02 <0.02 <0.06 <0.02

Max.

Packing and welding data

Dia. (mm) Current (A) Voltage (V)Weight / spool (kg) Part No.

0.8 70–110 16–18 5.0 S970850

0.9 90–130 17–19 6.0 S970960

1.0 100–140 17–19 6.0 S971060

1.2 120–150 24–29 6.0 S971260

1.6 200–320 25–33 6.0 S971660

GMaW Wire

8



Aluminium


Welding characteristicsexcellent flow characteristics and penetration

excellent crack resistance

Triple shaved for smoother feeding and consistent contact

applicationsused to weld alloys with a maximum of 2% alloying elements and for castings containing up to 7% Si

Many general construction and automotive applications


Welding grade argon

Alushield® Light

Alushield® Heavy

Classifications

AS 2717.2 e4043 AWS / ASTM A5.10 eR4043

DIN 1732, SG. AL SI.5 Werks. 3.2245, BS 2901 Pt.4 4043 A

Welding positions

■

■

■

■

■


Typical as welded



elongation (%) 8%



Min. 4.5

Typical <0.40 <0.05 <0.05 <0.05 <.010 <0.015

Max. 5.5



0.8 70–110 16–18 0.5 S430805

0.8 70–110 16–18 5.0 S430850

0.9 90–130 17–19 0.5 S430905

0.9 90–130 17–19 6.0 S430960

1.0 100–140 17–19 0.5 S431005

1.0 100–140 17–19 6.0 S431060

1.2 150–250 20–25 0.5 S431205

1.2 150–250 20–25 6.0 S431260

1.6 200–350 23–28 6.0 S431660

GMaW Wire

8



Aluminium


Welding characteristicsGood mechanical properties

excellent corrosion resistance

Low melting point ensures reduction in parent metal distortion


applicationsGeneral purpose welding of aluminium sheets, extrusions and castings

Many general construction and automotive applications


Welding grade argon

Alushield® Light

Alushield® Heavy

Classifications

AS 2717.2 e4047 AWS / ASTM A5.10 eR4047 DIN 1732SG. AL Si.12 Werks. 3.2585 BS 2901 Pt.4 4047 A

Welding positions

■

■

■

■

■

■


Typical as welded



elongation (%) 5%

Melting Range 573–585°C



Min. 11.0

Typical <0.50 <0.05 <0.15 <0.05 <0.10 <0.15

Max. 13.0



1.0 100–140 17–19 6.0 S471060

1.2 120–150 24–29 6.0 S471260

GMaW Wire

8



Aluminium


Welding characteristicsHigh strength


applicationsWhere high strength and resistance to sea water are required

Applications in shipbuilding, offshore, cryogenic equipment, railway constructions and automotive

Welding grade argon

ABS AWS A5.10–92 Alushield® Light BV Alushield® Heavy

Classifications

AS 2717.2, e5183, AWS / ASTM A5.10, eR5183, DIN 1732, SG. Al Mg 4.5 Mn Werks. 3.3548, BS 2901 Pt.4 5183

Welding positions

■

■

■

■


Typical as welded



elongation (%) 17%

Lloyd’s D O BF 5083 0and F S NA

Recommended shielding gases DNV AlMg4.5Mn / I1



Min. 0.60 4.3 0.07

Typical <0.25 <0.40 <0.05 <0.25

Max. 1.0 5.2 0.15



0.8 70–110 16–18 5.0 S510850

0.9 90–130 17–19 6.0 S510960

1.0 100–140 17–19 6.0 S511060

1.2 120–150 24–29 6.0 S511260

GMaW Wire

8



Aluminium


Welding characteristicsexcellent corrosion resistance and high strength


applicationsused to weld aluminium magnesium base metal alloys with a maximum of 5% Mg Suitable for a wide range of 3XXX, 5XXX, 6XXX and 5XX series

Applications in shipbuilding, storage tanks, railways and car industry

Classifications

AS 2717.2 e5356 AWS / ASTM A5.10 eR5356 DIN 1732 SG. AL Mg 5 BS 2901 Pt.4 5356

Approvals

Lloyd’s D O BF 5083-OandF S NA DNV AlMg5 / 11 ABS AWS A5.10.92 BV

Welding positions

Recommended hielding gases

Alushield® Light

Alushield® Heavy

Welding Grade Argon

■

■

■

■


Typical as welded



elongation (%) 17%



Min. 0.10 4.5 0.07

Typical <0.25 <0.40 <0.05 <0.10

Max. 0.30 5.6 0.15



0.8 50–150 14–21 0.5 S530805

0.8 50–150 14–21 5.0 S530850

0.9 80–180 16–22 0.5 S530905

0.9 80–180 16–22 2.0 S530920

0.9 80–180 16–22 6.0 S530960

1.0 110–220 17–23 0.5 S531005

1.0 110–220 17–23 2.0 S531020

1.0 110–220 17–23 6.0 S531060

1.2 150–250 20–25 0.5 S531205

1.2 150–250 20–25 2.0 S531220

1.2 150–250 20–25 6.0 S531260

GMaW Wire

8



Aluminium

autocraft al1100A high purity aluminium wire for the GMA welding of selected wrought aluminium alloys

Recommended for the joining of selected high purity 1XXX series aluminium alloys used extensively in electrical and chemical industry applications

Classifications

AS / NZS 2717.2: e1188 AWS / ASMe-SFA A5.10: eR1188


Single ‘V’ butt weld with 1060 Aluminium (reduced section tensile specimen)

Welding grade Argon

0.2% Proof stress 34.5 MPa

Tensile strength 69.0 MPa

elongation (in 2 inches)

29%

■

■

Wire analysis limits

Si: 0.06% Fe: 0.06% Cu: 0.005%

Mn: 0.01% Mg: 0.01% Zn: 0.03%

Ti: 0.01% Total others: 0.01%

Al: 99.88% min

* Single values are maximum allowable, unless otherwise stated.


Alushield® Light

Alushield® Heavy

Welding Grade Argon



Current range (A)

Pack type*


1.6 23–28 5.0–9.5 200–350 Spool 7.0 722218

2.0 25–31 53.0–7.5 250–400 Spool 7.0 723218

autocraft al4043An aluminium -5% silicon wire for GMA welding of selected wrought and cast aluminium alloys

For the repair welding of aluminium alloy castings (mainly 4XX and 6XX series)

For welding selected wrought (1XXX, 5XXX and 6XXX series) aluminium alloys

Classifications



Single ‘V’ butt weld with 6061-T6 Aluminium (reduced section tensile specimen) using welding grade Argon: Postweld heat

As welded Treated and aged

0.2% Proof stress

124 MPa 276 MPa

Tensile strength

186 MPa 303 MPa


8% 5%

■

■

■

Wire analysis limits

Single values are maximum allowable, unless otherwise stated

Si: 4.5–6.0% Fe: 0.80% Cu: 0.30%

Mn: 0.05% Mg: 0.05% Zn: 0.10%


Al: Balance





1.2 20–25 5.5–12.0 150–250 Spool 7.0 722237

1.6 23–28 5.0–9.5 200–350 Spool 7.0 722238


Alushield® Light

Alushield® Heavy

Welding Grade Argon

GMaW Wire

8



Aluminium

autocraft al5356An aluminium -5% magnesium wire for the GMA welding of a wide range of wrought and cast aluminium alloys containing magnesium

Classifications



Single ‘V’ butt weld with 5086 Aluminium (reduced section tensile specimen)

Welding grade Argon




17%

■Wire analysis limits

Single values are maximum allowable, unless otherwise-stated

Si: 0.25% Fe: 0.40% Cu: 0.10%

Mn: 0.05–0.2% Mg: 4.5–5.5% Cr: 0.05–0.20%

Zn: 0.10% Ti: 0.06–0.20%

Total others: 0.15%

Al: Balance


Alushield® Light

Alushield® Heavy

Welding Grade Argon






0.8 14–21 6.0–20.0 50–150 Mini Spool – Pack of 4

4 x 0.5 721221

0.9 16–22 6.0–17.5 80–180 Spool 7.0 722226

1.0 17–23 6.0–16.5 110–220 Spool 7.0 722224

1.2 20–25 5.5–12.0 150–250 Spool 7.0 722227

GMaW Wire

8



Aluminium

GMaW Wire

Superglaze 4043Popular filler metal chemistry containing silicon to lower melting point and provide fluidity. Developed for welding of heat treatable base alloys and more specifically the 6XXX series alloys. Moderately soft, provides good weld appearance, melting action and penetration. excellent operating characteristics.

Classifications AWS eR4043


0.9 7.26 eD028395A

1.2 7.26 eD028397A

1.6 7.26 eD028398A

2.4 7.26 eD028399A

Superglaze 5183Magnesium based alloy providing outstanding strength, making this chemistry an excellent candidate for structural applications such as marine, storage or rail cars.



0.9 7.26 eD028435A

1.2 7.26 eD028437A

1.6 7.26 eD028438A

Superglaze 53565% Magnesium alloy which is the most commonly used. It is suitable for welding most of the 5XXX base materials. The wire exhibits good strength, stiffness and good wire feeding characteristics.



0.9 7.26 eD028385A

1.0 7.26 eD028386A

1.2 7.26 eD028387A

1.6 7.26 eD028388A

8



Aluminium

comweld al110099.88% pure aluminium alloy rod

Suitable for gas welding and gas tungsten arc-(GTAW / TIG) welding applications

embossed with AS / AWS class ‘1100’

For the joining of selected high purity 1XXX series aluminium sheets and plates used extensively in the electrical and chemical industries

Classifications

AS / NZS 1167.2: R1188 AWS / ASMe-SFA A5.10: R1188

■

■

■

■

Rod analysis limits

Single values are maximum allowable, unless otherwise stated.

Si: 0.06% Fe: 0.06% Cu: 0.005%

Mn: 0.01% Mg: 0.01% Zn: 0.03%

Ti: 0.01% Others each: 0.01%

Al: 99.88% min

Packaging data

Rod Size (mm) Weight (kg), Pack type Carton size / kg Approx No. (rods / kg) Part No.

1.6 x 914 2.5 cardboard 15 30 321600

2.4 x 914 2.5 cardboard 15 30 321601


Argon Welding Grade

Alushield® Light

comweld al4043Aluminium – 5% silicon alloy rod

Suitable for gas welding and gas tungsten arc (GTAW / TIG) welding applications

embossed with AS / AWS class ‘4043’

For the repair welding (fractures and blow holes etc.) of selected aluminium alloy castings

Classifications


■

■

■

■

Rod analysis limits


Si: 4.5–6.0% Fe: 0.80% Cu: 0.30%

Mn: 0.05% Mg: 0.05% Zn: 0.10%


Al: Balance

Packaging data


1.6 x 914 2.5 cardboard 15 210 321610

2.4 x 914 2.5 cardboard 15 90 321611

3.2 x 914 2.5 cardboard 15 51 321612


Argon Welding Grade

Alushield® Light

tIG

8



Aluminium

comweld al4047Aluminium – 10% silicon alloy rod

Suitable for gas welding and gas tungsten arc (GTAW / TIG) welding applications

embossed with AS / AWS class 4047

used extensively for the brazing of many types of aluminium alloy sheets, extruded shapes and castings

Classifications

AS / NZS 1167.2: R4047 AWS / ASMe-SFA A5.10: R4047 AWS / ASMe-SFA A5.8: BAlSi-4

■

■

■

■

Rod analysis limits


Si: 11.0–13.0% Fe: 0.80% Cu: 0.30%

Mn: 0.15% Mg: 0.10% Zn: 0.20%

Total others: 0.15%

Al: Balance

Packaging data


1.6 x 914 2.5 cardboard 15 210 321620

1.6 x 914 100 rod Handipack 8 Pks – 322070

2.4 x 914 2.5 cardboard 15 90 321621


3.2 x 914 2.5 cardboard 15 51 321622


Argon Welding Grade

Alushield® Light

comweld al5356Aluminium – 5% magnesium alloy rod

Suitable for gas welding and gas tungsten Arc (GTAW / TIG) welding applications

embossed with AS / AWS class 5356

Produces intermediate deposit strength and good ductility and corrosion resistance for the welding of a wide range of 3XXX, 5XXX, 6XXX and 5XX aluminium alloys

Classifications


■

■

■

■

Rod analysis limits

Single values are maximum allowable, unless otherwise stated.

Si: 0.25% Fe: 0.40% Cu: 0.10%

Mn: 0.05–0.20%

Mg: 4.5–5.5% Cr: 0.05–0.20%

Zn: 0.10% Ti: 0.05–0.20%

Total others: 0.15%

Al: Balance

Packaging data


1.6 x 914 2.5 cardboard 15 210 321640

2.4 x 914 2.5 cardboard 15 90 321641


3.2 x 914 2.5 cardboard 15 51 321642


Argon Welding Grade

Alushield® Light

tIG

8 Consumables



Copper

Copper is a metal with some very important properties, the main ones being its high electrical conductivity, its high thermal conductivity, its excellent resistance to corrosion, and its ease of fabrication, either hot or cold.

Copper is also ductile and malleable and has a relatively low melting point at just over 1080°C.

The three basic commercial grades of copper that are available are:

Tough pitch copper, containing up to 0.1%oxygen

Phosphorous deoxidised (PDO) copper, containing up to 0.04%phosphorus

Oxygen-free copper, containing no deoxidants

The phosphorus deoxidised grade was originally developed to overcome problems encountered when flame welding tough pitch copper. It is now the standard commercial weldable grade used for pressure vessels and radiators. Oxygen-free grades have significantly higher electrical conductivity than oxygen-containing grades and are therefore used widely as electrical conductors.

types

Copper and copper alloys are generally grouped by compositional type and identified in standards by number or letter/number designations. However, it has been, and still is, common practice to refer to copper and copper alloys by their traditional names, such as brass and bronze, rather than by letters and number designations.

Copper and copper alloys may be divided into groups by general composition, and each group contains a range of specific alloys. The main groups considered here are:

unalloyed copper

Beryllium copper

Brasses

Bronzes

Silicon bronzes

Aluminium bronzes

Cupro-nickels

■

■

■

■

■

■

■

■

■

■

Welding

As has been stated earlier, copper has a very high thermal conductivity and a high coefficient of expansion. These provide the main problems encountered during welding of unalloyed copper. High levels of preheat and heat inputs are required for fusion welding. These in turn can cause distortion problems. Copper is also susceptible to hot cracking so heavy restraint needs to be avoided.

The thermal conductivity of many copper alloys is relatively low and welding without preheat may be possible. However, many alloys will crack readily when welded if too much heat is put into the weld area or if welding is carried out under restraint. Any copper alloys containing lead should not be welded.

Welding ProcessesCopper and its alloys can be welded, most frequently using inert gas shielded processes, such as MIG and TIG. MMA is used occasionally for welding some copper alloys and gas welding and brazing are also used for some applications.

TIG welding bronze statue

copper and copper alloys

8



Copper

Shielding gases for TIG or MIG welding may be pure argon or helium-argon mixtures, such as the BOC range of Alushield gases. Pure argon tends to produce a narrow penetration profile that is not very deep. This means than high levels of preheat are required to avoid fusion defects. Helium-argon mixtures with between 50% and 75% helium increases the energy available to the weld so that good weld fusion and penetration can be achieved at minimum preheat temperatures.

High power density processes, like laser and electron beam, are also suitable for welding copper and copper alloys.

The Submerged Arc and Flux Cored Wire processes are not used for welding copper or copper alloy systems.

Welding copper

unalloyed copper

Tough pitch copper contains oxygen and welding this type of copper can result in weld metal porosity and embrittlement if hydrogen is present. The oxygen and hydrogen combine to form steam and ‘steam porosity’ is likely to occur if these types of copper are welded with the oxy-acetylene process. Oxygen-free and PDO grades of copper have better weldability than tough pitch copper.

The usual welding processes for copper are MIG and TIG. Filler metals, such as AWS A5.7 type eRCu or BS 2901-3 type C1A, with additions of de-oxidants, should be used to control porosity.

With all coppers the main problem is that heat is rapidly dissipated from the weld and this can lead to fusion defects if enough heat is not put into the joint area. Preheat is, therefore, recommended for thicknesses above 5mm. Preheat levels range from about 200°C at 5mm to 600°C and above at 20mm. Highest preheats are required when welding with argon shielding gas but may be lowered or avoided if helium or helium gas mixtures are used, due to the increase in heat input these gases provide.

beryllium copper

Welding of beryllium copper is not carried out extensively but when it is the preferred processes are MIG and TIG. Filler metals used to weld unalloyed coppers are used for copper beryllium alloys since filler metals containing beryllium are not available.

However, welding can present a few problems. Cracking in the HAZ, due to the presence of age-hardening precipitates, may occur if insufficient preheat is applied. Also, beryllium will oxidise rapidly and be given off as fume if the arc region is not properly protected with inert shielding gas and the main problem here is that fume containing beryllium oxide is highly toxic and can cause death.

Welding of copper alloys containing beryllium must be carried out with care and use of fume extraction equipment and personal respiratory protection is essential.

brasses

Brasses are not readily weldable since the application of a welding arc causes the zinc to boil off as zinc oxide fume. Zinc oxide may be identified during welding as dense white fumes rising from the brass, impairing the welder’s visibility, and they also leave white ‘cobwebs’ on equipment and surrounding attachments, as further evidence. Zinc oxide will cause zinc fume fever if inhaled in sufficient quantity.

Loss of zinc from the vicinity of the weld can affect the properties of the material and also causes porosity in the weld metal.

If it is essential to weld brass, use of TIG welding, using a silicon bronze filler rod, such as AWS A5.7 type eRCuSi-A or BS 2901-3 type C9, would be the preferred option. Zinc will inevitably be lost from the brass and some weld metal porosity will occur, but may be kept to a minimum with care.

Welding of free-machining brass, containing significant amounts of lead, should not be attempted since they will almost certainly crack.

Silver Brazing or soldering of brass is a better bet than welding and can be carried out using suitable braze metals and fluxes.

bronzes

Bronzes, such as phosphor bronze and gunmetal, are not normally welded during manufacture but may require repairs to be carried out from time to time. They are not the easiest materials to weld and are frequently brazed or soldered rather than welded.

Phosphor bronzes are likely to suffer hot cracking when welded but reasonable results can be achieved using MIG or TIG welding with copper-tin filler metals, such as AWS A5.7 type eRCuSn-A or BS 2901-3 type C10. Moderate preheat is normally required, and high restraint should be avoided.

Gunmetal too may be welded similarly with care (provided it does not contain lead) but hot cracking is a distinct possibility.

‘Leaded’ phosphor bronzes and gunmetals are generally considered to be unweldable and hot cracking is virtually certain to result if attempts are made to weld these materials.

Bell metal is very difficult to weld because it is hard and brittle and prone to hot cracking. However, cracked church bells have been successfully repair-welded using gas welding and TIG welding with strips of matching bell metal composition as filler metal. High preheat, continuous heating throughout the welding process, and very slow cooling after welding are essential measures to be adopted to prevent cracking.

aluminium bronzes

Aluminium bronzes are generally weldable and usually without preheat since the thermal conductivity of aluminium bronze is relatively low. Welding with MMA electrodes is possible but MIG and TIG are the preferred welding processes. When TIG welding with argon shielding gas the use of AC current is necessary to break down the tenacious aluminium oxide film, but DC electrode negative may be used with helium-rich shielding gas.

Matching aluminium bronze filler metals are generally used when welding these alloys, and include fillers such as AWS A5.7 types eRCuAl-A2 and eRCuAl-A3, or BS 2901-3 types C12Fe and C13.

Porosity is likely to be a problem in multi-pass welds if correct cleaning procedures are not adopted, and high restraint may induce cracking.

Silicon bronzes

Silicon bronzes are reasonably weldable and again preheat is generally not required. MMA electrodes are available but the preferred welding processes are MIG and TIG. Silicon bronze filler metals with about 3% silicon are used and fillers of this type conform to specifications such as AWS A5.7 types eRCuSi-A or BS 2901-3 types C9.

8



Copper

Although an oxide film is likely to form on the weld, it is still standard practice to used DC electrode negative when TIG welding with either argon shielding gas or with a helium-argon mixture.

Hot cracking is a potential problem with silicon bronzes and so excessive heating and high restraint should be avoided.

cupro-nickels

Cupro-nickel alloys are readily weldable and may be welded using MMA, MIG, or TIG welding processes, generally without preheat. High quality welds can be obtained with all these welding processes.

electrodes and filler metals conforming to 70/30 copper-nickel are readily available. These conform to specifications such as AWS A5.7 types eCuNi (MMA) and eRCuNi (MIG and TIG) or BS 2901-3 type C18. Filler metal conforming to 90/10 copper-nickel is listed in BS 2901-3 as type C16. Fillers for cupro-nickels usually include titanium as deoxidant, to prevent the formation of porosity.

Argon or Alushield shielding gases are generally preferred for MIG and TIG welding, the latter often being carried out using DC electrode negative. Specialist shielding gases such as Specshield 11% He/ 2% H2 are used to reduce the incidence of surface oxides which can form on these materials especially when multi-pass TIG welding.

Contaminants such as sulphur, phosphorus, and lead are detrimental to cupro-nickels and are likely to cause cracking. Thorough cleaning of these alloys before welding is required.

8



Copper

bronzecraft ac-DcPhosphor bronze electrode containing 7% tin

For welding copper and copper alloys

Also for joining copper and copper alloys to-steel

easy to use, high quality weld deposit appearance

Classifications

AS / NZS 2576: e 6200 – A2 AWS / ASMe-SFA A5.6: e CuSn – C

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elongation 22%

Hardness 120 HV30

Packaging and operating data AC (minimum 45 OCV) DC- polarity


rods / kgCurrent range (A) Packet (kg) Carton (kg) Part No.Size (mm) Length (mm)

3.2 350 30 70–110 2.5 15 (6 x 2.5) 611783


Mn Sn Al P Fe Cu

0.02 7.50 0.008 0.26 0.20 Bal

MMa electrodes

8



Copper

autocraft Deoxised copper

A high copper alloy for GMA joining and overlay applications

Fabricating deoxidised copper and electrolytic pitch copper components

Repair of copper castings

Lower strength welding of galvanised steels and deoxidised copper to mild steel joints

Typical applications include the GMA welding of copper transformer connectors, copper bus bars, billet moulds and heater elements etc.

Classifications

AWS / ASMe-SFA A5.7: eRCu

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Welding grade Argon




30%

electrical conductivity 40% IACS

Hardness 55 HB

Weld metal density 7.47 x 103 / m3





1.6 28–32 5.5–11.5 160–380 Spool 13.6 720260

Typical wire analysis (%) limits

Mn Si P Sn Cu Others

0.5 0.5 0.15 1.0 >98.0 0.50

Single values are maximum allowable, unless otherwise-stated.


Alushield® Light

Alushield® Heavy

Welding Grade Argon

autocraft Silicon bronze

A copper based wire for the GMA welding of copper-silicon alloys including cusilman and everdur

used for the lower strength welding of-steels

extensively used for the GMA welding of-copper-silicon alloys used in hot water systems, heat exchangers, calorifiers and marine components for their corrosion resistance

Classifications

AWS / ASMe-SFA A5.7: eRCuSi–A

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Welding grade Argon




50%


Fe Mn Si Sn Zn Cu

0.25 1.0 3.40 0.90 0.90 Bal






0.8 15–20 4.5–10.5 65–150 Handi Spool 4.5 720159

0.9 21–26 7.5–14.5 100–250 Spool 13 720015

1.2 22–28 5.5–11.5 160–380 Spool 13 720255


Welding Grade Argon

Argoshield® 100


Argoshield® 52

Stainshield®

GMaW Wire

8Consumables



Cast Iron

Welding of cast IronCast irons, like steels, are essentially alloys of iron and carbon, but whereas the carbon content of steel is limited to a maximum of 2%, cast irons generally contain more than 2% carbon.

In order to facilitate a better understanding of these materials, they can be divided into five groups, based on composition and metallurgical structure: white cast iron, malleable cast iron, grey cast iron, ductile cast iron and alloy cast iron

White cast Iron

White cast iron derives its name from the white, crystalline crack surface observed when a casting fractures. Most white cast irons contain <4.3% carbon, with low silicon contents to inhibit the precipitation of carbon as graphite

It is used in applications where abrasion resistance is important and ductility not required, such as liners for cement mixers, ball mills, certain types of drawing dies and extrusion nozzles.

Microstructure white Cast Iron (x200)

White cast iron is generally considered unweldable. The absence of any ductility that can accommodate welding-induced stresses in the base metal and heat-affected zone adjacent to the weld results in cracking during cooling after welding.

Malleable cast Iron

Malleable cast iron is produced by heat treating white cast iron of a suitable composition. As pointed out earlier, iron carbide can decompose into iron and carbon under certain conditions. This reaction is favoured by high temperatures, slow cooling rates and high carbon and silicon contents

Ferritic Malleable cast Iron

At room temperature the microstructure therefore consists of temper carbon nodules in a ferrite matrix, generally known as ferritic malleable cast iron. The compact nodules of temper carbon do not break up the continuity of the tough ferritic matrix, resulting in high strength and improved ductility. The graphite nodules also serve to lubricate cutting tools, which accounts for the very high machinability of malleable cast iron.

Microstructure of ferritic malleable cast iron (x200)

Ferritic malleable cast iron has been widely used for automotive, agricultural and railroad equipment; expansion joints and railing castings on bridges; chain-hoist assemblies; industrial casters; pipe fittings; and many applications in general hardware.

Pearlitic Malleable cast Iron

If full graphitisation is prevented and a controlled amount of carbon remains in the iron during cooling, finely distributed iron carbide plates nucleate in the iron at lower temperatures. This can be achieved by alloying with manganese, or by replacing the second-stage anneal by a quench (usually in air or oil).

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Cast Iron

Microstructure of pearlitic malleable cast iron (x200)

Due to the presence of iron carbide in the microstructure, the strength and hardness of these castings are increased over those of ferritic malleable cast iron.

Grey cast Iron

Grey cast iron is one of the most widely used casting alloys and typically contains between 2,5% and 4% carbon, and 1% and 3% silicon. With proper control of the carbon and silicon contents and the cooling rate, the formation of iron carbide during solidification is suppressed entirely, and graphite precipitates directly from the melt as irregular, generally elongated and curved plates in an iron matrix saturated with carbon.

When a grey iron casting fractures, the crack path follows these graphite flakes and the fracture surface appears grey because of the presence of exposed graphite.

Microstructure of grey cast iron (x200)

The strength of grey cast iron depends almost entirely on the matrix in which these graphite flakes are embedded. Slow cooling rates and high carbon and silicon contents promote full graphitisation, and the majority of the carbon dissolved in the iron at high temperatures is deposited as graphite on the existing flakes during cooling. The structure then consists of graphite flakes in a ferrite matrix, referred to as ferritic grey cast iron.

If graphitisation of the carbon dissolved in the iron at high temperatures is prevented during cooling, iron carbide precipitates out and the matrix is pearlitic (referred to as pearlitic grey cast iron). Ferritic grey cast iron is normally soft and weak.

Ductile Iron

Ductile cast iron, also known as nodular iron or spheroidal graphite (SG) iron, is very similar in composition to grey cast iron, but the free graphite in these alloys precipitate from the melt as spherical particles, rather than flakes. This is accomplished through the

addition of small amounts of magnesium or cerium to the ladle just before casting. The spherical graphite particles do not disrupt the continuity of the matrix to the same extent as graphite flakes, resulting in higher strength and toughness compared with grey cast iron of similar composition

Microstructure of SG cast iron with bulls eye ferrite (x200)

Typical applications are agricultural (tractor and implement parts); automotive and diesel (crankshafts, pistons and cylinder heads); electrical fittings, switch boxes, motor frames and circuit breaker parts; mining (hoist drums, drive pulleys, flywheels and elevator buckets); steel mill (work rolls, furnace doors, table rolls and bearings); tool and die (wrenches, levers, clamp frames, chuck bodies and dies for shaping steel, aluminium, brass, bronze and titanium).

Mechanical PropertiesDue to the low toughness and ductility of cast iron (especially white and grey cast iron), standard tensile and impact toughness tests have limited applicability, and elongation and absorbed energy values are not always available. Some of the mechanical properties of the different types of cast iron are shown in the table below. The wide variation in mechanical properties within a particular class of cast iron, as shown below, can be attributed to a variation in microstructure.

The machinability of grey, malleable and ductile cast irons is superior to that of carbon steel, and these alloys even outperform free-cutting steel. The excellent machinability can be attributed to the lubricating effect of the graphite particles in the microstructure. Grey cast iron has a very high damping capacity (ability to quell vibrations), and is therefore well suited for bases and supports, as well as for moving parts.

WeldingCast irons include a large family of ferrous alloys covering a wide range of chemical compositions and metallurgical microstructures. Some of these materials are readily weldable, while others require great care to produce sound welds. Certain cast irons are considered unweldable.

A major factor contributing to the difficulty of welding cast iron is its lack of ductility. If cast irons are loaded beyond their yield points, they break rather than deform to any significant extent. Weld filler metal and part configuration should therefore be selected to minimise welding stresses.

MMA, Flux Cored Arc, MIG, TIG and Gas Welding welding processes are normally used with nickel-based welding consumables to produce high-quality welds, but cast iron and steel electrodes can also produce satisfactory welds in certain alloys.

8



Cast Iron

Iron castings are generally welded to:

repair defects in order to salvage or upgrade a casting before service,

repair damaged or worn castings, and

fabricate castings into welded assemblies.

Repair of defects in new iron castings represents the largest single application of welding cast irons. Defects such as porosity, sand inclusions, cold shuts, washouts and shifts are commonly repaired. Fabrication errors, such as inaccurate machining and misaligned holes, can also be weld repaired.

Due to the widely differing weldability of the various classes of cast iron, welding procedures must be suited to the type of cast iron to be welded.

White cast Iron

Because of its extreme hardness and brittleness, white cast iron is considered unweldable.

Malleable cast Iron

During welding, the ductility of the heat-affected zone (HAZ) of malleable cast iron is severely reduced because graphite dissolves and precipitates as iron carbide. Although postweld annealing softens the hardened zone, minimal ductility is regained. Despite these limitations, malleable cast irons can be welded satisfactorily and economically if precautions are taken.

Because most malleable iron castings are small, preheating is seldom required. If desired, small welded parts can be stress relieved at temperatures up to 550°C. For heavy sections and highly restrained joints, preheating at temperatures up to 200°C and a postweld malleabilising heat treatment are recommended. However, this costly practice is not always followed, especially when the design of the component is based on reduced strength properties of the welded joint.

Ferritic malleable grades display the best weldability of the malleable cast irons, even though impact strength is reduced by welding. Pearlitic malleable irons, because of their higher combined carbon content, have lower impact strength and higher crack susceptibility when welded. If a repaired area must be machined, welding should be performed with a nickel-based electrode.

MMA welding cast iron using low-carbon steel and low-hydrogen electrodes at low currents produces satisfactory welds in malleable iron. If low-carbon steel electrodes are used, the part should be annealed to reduce the hardness in the weld (due to carbon pick-up) and in the HAZ.

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Grey cast Iron

As grey cast iron contains graphite in flake form, carbon can readily be introduced into the weld pool, causing weld metal embrittlement. Consequently, techniques that minimise base metal dilution are recommended. Care must be taken to compensate for shrinkage stresses, and the use of low strength filler metals helps reduce cracking without sacrificing overall joint strength.

Grey cast iron welds are susceptible to the formation of porosity. This can be controlled by lowering the amount of dilution with the base metal, or by slowing the cooling rate so that gas has time to escape. Preheat helps reduce porosity and reduces the cracking tendency. A minimum preheat of 200°C is recommended, but 315°C is generally used.

The most common arc welding electrodes for grey cast iron are nickel and nickel-iron types. These electrodes have been used with or without preheating and / or postweld heat treatment. Cast iron and steel electrodes must be used with high preheats (550°C) to prevent cracking and the formation of hard deposits.

Ductile cast Iron

Ductile cast irons are generally more weldable than grey cast irons, but require specialised welding procedures and filler materials. Pearlitic ductile iron produces a larger amount of martensite in the HAZ than ferritic ductile iron and is generally more susceptible to cracking.

MMA using nickel-iron electrodes is the most common welding technique for welding ductile iron. Most castings do not require preheating, but preheats of up to 315°C are used on large components.

electrodes should be dried to minimise hydrogen damage and porosity. If machinability or optimum joint properties are desired, castings should be annealed immediately after welding.

Table of mechanical properties of a range of cast irons

Cast ironTensile strength ( MPa)

Compressive strength ( MPa) Hardness (HB) elongation (%) Toughness (J)

White 200–410 Not available 321–500 Very low Very low

Malleable 276–724 1350–3600 (pearlitic and martensitic)

110–156 (ferritic) 149–321 (pearlitic and martensitic)

1–10% 4–12 J @ 20°C

Grey 152–431 572–1293 156–302 <0.6% Very low

Ductile 345–827 359–920 143–302 2–20% 16–27 J @ 20°C

8



Cast Iron

Typical applications for the filler metal types used for welding cast iron

Filler Type Typical Application

Cast Iron Oxy-acetylene and arc welding of grey, ductile and blackheart malleable irons where good colour match is required. Different consumables give either a flake or a nodular graphite structure.

Ni Joining and repair of grey irons and for surfacing high dilution welds in stronger grades. Produces a soft peenable deposit. Special electrode coverings are available to help repair deep cavities and blow holes.

NiFe Joining and repair of ductile, blackheart malleable and higher strength grey irons. Also used to join cast iron to dissimilar metals and for welding austenitic irons. Can also be used on irons with high sulphur and phosphorus levels.

NiFeMn Similar applications to NiFe fillers, but a stronger more crack resistant deposit is produced.

NiCu used when a soft peenable deposit with good colour match is required on grey, nodular and blackheart malleable irons. Also useful for welding castings of unknown type and composition.

CuSn Mostly used for its good sliding and anti-seizing properties i.e. for surfacing applications, particularly on grey irons.

CuAl Similar applications to CuSn but with poorer surfacing properties, but higher strength.

CuMnNiAl Similar application to CuAl fillers, but used where higher strength is required.

Practical considerations

base Metal Preparation

Proper preparation of a casting prior to welding is very important. All traces of the defect must be removed from the casting, usually by chipping, grinding, arc gouging or flame gouging. Dye-penetrant inspection is recommended to ensure complete removal of all defects. Thorough cleaning of the joint faces and adjacent material prior to welding is essential for ensuring successful repair welding and for preventing porosity and wetting difficulties.

Castings that have been in service are often saturated with oil or grease. exposure to high temperatures during the weld thermal cycle can cause dissociation of these hydrocarbon compounds, resulting in the formation of porosity in the weld. For this reason any surface oil or grease must be removed prior to welding using solvents or steam cleaning. The surface skin of the casting, that may contain burned-in sand or other impurities from the mould, should also be removed. Castings that have been in service for extended periods of time may also require degassing by heating the casting uniformly to about 370°C for 30 minutes, or for a shorter time to almost red heat (approximately 540°C), using an oxy-fuel gas torch or circulating air furnace.

If localised degassing is preferred, the weld area can be heated by depositing a weld pass, which usually becomes very porous and then removing it by grinding. This welding and grinding operation is repeated until the weld metal is sound. The weld may then be completed as specified in the welding procedure. Castings that have been impregnated with a plastic or glass sealer should not be repair welded, because the sealer may inhibit fusion or produce excessive porosity in the weld.

It is also important that the outer surface of the casting and any ground surfaces be wiped with mineral spirits, such as acetone, to remove residual surface graphite prior to welding. Residual graphite inhibits wetting and prevents complete joining and fusion. When wetting difficulties are encountered, the following cleaning methods can be used:

electrochemical cleaning in a molten salt bath operating at temperatures of 455–510°C in a steel tank. By passing direct current through the bath, a surface essentially free of graphite, sand, silicon, oxides and other contaminants can be produced.

Abrasive blasting with steel shot is suitable for preparing the surfaces of ductile and malleable cast iron, but should not be used for grey cast iron.

Searing the surfaces to be welded with an oxidising flame or heating the casting to about 900°C in a strongly decarburising atmosphere may be suitable in some applications.

Before any cleaning procedure is used in production, wetting tests should be conducted using the proposed filler metal and welding procedure. The filler metal should be applied to a clean, flat surface and then examined visually. If the surface is not uniformly wetted, it has not been cleaned sufficiently.

Special welding techniques for cast irons Improved weld performance can be achieved by application of several special techniques. These include

Joint design modifications

Groove face grooving

Studding

Peening

Special deposition sequences and electrode manipulation

Joint design modification

Full penetration welds are better than partial penetration ones, since the crevice left unfused can act as a stress concentration, increasing the risk of cracking. It is therefore advisable, where possible, to modify joint design to allow full penetration weld to be made, as shown below. Welds at changes in thickness can suffer uneven expansion and contraction stresses during the welding cycle, and also are located at stress concentrations. A change in design to move the weld to a region of constant thickness is therefore beneficial in some cases since the weld is then removed from the ‘danger area’. A backing fillet weld can also be used to support a weld in a region of stress concentration.

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8



Cast Iron

Poor Design Improved Design

Partial penetration welds Full penetration welds

Uneven thickness Constant thickness

Without backing fillet weld With backing fillet weld

Modifications to joint design that would lead to the minimisation of stress concentrations and so reduce the risk of cracking in cast iron welds

Groove face grooving

Grinding or gouging grooves into the surface of the prepared weld groove, then filling the grooves with a weld bead, before filling the whole joint, as shown below, is sometimes recommended. This reduces the risk of cracking by deflecting the path of a crack. Also, as with conventional buttering, the beads that are in contact with the casting, and therefore most highly diluted, are deposited first, when the stresses on the fusion line and heat affected zone of the weld are lowest.

Gooving Joint face

The technique of grooving the joint face before filling. This interrupts the line of the heat affected zone

Studding

Improved joint strength can be achieved by driving or threading studs into the joint face. These should be staggered as shown below, so that a stud does not face another directly opposite it across the joint. Provided the studs are of material compatible with the filler metal this technique can help reduce underbead cracking in the HAZ or along the fusion line.

Stagged Studs (top view)

50 mm

Stagged Studs (cross section)

Screwing or driving staggered studs into the joint face before welding to improve joint strength

Peening

By hammering (peening) a deformable weld bead, thereby putting it into a state of compressive stress, the tensile stresses caused by thermal contraction can be opposed, thereby reducing the risk of cracking in and around the weld. This requires a ductile weld metal. Nickel fillers are very suitable, and when welding brittle grey cast irons this process is extremely useful. When stronger joints are required and iron-nickel consumables are used, then peening must be done at higher temperatures, while the metal is still sufficiently soft. Peening can be mechanised as well as done manually. For manual work a 13–19 mm ballpeen hammer is used to strike moderate blows perpendicular to the weld surface. Mechanised hammers should operate at 620 kPa, and at 750–1000 mm / min. The hammer head should be no wider than the weld bead and should have a radius equal to half the width.

Deposition techniques and electrode manipulation

arc welding

Stringer or weave techniques can be used in depositing the weld bead, though weaving should be kept to within three times the electrode core diameter. Minimum dilution will result from using the stringer technique in the flat position, with the arc directed at the weld pool rather than the base metal. When re-striking the arc, this should be done on deposited metal, rather than base metal, though any slag must first be removed. This can be done with a cold chisel or chipping hammer.

In long welds, or welds on thick base material, depositing short, staggered beads will help minimise distortion, by balancing contraction stresses. Buttering of thick joint faces before filling in the rest of the joint is recommended. This is particularly effective if the buttering layers are of a composition more tolerant to dilution by the base metal.

To minimise penetration, short circuit dip-transfer modes should be used with MIG, MAG and flux-cored welding processes, and arc

8



Cast Iron

lengths in MMA welding should be kept as short as possible whilst still maintaining good weld shape. In general, the welding current should be kept as low as possible within the range specified by the consumable manufacturer.

oxy-acetylene welding

When depositing cast iron by the gas welding process the torch flame should not be oxidising, as the resulting loss of silicon promotes the formation of brittle white iron in the deposit. Similarly, the tip of the inner cone of the flame should be kept between 3–6 mm from the casting surface, and should not actually touch. The welding rod should be melted by immersion into the molten weld pool, and not melted directly by the torch flame.

Two types of sequence are recommended for depositing cast iron by gas welding. With the so-called ‘block’ sequence, filler metal can either be deposited in blocks of ~2.5cm, before filling between the blocks. With the so-called ‘cascade’ sequence, thin layers are deposited, with each one being slightly longer than the preceding one. Both the block and cascade sequences are illustrated below.

Block sequence of bead deposition

Cascade sequence of bead deposition

braze welding

Since this process is particularly sensitive to the wetting of the base metal surface by the filler, cleanliness of the iron before welding is essential. This means that smeared graphite on the surface after grinding must be removed. The bronze welding rod is melted by contact with the base metal after preheating by the gas flame to 425–480°C. The slightly oxidising inner cone of the flame should not be brought into contact with the consumable rod or the base metal. The rounded edges recommended for the joint faces in bronze welding increase the interface area between the casting and the deposited metal.

cracking

All cast irons have a common problem affecting their weldability, namely their high carbon contents. Welding of cast iron is associated with rapid cooling of the weld pool and adjacent base metal, compared with the slower cooling rates experienced during casting, and tends to produce undesirable microstructures, such as iron carbide and high-carbon martensite. Martensite and iron carbide are both very brittle and may cause cracking, either spontaneous or during service. The degree of embrittlement depends on the amount of iron carbide and martensite formed, which in turn depends on the cast iron composition and thermal treatment. The presence of hard, brittle martensite in the HAZ also increases the risk of hydrogen-induced cracking.

Martensite in the HAZ may be tempered to a lower strength or a more ductile structure during post weld heat treatment, or it may be totally eliminated by ensuring very slow cooling rates after welding. Multiple-pass welding and minimum preheat and interpass temperatures are commonly specified to retard the cooling of cast iron welds and to prevent the transformation to martensite. Alternatively, welding procedures designed to reduce the size of the HAZ and thus minimise cracking can be used. Methods of accomplishing this include:

reduction of heat input,

use of small-diameter electrodes,

use of low melting point welding rods and wires, and

use of lower preheat temperatures.

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cast Irons

Type MMAW FCAW Gas Welding Gas Brazing

Grey Cast Iron BOC Smootharc C Cast NiFe

BOC Smootharc C Cast Ni

Nicor 55 Super Silicon Profill Mang Bronze

Profill Nickel Bronze

Profill Nickel Coat

SG and Nodular Cast Iron BOC Smootharc C Cast NiFe




Profill Nickel Coat

White Cast Iron (Chilled Iron) NR NR NR NR

Malleable Cast Iron BOC Smootharc C Cast NiFe




Profill Nickel Coat

NOTeS (1) use BOC Smootharc C Cast NiFe for joining, build up and crack repairs. (2) use BOC Smootharc C Cast Ni for cosmetic repairs.NR = Not Recommended

8



Cast Iron

Smootharc™ c cast ni

applicationsBOC Smootharc™ C Cast Ni is a pure nickel electrode for general purpose welding of all types of cast iron. It is suitable for the joining and repair of grey and malleable cast irons and dissimilar joints between these and steel, monel and stainless steels. Grey and malleable cast irons, machine bases, engine blocks and gear housings.

PreparationThe electrode will tolerate dirty and contaminated surfaces. No preheat is required for small castings and thin sections up to 15 mm. Above this, preheat up to about 150º is recommended.

Joint surfaces should be prepared by gouging. Select smallest diameter electrode practical, deposit short thin stepped layers and lightly ball peen the weld beads during welding to reduce shrinkage strains. Avoid arc striking on the base metal. On completion, allow the work piece to cool slowly. The deposit is soft and fully machinable.

Welding positions

Coating type Special

Welding current DC+, AC

Classifications

AWS A5.15-90, e Ni-C1 DIN 8573-83e Ni-BG 1

Typical all weld metal properties

Chemical composition, wt%

C Fe Ni

0.5 1.0 Bal

Mechanical properties

Tensile strength 250–300 MPa

Hardness 140–160 HV 40


Welding parameters Packing

Dia. (mm) Current (A) kg / pack Part No.

2.5 60–80 3.0 189002

3.2 70–110 3.0 189003

MMa electrodes

Smootharc™ c cast niFe

applicationsBOC Smootharc™ C Cast NiFe is designed to produce a higher matching strength weld metal for joining malleable, nodular and S.G. irons. It is also suitable for joining these to mild, low alloy and stainless steels. Smootharc™ C Cast NiFe is less sensitive to hot cracking sometimes caused by impurities in castings, compared to pure nickel type electrodes. Spheroidal graphite, nodular and ductile cast irons, eg machine bases, transmission housings, gearboxes, engine blocks and pump bodies.

PreparationThin sections may require preheat of approx. 150–300ºC. When welding without preheat, use low heat input method. Lightly ball peen weld beads during welding of thicker sections. On completion allow the work-piece to cool slowly. The deposit is fully machinable.

Welding positions

Coating type Special

Welding current DC+, AC

Classifications

AWS A5.15-90, e NiFe-C1, DIN 8573-83 e NiFe-1-BG 1

Typical all weld metal properties

Chemical composition, wt%

C Fe Ni

1.3 42 55

Mechanical properties


Hardness 170–200 HV


Welding parameters Packing

Dia. (mm) Current (A) kg / pack Part No.

3.2 70–110 3.0 189103

8



Cast Iron

MMa electrodes

castcraft 55Maintenance welding of S.G. cast irons

Higher strength nickel / iron deposit

easy starting and stable running on portable 240V welding machines

Applications include the higher strength repair and maintenance welding of spheroidal graphite (S.G.) irons, austenitic cast irons, meehanites and a wide range of grey cast-irons

Classifications

AWS / ASMe-SFA A5.15: eNiFe-CI

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Hardness 220 HV30

Core wire

Nickel Iron (55% Ni, 45% Fe)


electrodeApprox no. rods / kg

Current range (A)

Packet (kg)

Carton (kg) Part No.Size (mm) Length (mm)

2.5 300 49 35–85 2.5 15–6 x 2.5 611722

3.2 350 31 75–120 2.5 15–6 x 2.5 611723


C 0.95%

Mn 0.65%

Si 0.25%

Al 0.25%

Ni 53%

Fe Bal

castcraft 100Maintenance welding of cast irons

Soft, ductile and machinable nickel deposit

easy starting and stable running on portable 240V welding machines

Smoother weld deposit surface finish

Applications include the repair and reclamation of engine blocks, cylinder heads, differential housings, gear boxes, pump and machine housings and cast iron pulleys etc.

Classifications

AWS / ASMe-SFA A5.15: eNi-CI

Core wire

Nickel (98% Ni)



Hardness 170 HV30



Current range (A)



2.5 300 49 55–85 2.5 15 (6 x 2.5) 611732

20 rods 322110

3.2 350 31 75–120 2.5 15 (6 x 2.5) 611733

15 rods 322111

easyweld Blister Pack

10 x 2.5 mm / 5 x 3.2 mm rod Castcraft 100 Blister Pack 322217


C 1.0%

Mn 0.05%

Fe 0.5%

Si 0.1%

Al 0.2%

Ni Bal

nicore® 55Composite nickel-iron flux cored wire for the joining and repair of cast irons.

Also recommended for the dissimilar joining of cast iron to steels

Classifications

Meets AWS / ASMe-SFA A5.15: eNiFe-CI (equivalent electrode classification)

Typical all weld metal analysis (%) – using Stainshield®

C 1.10%

Mn 0.40%

Si 0.45%

Fe 50.0%

Balance Ni

Typical all weld metal mechanical properties – using Stainshield®


elongation 12%

Hardness 200 HV

Packing and operating data

Dia. (mm)Current Range (A)

Voltage range (V)

electrode stickout eSO (mm) Pack type Pack (kg) Part No.

1.2 220–250 27–29 13 Handispool 4.5 724046

Nicore 55 is a registered trademark of The esab Group, Inc Hanover, PA 17331, uSA.


Argoshield® 40

FcaW Wire

8



Cast Iron

Softweld For welding cast iron when weld must be machined. electrode is 96% nickel with low penetration.

Classifications AWS A5.15 eNi-CI


3.2 0.45 eD025116

MMa electrodes

8 Consumables



Gouge

The arc air gouging process uses the heat generated by an arc struck between the electrode and the workpiece to melt metal and a high velocity jet of air to force the melted metal away. Conventional welding power sources are suitable for the process. electrode holders are designed to provide both the current and the air jet.

The electrodes used are made of carbon covered by a layer of copper. The supply of air is generally provided from a shop compressor.

The main feature of the process is a forceful, piercing arc capable of making deep grooves and cuts.

The process may be used for cutting and removing weld metal in a wide range of ferrous and non-ferrous alloys although its main use is for cutting carbon and alloy steels.

The main safety issues with the process are electrical, high levels of noise, ejection of hot metal, and fume generation.

8



Gouge

boc Gouging carbons

The BOC Carbons have been produced for both effective and efficient metal removal by the arc-air gouging process.

They are manufactured for high quality gouging with:

First grade quality carbon / graphite mixture

Premium copper coating to ensure consistent levels of conductivity and-resistivity

Densely compacted carbon

Copper coating ensures consistent conductivity, resistivity and arc stability

Compacted quality carbon / graphite ensures fast and efficient metal removal

applicationsRemoves metal from a wide range of commonly found metals, both ferrous and non-ferrous

Pointed carbons are the most popular general purpose for most applications of metal removal

Jointed carbons have a male and female socket design allowing either semi or completely automated metal removal

Flat carbons are used when finer detail is required, including scarfing and special joint preparation

Coating type: premium copper coating

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Description Dia. (mm) Length (mm) Pack size Part No.

Carbon DC 4 305 100 40G

Carbon DC 5 305 100 50G

Carbon DC 6.5 305 50 65G

Carbon DC 8 305 50 80G

Carbon DC 9.5 305 50 95G

Carbon DC 11 305 50 110G

Carbon AC 4 305 100 40AG

Carbon AC 5 305 100 50AG

Carbon AC 6.5 305 50 65AG

Carbon AC 9.5 305 50 95AG

Carbon Jointed 8 355 50 80J

Carbon Jointed 9.5 355 50 95J

Carbon Jointed 11 355 50 110J

Carbon Jointed 16 432 25 160JL

Carbon Jointed 19 432 25 190JL

Carbon DC Flat 10 x 5 50 0510S

Carbon DC Flat 15 x 5 50 0515S

arc air Gouging

8 Consumables



Gas Welding, Brazing and Soldering

Welding techniqueSuccessful welding depends on the following factors:


Selection of the correct flame setting

Selection of the correct application techniques a Correct angle of rod to work b Correct travel speed

Selection of the welding preparation

(For Gas Welding Application Techniques refer to Welding Process section on page XX).

Silver brazing

choice of Filler MetalListed on page 458 are details of BOC ProSilver brazing alloys commonly used in all general purpose joining operations.

An alloy is normally selected for its melting and flow characteristics.

The easiest to use filler materials are the high silver, free flowing alloys, because of their low melting temperatures and narrow melting ranges. The higher the brazing temperature and the wider the melting range of the alloy the more difficult the brazing operation will be.

Pre-cleaningIt is important that the mating surfaces of the components to be brazed are fee from oil, grease and any surface oxide layer prior to joining. Most engineering components require nothing more than degreasing before assembly.

Oxide removal can be accomplished either chemically or mechanically. Mechanical removal is preferable because the surface is roughened and excellent bonding is obtained. A medium emery cloth provides about the right amount of surface roughness.

Oil and grease removal is best carried out using a solvent degreasing agent but hot, soapy water is better than nothing at all.

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3�

4�

FluxingThe choice of the correct flux is just as important as the choice of filler material. There are three desirable properties of a flux:

The flux must melt and become active below the melting point of the brazing alloy. Borax or borax based fluxes are not sufficiently molten at the low temperatures at which silver brazing alloys are used. A low temperature fluoride based flux such as easyflo needs to be employed.

The flux must be capable of removing the oxides found on the parent materials. easyflo flux will remove the oxides found on most of the common engineering materials such as mild steel, brass and copper. Special fluxes may be required on certain types of highly alloyed steel and tungsten carbide tool tips. It is also necessary to use a specially formulated flux on aluminium bronze or aluminium brasses containing more than 2% aluminium.

The flux must remain active at the brazing temperature for long enough to allow the brazing operation to be carried out. Fluxes are chemical compounds which dissolve oxides formed in heating. Like most chemical compounds a flux eventually reaches the point where it is saturated and becomes unable to dissolve any more oxide. If the flux residues appear blackened and glassy, the flux has very likely been exhausted during heating, and a flux with higher time / temperature stability should be used.

For most engineering requirements there are two fluxes which will take care of most needs. These are easyflo flux paste and Tenacity No. 4A flux paste.

easyflo Flux

This is the accepted general-purpose flux for use with all low-temperature silver brazing alloys with brazing temperatures not exceeding 800°C. It will successfully flux all the common engineering materials, and its residues are soluble in hot water. Where difficulty is encountered removing residues, immersion in 10% caustic soda is suggested.

tenacity no. 4a

This is a higher temperature flux suitable for use with alloys with brazing temperatures not exceeding 900°C or where long heating

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3�

Fundamentals of Gas Welding and brazing

8




times are involved. In common with easyflo flux it will deal with all common engineering materials and may be used on stainless steels. Tenacity No. 4A residues cannot be removed in hot water, and are best removed mechanically or by the use of 10% sulphuric acid.

Flux application

The best way to apply a flux is to paint it onto the joint as a paste before assembly. It is common to see operators heating the rod end and dipping it into the flux, and then applying both to the joint. This ‘hot rodding’ technique has the disadvantages that the flux does not protect the joint during the heating cycle and that the limited amount of flux applied does not allow alloy penetration into the capillary gap.

If a flux powder is used, it should be mixed to a double cream consistency with water and a few drops of detergent. It should be applied to the joint by means of a paint brush. Too much flux will rarely result in a bad joint but too little flux will invariably give joints of poor quality.

Heating the Joint and applying the alloyWhen heating a joint for brazing it is essential that it is slowly and evenly heated to the brazing temperature.

The type and size of flame used will depend on the parent materials and the mass of the components. Oxy / Acetylene, Air / Acetylene and Air / Propane or MAPP are commonly used but care should be taken with the first due to the high flame intensity, which may melt the parent materials.

If the mass of metal is very large, more than one torch should be used to raise the components to temperature before the flux becomes exhausted.

As a temperature guide, either the colour of the metals or the condition of the flux may be used. The flux on a joint that has reached the correct temperature for brazing should be clear, fluid and flow over the joint area like water.

When the brazing temperature is reached, the filler metal is applied by touching the joint gap with the rod and applying some indirect or splash heat from the torch to the parent material. The molten filler metal will follow the heat from the flame as it is directed along the joint. The brazing alloy should be applied according to its flow characteristics; an alloy with free flowing characteristics such as ProSilver 56T should be touched at one point on the joint, from where it will flow into and around the joint by capillary action, whereas a less-free flowing alloy such as ProSilver 39T should be applied along or around the entire joint, building up a fillet of alloy.

If phosphorus bearing filler rods are being used, for example ProSilver 5, the colour of the metal should be a dull cherry red before the rod is applied to the joint gap.

Once brazing has been completed the heating should be discontinued, as excess heating may cause metallurgical problems with the parent materials, and porosity in the filler materials.

When the alloy has solidified the joint can be quenched in water to help remove flux residues.

Quenching should only be carried out when it will not damage the properties of the parent metals, or cause cracking because of stresses caused by the thermal shock (e.g. in the case of Tungsten Carbide pieces).

Removal of Flux ResiduesThe method of residue removal depends on the type of flux which has been used. easyflo flux residues can be quite simply removed by soaking in hot water, provided they are not in a burnt and blackened condition. Complete flux residue removal is usually possible within 10–15 minutes of soaking in water with a temperature of 60°C or above. After soaking, the joints should be scrubbed under running water to ensure complete cleanliness.

Tenacity No.4A flux residues are not water soluble and are best removed by some mechanical means, e.g. shot blasting.

Acid pickling is not effective in removing flux unless the residues are in a burnt and blackened condition. If pickling is necessary it should be carried out after the flux residue removal operation.

Health and SafetyBrazing alloys and fluxes contain elements which, if overheated, produce fumes which may be harmful or dangerous to health. Brazing should be carried out in a well ventilated area with operators positioned so that any fume generated will not be inhaled. Adequate ventilation to prevent an accumulation of fumes and gases should be used. Where fume levels cannot be controlled below the recognised exposure limits, use local exhaust to reduce fumes and gases; in confined spaces without adequate ventilation, an air fed breathing system should be used; outdoors a respirator may be required. Precautions for working in confined spaces should be observed.

Apart from fume hazards, flux can be irritating to the skin and prolonged contact should be avoided.

Before use, read all the manufacturer’s instructions and refer to the warning labels on the packaging and ask your employer for the Materials Safety Data Sheet. you can obtain the MSDS by referring to our web site www.boc.com.au or www.boc.co.nz or by calling 131 262 in Australia or 0800 111 333 in New Zealand.

Joint DesignThe best brazed joints are those which have a capillary joint gap into which the molten filler metal can flow. A comparison of the different joint designs used in welding and brazing is shown below.

8




The most common type of joint used for brazing is the lap joint, or the sleeve joint in the case of tubular components. To design a good lap joint, two criteria should be considered:

The joint gap.

The degree of overlap.

It is these two parameters that determine the ultimate joint strength, rather than the properties of the filler metal.

A correctly designed brazed joint will often be stronger than the parent materials from which it is constructed.

The best degree of overlap for a brazed joint is 3–4 t where t is the thickness of the thinnest parent metal part making up the joint.

The general rule for tubular parts is that the overlap should be one pipe diameter for sizes up to 25 mm diameter tube.

The most suitable joint gap depends mainly on the flow characteristics of the filler metal. The joint gaps for the various alloys listed in the following section have been indicated. The gaps quoted are those which should be present at the brazing temperature, the cold clearances being adjusted as necessary to account for any difference in the expansion properties of the parent materials.

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Welding techniquesThe heat generated by an oxy-fuel flame is used to melt the parent metal in the joint forming a weld pool. If a filler rod is to be used then it must also be melted into the weld pool. The flame envelope also protects the molten weld pool and the end of the filler rod from the atmospheric contamination.

The weld is continuous and progresses at the speed in which the parent and filler materials can be melted to form the weld pool but fast enough not to allow the weld pool to burn through the component creating a hole.

The filler rod, if used, is constantly fed into the weld pool at the rate required to give the correct bead width, depth of penetration and reinforcement height for the application. The length of the weld will dictate how much filler rod is required, usually more than one length of will be needed and when a new length of rod is needed a stop and re-start will have to be effected. Stop-Start’s can affect the quality of the weld if care is not taken to ensure the weld pool is free of contamination and enough time is given to allow the weld pool to become fully molten.

There are three recognised gas welding techniques used, these are:

Leftward welding.

Rightward welding.

All Position rightward welding.

leftward Welding, or Forward Welding

Leftward welding is the most common techniques used of gas welding. In this technique the flame follows the filler rod along the joint of the weld and with the torch in the right hand the movement is from right to left and from left to right if the torch is held in the left hand.

Leftward Welding Technique

30–40° 40–50°

This technique can be used in all welding positions and the method is the same with the flame following the filler rod irrespective of the position welding is taking place.

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Rightward Welding, or backhand or backward welding

With this technique the filler rod follows the flame along the joint of the weld, with the torch in the right hand the movement is from left to right and the opposite when the torch is in the left hand.Rightward welding is limited in its uses and is only used in the flat (1G, PA) position and for material thicknesses between 4 –16mm thick. When welding butt joints of between 4–6 mm no edge preparation is required, for thicker materials of up to 16 mm edge preparation will be required. However, it is possible to complete this joint in one pass.

Rightward Welding Technique

30–40°40–50°

all-Position Rightward Welding (aPR)

With this technique the wire can follow, precede or be in-line with the flame, depending upon the welding position being used. The all-position rightward technique is for welding thicker materials in the vertical up, vertical down, horizontal-vertical and the overhead positions.

All-position Rightward Welding Technique

45–60°

The technique is mainly used for gas welding pipe of all diameters and wall thicknesses of up to 6mm in a single pass with no edge preparation to the material. This technique was developed to compete with Manual Metal Arc welding and is used mainly on construction sites for welding heating and ventilating pipe work.

WaRnInG Brazing can give rise to excessive noise, eye and skin burns due to the flame and its radiation, and can be a potential health hazard if you breathe in the emitted fumes and gases.

Brazing should be carried out in a well ventilated area with operators positioned so that any fume generated will not be inhaled. Adequate ventilation to prevent an accumulation of fumes and gases should be used. Where fume levels cannot be controlled below the recognised exposure limits, use local exhaust to reduce fumes and gases; in confined spaces without adequate ventilation, an air fed breathing system should be used; outdoors a respirator may be required. Precautions for working in confined spaces should be observed.

Apart from fume hazards, flux can be irritating to the skin and prolonged contact should be avoided.

Before use, read all the manufacturer’s instructions and refer to the warning labels on the packaging and ask your employer for the Materials Safety Data Sheet (MSDS). you can obtain the MSDS by referring to our web site www.boc.com.au or www.boc.co.nz or by calling 131 262 in Australia or 0800 111 333 in New Zealand.

8




Name CompositionMelting Range, (°C)

Recommended Joint Gap (mm) Remarks

ProSilver 56T 56% Ag:Cu:Zn:Sn 620–650 0.05–0.15 These two alloys have similar low melting temperatures and quick flowing characteristics. ProSilver 45T is the popular choice.

ProSilver 56T is used where maximum ductility and smoother joint fillets are required. Both alloys need well-fitted joints with small gaps for their best performance.

SilverCoat 56T

ProSilver 45T 45% Ag:Cu:Zn:Sn 640–680 0.05–0.15

SilverCoat 45T

ProSilver 39T 39% Ag:Cu:Zn:Sn 650–705 0.075–0.2 This series of three alloys of silver, copper, zinc and tin gives a range of fillet-forming materials designed for use where wide joint gaps may arise or where pronounced fillets may be required. They are not suitable for applications where slow heating may produce liquation.



ProSilver 15 15% Ag:Cu:P 645–800 0.05–0.15 Designed primarily for brazing copper without flux, these alloys can be used with flux on copper alloys but should not be used on ferrous or nickel-base metals. As the silver content of these alloys decreases, so does joint ductility. Where service conditions are severe, ProSilver 15 should be the alloy chosen.

ProSilver 5 5% Ag:Cu:P 645–810 0.05–0.15

ProSilver 2 2% Ag:Cu:P 645–800 0.05–0.15

PhosCopper 7% P:Cu 705–820 0.075–0.2 A free flowing self fluxing alloy for use on unstressed copper to copper joints. Higher melting temperature than the silver containing alloys.

ProSilver 494 49% Ag:Cu:Zn:Ni:Mn 680–705 0.1–0.25 ProSilver 494 and ProSilver 402 are specialised alloys designed for brazing of tungsten carbide.

ProSilver 402 40% Ag:Cu:Zn:Ni 660–780 0.1–0.25

8




brazingSelf fluxing

Phoscopper

Self fluxing for pure copper brazing due to the action of phosphorous; copper alloys like brasses and bronzes will require additional fluxes. Is not suitable for steel or alloys containing more than 10% nickel.

Produces rough-textured fillets of a greyish colour and when permitted to run uncontrolled over the work will roughen the surface. Not recommended where good appearance is desired or where subsequent electroplating is necessary.

The alloy has a relatively wide melting range and the parent metals brazed almost always have high thermal conductivity. For these reasons the work should be heated quickly to brazing temperature and oxy-acetylene is preferable to either natural-gas or propane. Brazing of tough pitch copper should be carried out with a slightly oxidizing flame to avoid hydrogen embrittlement.

Due to its wide melting range there is a tendency for low melting phases to run out of the joint if the heating rate is too low hence care has to be taken to heat quickly to the brazing temperature.

Biggest use of this alloy is in return bends in evaporative air-conditioner heat exchangers. It is also used in auto air-conditioners.

The alloy is used in non-vibration situations and is not recommended for plumbing due to hammering / vibration.

It is not recommended for use in shock-loading situations, sulphurized gas or marine environments.

Classification

AS / NZS 1167.1–B1

Chemical Composition, wt%

Phosphorous 7.00–8.25%

Copper 91.75–93.00%

Physical Properties

Density 6.9 g/cc

Solidus 705°C

Liquidus 820°C

Brazing Temp. 720–840°C

Application

Suitable Flux Tenacity 4A. No flux required for pure copper

Optimum Joint Gap 0.08–0.2 mm

Packaging Data

Wire Size (mm) Pack Size Part No.

3.0 x 750 5.0 (kg) LTAP0043

5.0 x 750 5.0 (kg) LTAP0044

3.0 x 750 15 rods LTAP0083

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brazing Self fluxing

ProSilver 2





ProSilver 2 is the main alloy used in plumbing and in the manufacture of copper hot water tanks where water hammer necessitates a silver content.


Classification

AS / NZS 1167.1–B2


Silver 1.80–2.20%


Copper Balance

Physical Properties

Density 7.05 g / cc

Solidus 645°C

Liquidus 800°C


Application

Suitable Flux Tenacity 4A No flux required for pure copper


Packaging Data


2.5 x 750 5.0 (kg) LTAP0242

3.0 x 750 5.0 (kg) LTAP0243

2.5 x 750 1.0 (kg) LTAP0212

3.0 x 750 1.0 (kg) LTAP0213

2.5 x 750 15 rods LTAP0282

2.5 x 750 rod LTAP0296

3.0 x 750 rod LTAP0298

8




ProSilver 5





ProSilver 5 has improved strength / ductility and gap filling properties compared to ProSilver 2.


Classification

AS / NZS 1167.1–B3


Silver 4.75–5.25%


Copper Balance

Physical Properties

Density 7.24 g / cc

Solidus 645°C

Liquidus 810°C


Application

Suitable Flux Tenacity 4A. No flux required for pure copper


Packaging Data


2.0 x 750 2.5 (kg) LTAP0521

2.5 x 750 2.5 (kg) LTAP0522

3.0 x 750 2.5 (kg) LTAP0500

2.0 x 750 1.0 (kg) LTAP0511

2.5 x 750 1.0 (kg) LTAP0512

2.5 x 750 10 rods LTAP0572

2.0 x 750 rod LTAP0599

2.5 x 750 rod LTAP0596

brazingSelf fluxing

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ProSilver 15





ProSilver 15 is used for high vibration joints on refrigerator copper pipes. It is also used for brazing contacts onto copper-based parts because of its good flow characteristics and good electrical conductivity.


Classification

AS / NZS 1167.1–B4


Silver 14.50–15.50%


Copper Balance

Physical Properties

Density 7.5 g / cc

Solidus 645°C

Liquidus 800°C


Application

Suitable Flux Tenacity 4A No flux required for pure copper


Packaging Data


2.0 x 750 2.5 (kg) LTAP1521

2.5 x 750 2.5 (kg) LTAP1522

3.0 x 750 2.5 (kg) LTAP1523

1.5 x 750 1.0 (kg) LTAP1550

2.0 x 750 1.0 (kg) LTAP1511

2.5 x 750 1.0 (kg) LTAP1512

3.0 x 750 1.0 (kg) LTAP1513

2.5 x 750 5 rods LTAP1562

1.5 x 750 rod LTAP1551

2.0 x 750 rod LTAP1599

2.5 x 750 rod LTAP1596

3.0 x 750 rod LTAP1598

brazing Self fluxing

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brazingcd Free

ProSilver 34t

This alloy was developed as the cadmium-free replacement for ProSilver 34.

Suitable for carbon and low alloy steels, copper and copper alloys (aluminium bronzes with more than 2% aluminium requires special flux), nickel and nickel alloys, stainless steels (not exposed to continuous contact with water).

Due to its wide melting range, this alloy can be used to fill joint gaps that can not be closely controlled.

Should not be quenched from high temperatures (>300°C). Should not be quenched when used to braze components with widely differing coefficients of thermal expansion, due to risks with cracking.

Suitable for continuous service operating temperatures up to 200°C.

Classification

AS / NZS 1167.1–A18


Silver 33.00–35.00%

Copper 35.00–37.00%

Zinc 25.50–29.50%

Tin 2.50–3.50%

Physical Properties

Density 8.71 g / cc

Solidus 630°C

Liquidus 730°C


Application

Suitable Flux Tenacity 4A, easyflo


Packaging Data


1.5 x 750 0.5 (kg) LTAT3401

2.5 x 750 0.5 (kg) LTAT3403

1.5 x 750 rod LTAT3492

ProSilver 30t

Suitable for brazing of all low alloy and carbon steels, copper and copper alloys, nickel alloys.

Can be used for brazing where close tolerances on joint gaps cannot be held and can form large fillets.

The joint area should be brought to the brazing temperature before application of the alloy to prevent liquation – separation of low melting components from the alloy under slow heating conditions.

Should not be quenched after brazing to avoid risk of cracking.

Maximum continuous operating service temperature should not exceed 200°C.

Classification

AS / NZS 1167.1–A16


Silver 29.00–31.00%

Copper 34.50–36.50%

Zinc 30.00–34.00%

Tin 2.25–2.75%

Physical Properties

Density 8.57 g / cc

Solidus 665°C

Liquidus 755°C


Application

Suitable Flux Tenacity 4A


Packaging Data


1.5 x 750 0.5 (kg) LTAT3001

2.5 x 750 0.5 (kg) LTAT3003

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brazing cd Free

ProSilver 39t

Suitable for brazing of all low alloy and carbon steels, copper and copper alloys, nickel alloys.

Can be used for brazing where close tolerances on joint gaps cannot be held and can form large fillets.

The joint area should be brought to the brazing temperature before application of the alloy to prevent liquation – separation of low melting components from the alloy under slow heating conditions.



Classification AS / NZS 1167.1–A15


Silver 38.00–40.00%

Copper 29.50–31.50%

Zinc 26.00–30.00%

Tin 2.25–2.75%

Physical Properties

Density 8.76 g / cc

Solidus 650°C

Liquidus 705°C


Application

Suitable Flux easyflo


Packaging Data


1.5 x 750 0.5 (kg) LTAT3901

2.5 x 750 0.5 (kg) LTAT3903

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ProSilver 45t


Suitable for carbon and low alloy steels, copper and copper alloys (aluminium bronzes with more than 2% aluminium requires special flux), nickel and nickel alloys, stainless steels for food and medical applications (not exposed to continuous contact with water).

Low brazing temperature coupled with a narrow melting range makes it free flowing and produces joints with small, smooth fillets.

Good corrosion resistance.

used widely in marine applications due to its resistance to de-zincification.


Classification AS / NZS 1167.1–A19


Silver 44.00–46.00%

Copper 26.00–28.00%

Zinc 23.50–27.50%

Tin 2.00–3.00%

Physical Properties

Density 9.2 g / cc

Solidus 640°C

Liquidus 680°C


Application

Suitable Flux easyflo, Tenacity 4A


Packaging Data


1.5 x 750 2.5 (kg) LTAT4520

1.5 x 750 0.5 (kg) LTAT4501

2.5 x 750 0.5 (kg) LTAT4503

3.0 x 750 0.5 (kg) LTAT4504

1.5 x 500 5 rods LTAT4563X

1.5 x 750 rod LTAT4592X

2.5 x 750 rod LTAT4596X

0.125 x 25 25g coil LTAT4559

brazingcd Free

Silvercoat 45t

This alloy was developed as the cadmium-free replacement for SilverCoat 45.

SilverCoat 45T is the extruded flux coated version of the standard ProSilver 45T.

Suitable for carbon and low alloy steels, copper and copper alloys (aluminium bronzes with more than 2% aluminium requires special flux), nickel and nickel alloys, stainless steels for food and medical applications (not exposed to continuous contact with water).

Low brazing temperature coupled with a narrow melting range makes it free flowing and produces joints with small, smooth fillets.

Good corrosion resistance.

used widely in marine applications due to its resistance to de-zincification.


Classification

AS / NZS 1167.1–A19


Silver 44.00–46.00%

Copper 26.00–28.00%

Zinc 23.50–27.50%

Tin 2.00–3.00%

Physical Properties

Density 9.2 g / cc

Solidus 640°C

Liquidus 680°C


Application

Suitable Flux No flux required. use easyflo for large overlaps.


Packaging Data


1.5 x 500 250 (g) LTAF4530T

1.5 x 500 500 (g) LTAF4531T

1.5 x 500 2 rods LTAF4550T

1.5 x 500 rod LTAF4589TX

8




brazing cd Free

ProSilver 56t

Cadmium-free brazing alloy with a short melting range, suitable for brazing of most metals such as copper alloys and stainless steels for food and medical applications.

Very free flowing and produces neat joints with small fillets.

Has some resistance to de-zincification and is used for brazing of stainless steel food handling equipment.



Classification

AS / NZS 1167.1–A2


Silver 55.00–57.00%

Copper 21.00–23.00%

Zinc 15.00–19.00%

Tin 4.50–5.50%

Physical Properties

Density 8.76 g / cc

Solidus 620°C

Liquidus 650°C


Application

Suitable Flux easyflo


Packaging Data

Wire Size (mm) Pack Size (kg) Part No.

1.5 x 750 0.5 LTAT5601

2.5 x 750 0.5 LTAT5603

Silvercoat 56t

SilverCoat 56T is the extruded flux coated version of the standard ProSilver 56T.

Cadmium-free brazing alloy with a short melting range, suitable for brazing of most metals such as copper alloys and stainless steels for food and medical applications.

Very free flowing and produces neat joints with small fillets.

Has some resistance to de-zincification and is used for brazing of stainless steel food handling equipment.



Classification

AS / NZS 1167.1–A2


Silver 55.00–57.00%

Copper 21.00–23.00%

Zinc 15.00–19.00%

Tin 4.50–5.50%

Physical Properties

Density 8.76 g / cc

Solidus 620°C

Liquidus 650°C


Application

Suitable Flux No flux required use easyflo for large overlaps


Packaging Data


1.5 x 500 250 (g) LTAF5630

8




brazingtungsten carbide

ProSilver 402

Cadmium-free brazing alloy with a wide melting range, suitable for forming fillets. Suitable for brazing of stainless steel for dry applications and for brazing tungsten carbide up to 9 mm long – for longer lengths use ProSilver 494.

Classification

AS / NZS 1167.1–A8


Silver 39.00–41.00%

Copper 29.00–31.00%

Zinc 26.00–30.00%

Nickel 1.50–2.50%

Physical Properties

Density 9.81 g / cc

Solidus 660°C

Liquidus 780°C


Application



Packaging Data


1.5 x 750 0.5 (kg) LTAN45214

1.5 x 750 5 rods LTAN45213

1.5 x 750 rod LTAN45212

ProSilver 494


Recommended for brazing of tungsten carbide up to 19 mm long.

The presence of nickel and manganese helps in wetting carbides even those containing titanium.

Classification

AS / NZS 1167.1–A20


Silver 48.00–50.00%

Copper 15.00–17.00%

Zinc 21.00–25.00%

Nickel 4.00–5.00%

Manganese 6.50–8.50%

Physical Properties

Density 9.81 g / cc

Solidus 680°C

Liquidus 705°C


Application



Packaging Data


1.5 x 750 0.5 (kg) LTAT5301

1.5 x 750 5 rods LTAT5360

1.5 x 750 rod LTAT5392X

8




ProFill nickel bronze

Fusion welding of similar copper alloys

Suitable for steel, cast iron and malleable iron

Specifications

Coating Bare

Classification AWS RBCuZn-D

Joining process Braze welding and fusion welding

Welding characteristics High strength and wear resistant, self fluxing Brazing of nickel based alloys

Brazing of nickel based alloys

Build up of worn ferrous components

Melting range 920–935


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Dia. (mm)

Length

(mm)Weight per pack (kg)

Rods per

pack Part No.

3.2 750 1.000 — GRNB321

5.0 750 2.500 — GRNB5025

5.0 750 1.000 — GRNB501

Gas Welding

ProFill nickelcoat

Fusion welding of similar copper alloys, brazing of nickel based alloys


Specifications

Coating Flux coated

Classification AWS RBCuZn-D


Welding characteristics High strength and wear resistant, self fluxing



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Dia. (mm) Length (mm) Weight per pack (kg)

Rods per pack

Part No.

2.4 500 — 5 GRNC24H5

3.2 750 2.500 — GRNC3225

3.2 750 1.000 — GRNC321

3.2 750 — 5 GRNC32H5

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ProFill Mang bronze

Due to dezincification, not suitable for copper pipes carrying hot water or sea water


Specifications

Coating Bare rod

Classification AWS RBCuZn-C

Joining process Braze welding

Welding characteristics Low fume and high strength, self fluxing


Tensile strength (MPa) 460

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Dia. (mm)Length (mm)

Weight per pack (kg)

Rods per pack Part No.

1.6 750 2.500 GRMB1625

1.6 750 1.000 GRMB161

1.6 750 5 GRMB16H5

2.4 750 2.500 GRMB2425

2.4 750 1.000 GRMB241

2.4 750 5 GRMB24H5

3.2 750 2.500 GRMB3225

3.2 750 1.000 GRMB321

3.2 750 5 GRMB32H5

6.3 750 2.500 GRMB6325

6.3 750 5 GRMB631

Gas Welding

ProFill tobin bronze

For mild steel low strength applications e.g. car panel filling

Suitable for brass and bronzes, mild steel and ferrous materials

Specifications

Coating Bare rod

Classification DIN L-Cu40Zn


Welding characteristics Low fume



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Wire Dia. (mm)

Length (mm) Weight per pack (kg)

Rods per pack

Part No.

1.6 750 2.500 — GRTB1625

1.6 750 1.000 — GRTB161

1.6 750 0.060 5 GRTB16H5

2.4 750 2.500 — GRTB2425

2.4 750 1.000 — GRTB241

2.4 750 0.135 5 GRTB24H5

3.2 750 2.500 — GRTB3225

3.2 750 1.000 — GRTB321

3.2 750 0.250 5 GRTB32H5

5.0 750 2.500 — GRTB5025

5.0 750 1.000 — GRTB501

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ProFill Mangcoat

Due to dezincification, not suitable for copper pipes carrying hot water or sea water


Specifications

Classification AWS RBCuZN-C

Joining process Braze welding

Welding characteristics Low fume and high strength, self fluxing



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Wire dia. (mm)

Length (mm)

Weight per pack (kg)

Rods per pack Part No.

2.4 500 2.500 — GRMC2425

2.4 500 1.000 — GRMC241

2.4 500 — 5 GRMC24H5

3.2 750 2.500 — GRMC3225

3.2 750 1.000 — GRMC321

3.2 750 — 5 GRMC32H5

Gas Welding

8




comweld nickel bronze Rod

High strength, wear resistant brazing alloy

High strength braze welding of steels and cast or malleable irons

Fusion welding of copper based alloys of similar composition

Crimson end tip colour for instant identification

Classifications

AS / NZS 1167.1, AS / NZS 1167.2: R Cu Zn-D AWS / ASMe-SFA A5.8 / A5.27: RB Cu Zn-D

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Packaging data


2.4 x 750 5 plastic pack 35 321224

3.2 x 750 5 plastic pack 19 321225

5.0 x 750 5 plastic pack 8 321226

comweld Mild SteelAnnealed, low carbon steel rod for oxy-acetylene welding

Recommended for gas welding of steels and wrought irons

Not suitable for gas tungsten arc welding

Classifications

AS / NZS 1167.2: RG AWS / ASMe-SFA A5.2: R45

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C: 0.07% Mn: 0.50% Si: 0.008%

S: 0.008% P: 0.011% Fe: Balance

Packaging data


1.6 x 500 1 Handipack 130 322045

1.6 x 1,000 5 plastic pack 64 321334

2.4 x 750 5 plastic pack 29 321337

3.2 x 750 5 plastic pack 16 321339

Joining process

Gas (fusion) welding only


Not recommended

comweld High testCopper coated, steel filler rod for gas and gas tungsten arc (TIG) welding

Higher strength (400–450 MPa) oxy-acetylene and TIG welding of steels

Classifications


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C: 0.12% Mn: 1.17% Si: 0.25%

S: 0.009% P: 0.015% Fe: Balance

Packaging data


1.6 x 750 5 plastic pack 84 321357

2.4 x 750 5 plastic pack 34 321360

3.2 x 750 5 plastic pack 21 321362

Joining process



Argon Welding Grade

Gas Welding

8




comweld comcoat nFlux coated nickel bronze rod

High strength, excellent wear resistance

High strength braze welding of steels and cast or malleable irons

Fusion welding of copper based alloys of similar composition

Pink flux colour for instant identification

Classifications

AS / NZS 1167.1, AS / NZS 1167.2: R Cu Zn-D AWS / ASMe-SFA A5.8 / A5.27: RB Cu Zn-D

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Packaging data

Rod size (mm) Pack (kg) / type

easyweld Handipack

Blister Pack

Approx No. (rods / kg) Part No.

2.4 x 500 3 rod pack – 322208


3.2 x 750 2.5 plastic pack 19 321215


comweld tobin bronze Rod

Low strength copper-zinc brazing alloy

Recommended for the fusion or braze welding of selected brasses and bronzes

Suitable for low strength brazing of steels

Not suitable for cast irons

White end tip colour for instant identification

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Classifications

AS / NZS 1167.1, AS / NZS 1167.2: R Cu Zn-A AWS / ASMe-SFA A5.8 / A5.27: RB Cu Zn-A

Packaging data

Rod Size (mm) Weight (kg), Pack type Blister Pack Approx No. (rods / kg) Part No.

1.6 x 750 5 plastic pack 83 321246

2.4 x 750 5 plastic pack 37 321247

3.2 x 750 5 plastic pack 20 321249


5.0 x 750 5 plastic pack 8 321250

comweld comcoat tFlux coated tobin bronze rod

Recommended for the ‘self fluxing’ fusion braze welding of selected brasses and bronzes

Suitable for low strength brazing of steels

Not suitable for cast irons

White flux colour for instant identification

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Classifications

AS / NZS 1167.1, AS / NZS 1167.2: R Cu Zn-A AWS / ASMe-SFA A5.8 / A5.27: RB Cu Zn-A

Packaging data

Rod Size (mm) Weight (kg), Pack type Blister Pack Approx No. (rods / kg) Part No.

2.4 x 500 5 rod blister pack – 322207

3.2 x 750 5 plastic pack 19 321236

Gas Welding

8




comweld Manganese bronze Rod

General purpose brazing alloy

Recommended for braze welding of steels and-cast and malleable irons

Not suitable for copper pipes in hot water systems

Blue end tip colour for instant identification

Classifications

AS / NZS 1167.1, AS / NZS 1167.2: R Cu Zn-C AWS / ASMe-SFA A5.8 / A5.27: RB Cu Zn-C

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Packaging data

Rod Size (mm) Pack (kg) / type Approx No. (rods / kg) Part No.

1.6 x 750 5 plastic pack 90 321195

2.4 x 750 5 plastic pack 37 321199

3.2 x 750 5 plastic pack 20 321202

5.0 x 750 5 plastic pack 8 321203

6.3 x 750 5 plastic pack 5 321204

comweld comcoat cFlux coated manganese bronze rod

General purpose brazing alloy

Recommended for braze welding of steels and-cast and malleable irons

Not suitable for copper pipes in hot water systems

Blue flux colour for instant identification

Classifications

AS / NZS 11671, AS / NZS 1167.2: R Cu Zn-C AWS / ASMe-SFA A5.8 / A5.27: RB Cu Zn-C

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Packaging data

Rod size (mm) Pack (kg) / type

easyweld Handipack

Blister Pack

Approx No. (rods / kg) Part No.

2.5 50 321191

2.4 x 500 20 rod Handipack 322020

5 rod blister pack 322206

3.2 x 790 5 plastic pack 19 321186

15 rod Handipack 322021

comweld Silicon bronze Rod

Premium quality deoxidised silicon-bronze alloy

Recommended for the braze welding and GTA (TIG) welding of copper silicon alloys (everdur and Cusilman)

Canary yellow end tip colour

Classifications

AS / NZS 1167.1, AS / NZS 1167.2: R Cu Si-A AWS / ASMe-SFA A5.7: R Cu Si-A (uNS no. C65600)

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Packaging data

Rod Size (mm) Pack weight (kg) / type Approx No. (rods / kg) Part No.

3.2 x 750 5 plastic pack 19 321295

Gas Welding

8




Soldering

comweld 40 / 60 Soft SolderComweld 40 / 60 solder is a low cost general purpose solder for general sheet metal work, plumbing (not water pipes) such as gutters and flashings and automotive radiator repairs.

General purpose low cost solder

General for sheet metal and plumbing applications

General wide range of packaging options

Classifications

AS 1834 Part 1 40Sn

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Colour code and identification

Cored wire reels – green label

Sticks – marked 40 / 60

Handipack (H / P) coil, yellow backing card and label

Joining process

Soldering only

Soldering iron bit temperature

294°C


Sn Pb

40% (Tin) 60% (Lead)

Typical properties


Shear strength 37 MPa

Approx. melting range 183–234°C

electrical conductivity 10.1% IACS

Packaging data

Rod Size (mm) Pack weight / type Part No.

12 x 6 x 400 (W x B x L)

250 g stick 322305

3.2 250 g acid core wire 322313

1.6 15 g resin core H / P 322220

comweld 50 / 50 Soft SolderComweld 50 / 50 solder is a higher quality general purpose solder for general sheet metal work, and plumbing (not water pipe) applications where better free flowing characteristics are important.

Higher quality general purpose solder

For electrical and electronic applications

Wide range of packaging options

Classifications

AS 1834 Part 1 50Sn

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Cored wire reels – orange label

Sticks – marked 50 / 50

Joining process

Soldering only


272°C

Typical properties


Shear strength 40 MPa

Approx. melting range 183–212°C

electrical conductivity 10.9% IACS

Packaging data

Rod size (mm) Pack weight / type Part No.

12 x 6 x 400 (W x B x L)

250 g stick 322306

3.15 250 g solid wire 322310

500 g acid core wire 322318


250 g resin core wire 322319

comweld General Purpose, cast Iron Rod (Super Silicon)

A high strength, general purpose, cast iron alloy for joining and building up grey cast iron castings

Machinable weld deposit

Classifications

AS / NZS 1167.2: RC11

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Packaging data


5.0 x 700 2.5 Plastic 8 321420

Gas Welding

8




Soldering

comweld Metal Mate Solder KitComweld Metal Mate Solder Kit contains a 14 gm 965 solid solder coil complete with a 14 ml bottle of Comweld 965 Soldering Flux.

Classifications

AS 1834 Part 1 96.5 Sn / 3.5Ag

Identification

Clear plastic jar, white lid and white label with blue print


Sn Ag

96.5% (Tin) 3.5% (Silver)

Packaging data

Rod Size (mm) Pack weight / type Part No.

1.6 1.6 mm x 14 g solid wire coiled around a 14 ml bottle of 965 soldering flux

321690

comweld 965 Solder (Soft Silver Solder)Comweld 965 Solder is a tin / silver eutectic solder which has the highest strength of all soft solders. Due to it’s high strength, good electrical and thermal conductivity, non toxicity (lead, zinc and cadmium free) and also the fact that it remains bright and shiny, make Comweld 965 Solder the most universal of soft solders. Comweld 965 Solder is used for the joining and repair of copper, bronze, brass, nickel, monel, steel, stainless steel, pewter, chrome plate, metal sculpture, model making, costume jewellery and or a combination of metals with the exception of aluminium and magnesium.

Highest strength soft solder

Lead, zinc and cadmium free

Non toxic solder for electrical, surgical and food equipment applications

Wide range of packaging options

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Classifications

AS 1834 Part 1 96.5Sn / 3.5Ag


Blue labels and backing cards

Joining process

Soldering only


281°C


Sn Ag

96.5% (Tin) 3.5% (Silver)

Typical properties


Density 7.5 g / cm3

Approx. melting point 220°C

Typical properties

electrical conductivity 17% IACS

Packaging data

Rod size (mm) Pack weight / type Part No.

3.15 250 g solid wire 322320

3.15 500 g solid wire 322321


1.6 15 g HandiPack coil acid core wire

322221

8




Sb Flux easyfloPreferred general purpose flux suitable for most engineering materials. Suitable for use with all ProSilver alloys. Residue soluble in hot water or 10% caustic soda.

Temperature range 550–880°C

Size Part No.

250g efloflux

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GP Sb Flux tenacity 4aFor higher melting point applications and longer heating cycles. Suitable for use with all ProSilver alloys. Preferred for ProSilver 2.5 and 15 if heating cycle is long.


Size Part No.

250g Ten4AFlux

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Flux tenacity 20For copper, brass gas welding and steel brazing. Suitable for higher temperatures and extended cycle times. Suitable for ProFill bronze alloy range. use as a powder or mix with water for a paste.


Size Part No.

250g Ten20Flux

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Fluxes

8




Fluxes

comweld aluminium FluxDescription and applicationComweld Aluminium Flux is an all purpose flux for fusion welding sheet and cast aluminium. Comweld Aluminium Flux is recommended for use with the following Comweld Aluminium welding rods, AL1100 (Pure), AL4043 (5% Silicon) and AL5356 (5% Magnesium).

Identification

White powder in black plastic jars

Melting point 545°C

Packaging data

Pack weight / type Part No.

250 gm black plastic jar 321740

comweld copper and brass FluxDescription and applicationComweld Copper and Brass Flux is specially developed for the braze welding of-copper, brass and bronze and the brazing of copper, steel, etc. Comweld Copper and Brass Flux is particularly suitable for use with Manganese Bronze, Tobin Bronze, Nickel Bronze and Silicon Bronze rods.

Identification

Pink powder in black plastic Jars or drums.

Melting point: 645°C

Packaging data



comweld Silver brazing Flux no. 2Description and applicationComweld Silver Brazing Flux no. 2 and Silver Brazing Alloys with a high silver content (42–50%) produce excellent joints on carbon steel, stainless steel, nickel alloys and copper and brass. Dissimilar metals in the above groups can be easily brazed.

Identification

White paste in either a black / white plastic jar


Packaging data




3.5 kg white plastic Jar 321843

comweld G.P. Silver brazing FluxDescription and applicationComweld General Purpose Silver Brazing Flux is recommended for use with Cadmium bearing and Cadmium free silver brazing alloys with a low to medium silver content (2–40%).

Identification

White paste in either a black or white plastic jar


Packaging data




3. 5 kg white plastic jar 321853

comweld 965 Soldering FluxDescription and applicationComweld 965 Soldering Flux, when used in-conjunction with Comweld Soft Solders, enables excellent joints to be made on almost all-metals and combinations of metals.

Identification

Pink liquid in black plastic bottles and drums

Packaging data


125 ml bottle 321890

1 litre bottle 321894

comweld VapafluxFor Braze Welding of Steel

used with Comweld Manganese & Nickel Bronze Rods

used in a Liquid Form Only

Identification:

Clear Liquid in a Tin Plate Can.

Flash Point

(True Closed Cup) 17°C

Packaging Data

Pack Volume Pack Type Part No.

19 L Tin Plate Can 321885

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8 Consumables



Hardfacing

Millions of dollars worth of equipment is thrown away each year because it no longer performs efficiently.

A large percentage of this equipment could, however, be protected by hardfacing or reclaimed by welding. In many cases, the degeneration of the equipment could have been stopped if preventative maintenance was carried out, as a matter of routine.

There should be differentiation between repair welding, reclamation and preventative maintenance.

Repair WeldingRepair welding is aimed at repairing structural damage, such as fatigue, cracks, fractures, etc. The principle governing repairs is normally based on either matching the welding consumable chemically or mechanically (tensile strength, proof stress, elongation, etc) to the base metal.

ReclamationReclamation is aimed at restoring the dimensions of the components that have been altered due to wear, corrosion, thermal fatigue, machining defects, etc.

Typical components that are normally reclaimed include:

Steel mill rolls

Idler rolls

Track rolls

Dragline jewellery

Carrier rolls

Preventative MaintenancePreventative maintenance is the pro-active use of welding, to prevent excessive wear taking place on components.

Hard surfacing is a form of preventative maintenance.

Typical components that are normally hard surfaced include:

Front end loader buckets

Crusher jaws and mantles

Sugar mill rollers

Agricutural tyres

Brick and paver mixer paddles

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ProcessesThe standard welding processes employed during both reclamation and preventative maintenance may include:

Manual metal arc welding (MMA)

Gas shielded metal arc welding (GMAW)

Submerged arc welding (SAW)

Flux cored arc welding (FCAW)

open arc

gas shielded

submerged arc

The biggest advances have been made in the area of flux cored welding consumables. It is also the area which has the widest selection of alloys available as well as a wide range of material properties.

Wear MechanismsFor effective reclamation and preventative maintenance, a proper understanding of the mechanism causing the degeneration is required before welding consumables can be selected.

1. abrasion

Abrasion is labelled as the single most important mechanism of all wear in industry.

Abrasion 50%

Impact 10%

Metal-to-metal wear 14%

Chemical (corrosion) 10%

Temperature 5%

Abrasion or metal-to-mineral wear is further subdivided into:

a) High stress abrasion This occurs when abrasive materials are deliberately broken into smaller sizes, i.e. crushing operations

b) Low stress abrasion This occurs when abrasive materials are transported along the surface in both a sliding and rolling action, in such a way that a reduction in particle size does not normally take place, i.e. feed chutes slurry pipelines, etc.

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8



Hardfacing

2. Metal-to-metal wear

This occurs when there is movement of one component relative to the other.

Typical examples of metal-to-metal wear are:

a) Journal ends of steel mill rolls

b) Track rolls of earth moving equipment

3. temperature

Temperature, when it becomes sufficiently high, will cause oxidation and subsequently scaling.

More detrimental, however, are fluctuating temperatures, which lead to thermal fatigue cracking or fire cracking, as in steel mill roll applications.

4. corrosion

This is the degradation of metals due to chemical reaction, whether by an acidic medium flowing through a pipe or the exposure of components to corrosive atmospheres, i.e. coastal operations.

5. Impact

This is the degradation of metals due to the repeated point loading of the component that causes the surface to fatigue rapidly and disintegrate, i.e. impact crusher or gyratory crushers.

Welding consumables classificationWelding consumables are further grouped in terms of alloy types, where each exhibits certain characteristics that would make them suitable to apply when certain tribological conditions are encountered.

1XXX Steels

Alloy type Description Features Typical applications

11XX Pearlitic Steel Strong, multi-run capabilities General rebuilding, butter layers, spindles, rollers, track lines, sprockets, tractor idler wheels

12XX Austenitic manganese steel Tough, work hardening, impact resistant Crusher jaws, rolls, mantles, ball mill liners, railway points

13XX Austenitic stainless steel Tough, corrosion/heat resistant, forms strong welds between dissimilar steels

Crossings, bearings at medium temperatures, track grousers, anvils, pneumatic tools, butter layers under 2XXX hardfacing

14XX Low carbon martensitic steel Strong Clutch parts, railway points and crossings, track components

15XX Tool steel Very hard, hot strength Machine tools, shears, guillotine blades, metal forming tools

16XX Martensitic stainless steel Hard, corrosion/heat resistant Cutting knives, punches, dies, steel mill rolls.

17XX High carbon austenitic steel Tough, work hardened Crushing rolls, hammers, tractor grousers

18XX High carbon Martensitic steel Very hard, abrasion resistant Post-hole augers, earth scoops, conveyor screws, loader buckets, pump housings

19XX High carbon Martensitic steel with primary alloy carbide

Hard, check crack-free abrasion resistant

Clinker crushing rolls, hammers, drill collars

2XXX Chromium White Irons


21XX Austenitic iron Corrosion, abrasion and impact resistant

Crushing equipment (jaws, rolls, hammers, mantles) pump casings, impellors, pipeline elbows

22XX Martensitic iron Very hard, corrosion, erosion resistant Agricultural plough shares, tines mill scraper blades, wear bars, bucket lips, crushing rolls

23XX Austenitic chromium carbide iron High abrasion resistance Screen butt straps, quarry screen plates, chutes, grizzly bars, dragline teeth dredge bucket lips, shovel teeth

24XX Complex chromium carbide iron includes types containing up to 45% tungsten

Very highly abrasion resistant plus hot abrasion resistance

Sizing screens, ball mill liner plates, pump impellors, crusher jaws, agricultural implements, scapers

25XX Martensitic chromium carbide iron Highly erosion resistant Wet applications in mining and crushing industries (ball mill liners)

26XX Low chromium white iron Resistant to fine abrasion Pug mill praddles, clay augers, screens and granulators

8



Hardfacing

3XXX Tungsten Carbide Composites (Minimum 45wt% Tungsten Carbide)


31XX Carbide chips in Cu alloy matrix >4000 µm

Protruding carbides useful as individual cutting edges

Rock drills, oil drills, oil well tools

32XX Tungsten carbide granules in an Fe rich matrix >850 µm

Cutting and wear resistant applications Bucket teeth, ripper points, oil drill collars, auger blades and teeth, oil well drills, bulldozer end tips

33XX 425–850 µm Gouging resistant Rock drills, ditcher teeth, dry cement pump screws, suction dredge blades

34XX 150-425 µm Gouging resistant Ripper lines, ditcher teeth, cement pump screws, churn-drills

35XX <150 µm extreme abrasion resistance Tool joints

36XX Tungsten carbide granules in a Ni-B matrix < 75 µm

Hot abrasion resistance and cutting Plough share edges, knives, boring bars, bottle machine parts, sand slingers, sand mixer blades

4XXX Cobalt Alloys


41XX Complex Co-base solid solution Tough, creep resistant, cavitation resistant

Hot shear blades, valve seats

42XX Hypo-eutectic Co-Cr-W alloy Strong, cavitation resistant exhaust valves in diesel engines, cold shear blades

43XX Hypo-eutectic Co-Cr-W alloy Hard, cavitation resistant Scrapers, feeders, screws etc. in chemical, mining and cement industries

44XX Co-Cr-Ni-W alloy (powder) Strong, cavitation resistant Timber saw blades, valve seats, shear blades

5XXX Nickel Alloys


51XX Complex Ni-base solid solution Tough, creep resistant, hot hardness Hoppers, forging dies and hammers, hot trimming and punching dies.

52XX Low melting point Ni-B alloy High hot erosion resistance Slurry pumps and piping

53XX Tungsten carbide (<45 wt%) in a Ni-B matrix

Lower abrasion resistance than 36XX Hot forging dies, parts subjected to hot erosion in chemical plants

54XX Solid solution Highly corrosion resistant Valve bodies and parts subject to oxidation

6XXX Copper Alloys


61XX Phosphor bronze (4–6% Sn) Soft corrosion resistant Light load bearings

62XX Phosphor bronze (7–9% Sn) Good bearing properties, wear/ corrosion resistant

Medium load bearings, crank press, transmission housing, pump rotors

63XX High tensile brass (Cu-Zn-Mn) Low friction bearing, wear/corrosion resistant

Light load bearings, hydraulic rams and pistons

64XX Nickel bronze (9–13% Ni) Low friction bearing, work hardens, corrosion resistant

Gear teeth, cams, bearings, percussion heads, slides, service where work hardening required

65XX Aluminium bronze (9.5–14% Al) Tough erosion/cavitation resistant Heavy load bearings, valve seats, marine castings, overlay deposited on steel

66XX Nickel aluminium bronze Tough, work hardens, impact/ corrosion resistant

Form dies, impellers, axles, valve seats, propellers

67XX Complex aluminium bronze (Cu-Mn-Fe-Ni-Al)

erosion/cavitation/corrosion resistant Seawater pumps, impellers under heavy load, propellers and applications subject to severe cavitation

8



Hardfacing

application and FinishingThe success of any reclamation or preventative maintenance repair does not lie only in the correct identification of the wear mechanism or choice of the consumable, but also in the application and finishing of the build-up material.

Pre-heating

Many components that can be reclaimed are made from either cast steel or alloyed steel plate.

As a precautionary step, components should never be welded cold, with the exception of manganese steel. The degree of preheating is highly dependant on the composition of the component (see page 332).

buffer layers

Buffer layers are applied when the base material has a low weldability or to reduce the dilution when welding highly alloyed consumables.

Austenitic buffers will stop cracks from progressing into the base material, but are not suitable for use under Martensitic steels (14XX, 18XX, 19XX alloys).

Dilution

Deposit dilution occurs when base metals melted by the electric arc, mix with the molten weld metal during the welding process.

Dilution can result in:

a) The depletion of alloying elements in the weld metal resulting in lower hardness figures or

b) The absorption of elements like carbon into the deposited weld metal with increased hardness and possible relief cracking in low-alloyed surfacing materials

Relief checking

Relief checking occurs in high hardness and carbide bearing hardfacing alloys as a result of a large difference between the rate of expansion and contraction between it and the base material. Relief checking occurs only in the weld metal itself. Often the amount of relief checking can be minimised if high pre-heat temperatures are used and cooling occurs at a very slow rate.

Finishing

Reclaimed components are often re-machined. It is therefore necessary to establish beforehand the final hardness of the required reclamation.

Hardness of 450 HB can still be machined, although deposits harder than 480 HB are normally ground.

8



Hardfacing

MMa electrodes

cobalarc austexMetal enriched, rutile type electrode

For joining dissimilar steels or as a buffer layer prior to hard surfacing

Tough, machinable austenitic stainless steel-deposit

Classifications

AS / NZS 2576:1315-A4 W.T.I.A. Tech. Note 4: 1315-A4

Typical all weld metal deposit analysis (%)

C Mn Si Cr Ni

0.10 1.50 0.90 24.5 9.3

■

■

■

Typical weld deposit hardness HRC HV30

All weld metal deposit 20 240

Work hardened deposit 40 400


electrode Approx no. rods / kg


3.2 380 20 105–140 5 15 (3 x 5) 613973

4.0 380 13 140–180 5 15 (3 x 5) 613974

5.0 450 7 170–210 5 15 (3 x 5) 613975

Finishing recommendations

Machinable with carbide tools 3.2 mm size can be used for vertical welding by depositing overlapping horizontal stringer passes

cobalarc MangcraftAustenitic manganese steel electrode

For building up and reinforcing 11–14% manganese steels

Tough and impact resistant weld deposit

Work hardens under heavy impact

Classifications

AS / NZS 2576: 1215 - A4 W.T.I.A. Tech. Note 4: 1215 - A4


C Mn Si

0.60 12.0 0.10

■

■

■

■


All weld metal deposit 15 –

Work hardened deposit 43 425




4.0 380 17 130–170 5 15 (3 x 5) 611504

5.0 450 10 150–200 5 15 (3 x 5) 611505


Machinable with carbide tools

cobalarc 350Metal enriched, rutile type electrode.

For re-building worn steel components

Tough, machinable low carbon martensitic steel deposit

For the manual arc build-up and surfacing of steel gear, shafts, rails, shovel pads, track links, rolls and wheels etc.

Classifications

AS / NZS 2576: 1435-A4 W.T.I.A. Tech. Note 4: 1435-A4

■

■

■

■


C Mn Si Cr Mo

0.07 0.85 0.30 1.85 0.5


Single layer on mild steel 28 290





3.2 380 25 100–150 5 15 (3 x 5) 611443

4.0 380 16 140–200 5 15 (3 x 5) 611444


Machinable

8



Hardfacing

MMa electrodes

cobalarc 650Metal enriched, rutile type electrode

For re-building or surfacing worn steel components

Air hardening, crack free, martensitic steel deposit

Typical applications include the surfacing of-agricultural points, shears and tynes, grader and dozer blades, conveyor screws and post hole augers etc.

■

■

■

■

Classifications


Typical all weld metal deposit analysis (%):

C Mn Si Cr Mo

0.58 1.1 0.6 5.3 0.25

Packaging and operating data AC (minimum 55 OCV) DC+ or DC– polarity



3.2 380 31 105–135 5 15 (3 x 5) 611463

4.0 380 21 140–180 5 15 (3 x 5) 611464





Not machinable / grinding only

cobalarc 750Rutile type, AC / DC hard surfacing electrode

easy arc starting and stable running on-portable AC welding sets ( ≥ 45 OCV)


Typical applications include the surfacing of-agricultural equipment and components including points, shears, post hole augers, ripper teeth and tynes etc.

Classifications


■

■

■

■


C Mn Si Cr Mo

0.60 0.46 0.75 5.9 0.40



Two layers on mild steel* 62 750

* Not recommended for multi-pass welding heavier than 3 layers

Packaging and operating data AC (minimum 45 OCV) DC– polarity



3.2 380 26 95–130 5 15 (3 x 5) 611473

4.0 380 17 120–170 5 15 (3 x 5) 611474

easyweld Blister Pack

10 x 3.2 mm rod Cobalarc-750 Blister Pack 322218



3.2 mm and 4.0 mm sizes can be used for vertical welding by depositing overlapping horizontal stringer passes.

8



Hardfacing

MMa electrodes

cobalarc cR70Highly alloyed manual arc electrode

High chromium carbide iron deposit

Primary chromium iron carbides in-a-single-layer

Ideal for coarse abrasion and low to-moderate impact loading

Typical applications of Cobalarc CR70 include the hard surfacing of crusher cones and mantles, swing hammers, bucket teeth and lips, dozer end plates and sugar mill rolls-etc.

Classifications


■

■

■

■

■

Typical weld deposit analysis (%)

Single layer on mild steel:

C Mn Si Cr

3.3 1.5 1.0 25

All weld metal deposit:

C Mn Si Cr

4.0 1.8 1.2 31




3.2 380 18 90–140 5 15 (3 x 5) 613493

4.0 380 11 130–200 5 15 (3 x 5) 613494

5.0 450 6 180–250 5 15 (3 x 5) 613495




Deposits contain chromium carbides with hardness up to 1,500 HV


Grinding only

3.2 and 4.0 mm sizes can be used for vertical welding by depositing overlapping horizontal stringer passes.

cobalarc toolcraftVersatile manual arc welding electrode

Secondary hardening, shock resistant properties

Crack free Cr-Mo steel deposit for repairing blades, dies, punches etc.

Also suitable for general hard surfacing in low stress abrasion conditions

Classifications


■

■

■

■


C Mn Si Cr Mo

0.58 0.10 0.20 5.5 6.8



All Weld Metal Deposit 60 700




3.2 380 28 90–125 5 15 (3 x 5) 611523

2.5 300 54 60–90 20 Rod 322115



3.2 mm size can be used for vertical welding by depositing overlapping horizontal stringer passes

8



Hardfacing

MMa electrodes

cobalarc borochromeHighly alloyed manual arc electrode

Martensitic chromium carbide iron deposit

Ideal for fine particle (wet or dry) abrasion and low impact loading.

Primary chromium iron carbides in a hard, martensitic matrix

Typical applications include the hard surfacing of sand chutes, dredge components, ripper shanks, screens, grizzly bars, scraper blades and bucket lips and teeth

Classifications


■

■

■

■

■


Single layer on mild steel

C Mn Si Cr V B

2.7 0.4 1.8 20.0 1.4 1.0

All weld metal deposit

C Mn Si Cr V B

3.2 0.4 2.4 24.0 1.7 1.2




4.0 380 11 140–180 5 15 (3 x 5) 613964

5.0 450 6 170–210 5 15 (3 x 5) 613965




Deposits contain chromium carbides with hardness up to 1,500 HV


Grinding only

Stoody tube borium ac/DcReplaces Cobalarc 4

Highly Alloyed Tubular electrode.

Partially Dissolved Tungsten Carbides bonded in an Iron Rich Matrix.

Resistant to extreme Abrasion and Low Impact Loading.

Classifications

AS/NZS 2576: 3460-A4.

W.T.I.A. Tech Note 4: 3460-A4.

■

■

■

Operational Characteristics/Welding Parameters:

Dia. (mm) 4.0 4.8 6.4

Mesh Size 20–30 20–30 10–30

Position Flat Flat Flat

Typical Weld Deposit Analysis*:

C Mn W Cr

Single Layer on Mild Steel

3.1 0.9 44 6

All Weld Metal Deposit

3.7 1 53 7


AC (min 50 OCV), DC+ polarity.

electrode electrodes/kg

Current Range (A)

Packet Carton Part No.

Size (mm) Length (mm)

5.5 350 9 120–150 4.5kg vac pack

10229500

NOTe: one size only

Typical Weld Deposit Hardness

HRC HV30

Single Layer on Mild Steel 62 750

All Weld Metal Deposit 64 800

Deposits contain Tungsten Carbides with hardness up to 2,200 HV.

* Actual weld deposit consists of undissolved Tungsten Carbide particles in a eutectic matrix of C-W-Cr-Fe. The analysis of the matrix will vary with the proportion of Tungsten Carbides dissolved during welding.

Finishing Recommendations

Grinding only.

8



Hardfacing

cobalarc 9eHighly alloyed extruded electrode

Versatile, complex carbide iron deposit

Resistant to both coarse and fine abrasion and moderate to heavy impact loading

Typical applications include the hard surfacing of railway ballast tampers, dredge buckets and lips, earth-moving equipment, power shovels, rolling mill guides, sizing screens, ripper teeth and crushing equipment

Classifications

AS / NZS 2576: 2460-A4

W.T.I.A. Tech. Note 4: 2460-A4

■

■

■

■



C Mn Si Cr Ni Mo V

4.0 0.9 1.1 25.0 0.4 1.5 0.2


C Mn Si Cr Ni Mo V

4.8 1.1 1.4 30.0 0.5 1.7 0.2




Deposits contain complex chromium carbides with hardness up to 1,500 H.




3.2 380 17 60–120 5 15 (3 x 5) 613350

4.0 380 10 70–150 5 15 (3 x 5) 613360

5.0 450 5 150–300 5 15 (3 x 5) 613370


Grinding only

Identification colours

White (Single dot near holder end)

3.2 mm and 4.0 mm sizes can be used for vertical surfacing by depositing overlapping horizontal stringer passes

MMa electrodes

8



Hardfacing

Stoody 965 G / oGas (-G) and self shielded (-O), tubular hardfacing wires


Resistant to hard particle abrasion and moderate impact loading

Typical applications include the surfacing of agricultural points, shares and tynes, sand dredge cutter heads, dredge rollers and tumblers, conveyor screws, bucket lips, etc.

Classifications

1.2* and 1.6 mm

2.4† mm

AS / NZS 2576: 1855-B5 1855-B7

W.T.I.A. Tech. Note 4: 1855-B5 1855-B7

*1.2 mm and 1.6 mm Stoody 965-G wires are B5 type wires which require a shielding gas.

†2.4 mm Stoody 965-O is a B7 type open arc wire which requires no shielding gas.

■

■

■

■


C: 0.50 Mn: 1.70 Si: 1.40

Cr: 6.20 Fe: balance





Not machinable, grinding only

Packaging and operating data DC electrode Positive


Rec. stickout eSO (mm) Pack type


1.2 120–250 18–24 15–20 300 mm Spool 15 11423100

1.6 140–260 23–26 15–25 300 mm Spool 15 11501500

2.4 250–450 24–28 20–35 Coil 27 11946100


1.2 mm and 1.6 mm Cobalarc 650-G

Stainshield®

2.4 mm Cobalarc 650-O

Open arc or Industrial grade CO2

1.2 mm and 1.6 mm sizes can be used for vertical surfacing by depositing overlapping horizontal stringer passes.

Stoody Super build up G / o

Gas (-G) and self shielded (-O), tubular hardfacing wires.

Tough, machinable low carbon martensitic steel deposit.

Recommended for the build-up and surfacing of steel track rolls, idler wheels, track pads, drive sprockets, pins, links and other components subject to abrasion and / or metal-to-metal wear.

Classifications

1.2* and 1.6 mm

2.4† mm

AS / NZS 2576: 1435-B5 1435-B7

W.T.I.A. Tech. Note 4: 1435-B5 1435-B7

*1.2 mm and 1.6 mm Stoody Super Build up-G wires are B5 type wires which require a shielding gas.

†2.4 mm Stoody Super Build up-O is a B7 type open arc wire which requires no shielding gas.

■

■

■


C: 0.10 Mn: 1.50 Si: 0.40

Cr: 2.60 Mo: 0.70 Fe: balance





Machinable carbide tools recommended





1.2 120–220 18–24 15–20 300 mm Spool 15 11423600

1.6 140–260 23–26 15–25 300 mm Spool 15 11946200

2.4 250–450 24–28 20–35 Coil 27 11183600


1.2 mm and 1.6 mm Cobalarc 350-G

Stainshield®

2.4 mm Cobalarc 350-O


1.2 mm and 1.6 mm sizes can be used for vertical surfacing by depositing overlapping horizontal stringer passes.

FcaW Wire

8



Hardfacing

Stoody 850-oSelf shielded (-O), tubular hardfacing wire

Air hardening, crack prone high carbon, martensitic steel deposit

Resistant to severe abrasion and low impact loading

Typical applications include the hard surfacing of agricultural, mining and materials handling equipment including tynes, points, conveyor screws, dredge buckets, cane harvester cutters / elevators and sugar mill scraper plates

Classifications

AS / NZS 2576: 1865-B7.

W.T.I.A. Tech. Note 4: 1865-B7

■

■

■

■


C: 0.95 Mn: 0.6 Si: 0.9

Cr: 6.5 Mo: 3.5 B: 1.5








1.2 120–250 18–24 15–20 300 mm Spool 15 11945500


Grinding only


Open arc or welding grade CO2

1.2 mm size can be used for vertical surfacing by depositing overlapping horizontal stringer passes.

FcaW Wire

Stoody Dynamang-oSelf shielded (-O), tubular hardfacing wire

Tough, work hardening austenitic manganese steel deposit

Typical applications include the repair of manganese steel crusher rolls, jaw and hammer crushers, gyratory mantles, blow bars and dredge pump cutters etc.

Classifications

AS / NZS 2576: 1215-B7


■

■

■


C: 0.90% Mn: 13.40% Si: 0.37%

Ni: 2.7% Cr: 2.50%

Typical weld deposit properties



elongation 42%



electrode stickout (mm) Pack type


1.6 150–220 22–26 15–25 Spool 15 11446700

2.8 200–375 25–28 20–35 Coil 27 11249900



Work hardened 52 540


Machinable as deposited.



1.6 mm size can be used for vertical surfacing by depositing overlapping horizontal stringer passes.

8



Hardfacing

Stoody 100 Hc-o2.4 and 2.8 mm

Self shielded (-O), tubular hardfacing wire

High chromium carbide iron deposit or ground engaging applications

Resistant to coarse abrasion and low to moderate impact loading

Typical applications include hard surfacing of crusher cones and mantles, swing hammers, earthmoving buckets, blades and rippers

Classifications

AS / NZS 2576: 2360-B7


■

■

■

■

Typical weld metal deposit analysis (%)


C: 4.2 Mn: 0.7 Si: 0.7 Cr: 20


C: 5.5 Mn: 1.0 Si: 0.9 Cr: 25




Deposits contain chromium carbides with hardness up to 1,500 HV (80 HRc)





2.4 250–350 25–30 35–55 Coil 27 11313400

2.8 300–450 27–33 35–55 Coil 27 11001000


Grinding only



Stoody 101 Hc G / o1.2 and 1.6 mm

High alloy, tubular hardfacing wire

High chromium carbide iron deposit or ground engaging applications

Resistant to severe abrasion and low to moderate impact loading

Typical applications include the hard surfacing of crusher cones and mantles, swing hammers, earthmoving buckets, scarifier points and sugar harvesting and milling equipment

Classifications

1.2* mm 1.6† mm

AS / NZS 2576: 2360-B5 2360-B

W.T.I.A. Tech. Note 4: 2360-B5 2360-B7

*1.2 mm Stoody 101 HC-G is a B5 type wire which requires a shielding gas.

†1.6 mm Stoody 101 HC-o is a B7 type wire which requires no shielding gas

■

■

■

■

Typical weld metal deposit analysis (%)


C: 4.0 Mn: 0.7 Si: 0.7 Cr: 14.0


C: 5.2 Mn: 0.7 Si: 0.7 Cr: 19.0









1.2 Coarseclad-G 150–200 22–26 12–20 Spool 15 11436300

1.6 Coarseclad-O 200–260 24–28 15–25 Spool 15 11304700


Grinding only


1.2 mm Coarseclad-G

Stainshield®

1.6 mm Coarseclad-O


1.2 mm size is suitable for vertical-up surfacing using a wide weaving technique.

FcaW Wire

8



Hardfacing

FcaW Wire

Stoody Fineclad-oSelf shielded (-O), tubular hardfacing wire

Chromium iron carbides in a hard, martensitic matrix

Resistant to fine, wet or dry abrasion

Typical applications include the surfacing of sand chutes, dredge components, ripper shanks, screens, grizzly bars, scraper blades, and bucket teeth and lips etc

Classifications

AS / NZS 2576: 2565-B7


■

■

■

■



C: 3.5 Mn: 0.3 Si: 0.4

Cr: 14 B: 0.5


C: 4.8 Mn: 0.5 Si: 0.6

Cr: 20 B: 0.75






Wire dia. mm


electrode stickout (mm) Pack type


1.6 200–260 24–28 15–25 Spool 15 11945800

2.4 250–350 25–30 35–55 Coil 27 11945900


Grinding only



1.6 mm size can be used for vertical surfacing by depositing overlapping horizontal stringer passes

Stoody 104(Replaces Cobalarc 104-SA)

Submerged arc (-SA) tubular build-up wire.

Tough, machinable, low carbon pearlitic steel deposit.

Resistant to high compressive loading.

For the unlimited build-up of worn steel components.

Classifications

AS/NZS 2576: 1125-B1.

W.T.I.A.Tech Note 4: 1125-B1.

■

■

■

■

Typical All Weld Deposit Analysis

C Mn Si Cr Fe

0.07 2.9 1.25 1.15 bal

Typical Weld Deposit Hardness

HRC HV30


Finishing Recommendations:

Machinable.

Recommended Flux:

Stoody S


AC, DC electrode positive or negative

Wire diameter

mm

Current Range (A)

Voltage Range (V)

electrode

Stickout (eSO) mm

Pack Type Weight (kg) Part No.

3.2 350–400 26–30 25–35 Coil 27kg 11820300

3.2 350–400 26–30 25–35 Half Pack 90kg 11040900

3.2 350–400 26–30 25–35 Drum 226kg 11039500

Deposit Characteristics:

Abrasion resistance Low

Impact resistance excellent

Compressive strength excellent

Hardness 29 HRc

Surface cross checks No

Magnetic yes

Deposit Layers unlimited

Machinability yes


Stoody Build up-O self shielded tubular wire

AS/NZS 2576:1125-B7

8



Hardfacing

chainlinc A self shielded, flux cored electrode for rebuilding heavily worn components such as dragline chains. It is characterised by a soft, low penetrating arc and is suitable for semi-auto or auto welding. It produces a tough low alloy deposit.

Classifications

AS 2576: 1125-B7 (metal-to-metal wear), 26–29 Rc. DIN 8555 Part 1: MF1-250


2.8 25 Coil 032401

lincore 30-S extremely tough and forgeable deposit for rebuilding mild and alloy steels. For rebuilding idlers, crane and mine car wheels, build-up of steel rolls.

Classifications (with 802, 860 or 880 flux)

AS 2576 : 1130-B1. 29–31 Rc. DIN 8555 Part 1: uP1-GF-802 / 860 / 880-300


3.2 22.68 Coil 032403

3.2 272.16 Speed feed drum

032413

lincore 33 A hard wearing low alloy steel for rebuilding and hardfacing heavily worked machinery components. For rebuilding gears, idlers, pins, chains and trunnions.

Classifications

AS 2576: 1130-B7. DIN 8555 Part 1:uP1-GF-880M-300 (with 880M flux)


1.6 9.98 Readi reel eD016872

2.0 6.35* Coil eD011237

2.0 25 Coil eD011238

2.8 25 Coil eD011240

1.6 11.34 reel eD031117

*4 per box

lincore 36lS A highly versatile wire for semi and fully automatic rebuilding of metal-to-metal wearing parts. For rebuilding drill rods, rail car wear surfaces, mining machinery, gears and pins.

Classifications

AS 2576: 1440-B7. DIN 8555 Part 1: uP2-GF-880M-350 (with 880M flux)


1.6 12.5 Spool 032510

lincore 40-SA long-lasting alloy steel that resists metal-to-metal and abrasive wear. For final overlay on tractor idlers, rollers, and mine car wheels.

Classifications (with 802 or 880 flux)

AS 2576: 1440-B1 (metal-to-metal wear) 38-41 Rc. DIN 8555 Part 1: uP2-GF-802 / 880-40


3.2 22.68 Coil eD015892

lincore 42-SMulti-layer weld deposit resistant metal-to-metal wear. For final overlay on tractor idlers, rollers, shafts etc.


AS 2576: 1440-B1 (metal-to-metal wear)


3.2 22.68 Coil eD029159

3.2 136.2 Drum eD029264

lincore 40-oOpen arc version of the above product, used in similar applications, in areas where submerged arc welding is not practical.

Classification AS 2576: 1440-B7


2.8 22.68 Coil eD025908

lincore 50Hardfacing protection of parts that must resist both abrasion and moderate impact. For crusher rolls and grinding equipment, agricultural points and digger teeth.

Classifications

AS 2576: 2150-B7 (or 802 flux) 2155-B1 (with 880 flux)


1.2 9.98 Readi reel eD020826

1.6 9.98 Readi reel eD020827

2.8 22.68 Coil eD011275

lincore 55An excellent general purpose deposit for protection against metal-to-metal and abrasive wear. For earthmoving equipment, high hardness gears, augers and agricultural tools.

Classifications

AS 2576: 1855-B1. DIN 8555 Part 1: uP6-GF-880M-55 (with 880M flux)


2.0 6.35 Coil eD011277

2.0 22.68 Coil eD031122

2.8 22.68 Coil eD011280

FcaW Wire

8



Hardfacing

lincore 60-o High alloy abrasion resistant deposit for crushing equipment, mixing paddles, ground engaging tools, hammers and augers.

Classifications

AS 2576: 2355-B7 (severe abrasion and moderate impact), 56-60 Rc. DIN 8555 Part 1 1983: MF10-60-RGNZ


1.2 9.98 Readi reel eD031131

1.6 9.98 Readi reel eD031132

2.0 22.68 Coil eD019887

lincore 65-oSelf-shielded, flux-cored wire that resists severe abrasion with light impact. Higher carbon and chrome deposits than Lincore 60-0. use on wear plate, coal pulveriser rolls, earth engaging tools, and on slurry pipe and elbows.


2.8 22.68 Coil eD026077

3.2 22.68 Coil eD026076

2.8 226.8 Drum eD026083

lincore 15crMn Premium austenitic manganese steel for joining manganese steel to itself or dissimilar metals, or as a build-up prior to hardfacing with Lincore 50 or Lincore 60-0.

Classifications

AS 2576: 1720(b)-B7 (severe impact). Work hardens to 50 Rc DIN 8555 Part 1: MF8-250RKNP


2.0 11.34 Spool eD031126

2.8 22.68 Coil eD022061

lincore M Produces austenitic manganese steel deposit. For crusher cones, jaws and manganese rail points.

Classifications

AS 2576: 1220-B7 (severe impact). Work hardens to 50 Rc DIN 8555 Part 1: MF7-250KNP


2.0 11.34 Spool eD031130

2.8 22.68 Coil eD011164

crushcore Specifically designed for roller arcing on rotating sugar crushing rolls.

Classifications

AS 2576:2155-B7 (impact and abrasion)* 54–58 Rc. DIN 8555 Part 1: MF10-55GRN


2.0 25 Coil 032601

2.8 25 Coil 032600

*Note: Deposit carbon content may exceed Classifications limits.

lincore t & DHot tool steel deposit for rebuilding cutting tools, dies, blades and edges. Can be temper hardened to above 55 Rc.

Classifications

AS 2576:1550-B7 (severe metal-to-metal wear) 52-55 Rc. DIN 8555 Part 1: MF3-50-T


1.6 11.34 Spool eD031134

FcaW Wire

8



Hardfacing

lincore 420 A high hardness, crack free 420-type stainless steel deposit that resists heat, corrosion and frictional wear. For steel mill rolls, cable sheaves; stainless steel cladding.


AS 2576 1650-B1 (multi-purpose hardfacing) 48-51 Rc. DIN8555 Part 1 1983: uP5-GF802 / 880 50-CR


3.2 22.68 Coil 032505

3.2 230 Drum 032523

lincore 423cr A high chromium wire giving excellent corrosion resistance. Also resists softening while tempering due to alloying with vanadium and molybdenum. For steel mill castor rolls and other applications where low coefficients of friction are required.

Classifications (with 802 flux)

AS 2576 1640-B1 (metal-to-metal wear) 41-45 Rc. DIN 8555 Part 1-1983: uP5-GF-802-40-CR


2.4 22.68 Coil eD018553

lincore 424a Metal-cored wire with higher nickel content than 41NiMo alloy. Flux recommendation is 801 / 880.


3.2 22.68 Coil eD018560

lincore 96S A martensitic 420 type of stainless steel deposit that resists heat corrosion and metal-tometal wear. For steel with rolls, cable sheaves, stainless steel cladding.

Classification (with 802 or 880 flux)

AS 2576 4650-B1: 51-53HRC

Size (mm Weight (kg) Part No.

3.2 22.68 Coil 032507

3.2 230 Drum 032522

Submerged arc Wire

8



Hardfacing

Submerged arc Flux

Submerged arc Flux

unalloyed

alloyed

802A neutral flux designed for use with solid stainless steel electrodes and some Lincore build-up and 400 series martensitic stainless steel hardfacing wires.

Classification AS1858.1 FBL


40 Bag KC802040

880 A neutral flux that may be used with some hardfacing and build-up wires.

Classification AS1858.1 FBL


45 Bag KC880045

260 Drum KC880260

801A neutral flux that may be used with some hardfacing and build-up wires.


45 Bag KC80104

H535Versatile hardfacing flux for abrasive wear resistance that still allows for some machinability. Can also be used for build-up. Applications include steel mill rolls, crane wheels, idlers and tractor rollers.

Classification (with L-60 wire)

AS 2576 1435-B4 (metal-to-metal wear) 25-45 Rc. DIN 8555 Part 1: uP1-GZ-H535-350


45 Bag KC535045

QR8045Low alloy flux for semi-automatic or automatic submerged arc surfacing with L-50 or L-60 wire. Applications include rebuilding and hardsurfacing worn low alloy and carbon steel wheels, rolls, rails and other components where metal-to-metal friction is the major cause of wear.


AS 2576 1440-B4 (metal to metal wear) DIN 8555 Part 1:uP1-GZ-QR8045-40


AS 2576 1125-B4 (metal-to-metal wear) 28-30 Rc. DIN 8555 Part 1: uP1-GZ-QR8045-300


50 Bag KCQR8045050

8



Hardfacing

Documents

BOC IPRM S08-Consumables