Metrode

News

Summer

2010

In this issue: -

Superoot 316L

application story

Power generation

MT304H

Essen worldwide

Storage & Handling

Submerged arc flux

New packaging

USA symposium’s

New people

New RCC-M range

Exhibition News

Sports News

Local MP visits

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Metrode Superoot Flux Cored TIG –

A tall story

Burj Khalifa (Arabic: "Khalifa Tower"), formerly

known as Burj Dubai prior to its inauguration, is

a skyscraper in Dubai, United Arab Emirates, and

the tallest man-made structure ever built, at

828 m (2,717 ft) Construction began on 21

September 2004, with the exterior of the

structure completed on 1 October 2009. The

building officially opened on 4 January 2010 and

just over a week later some spectacular storms

gave the buildings lighting arrestor a pretty stern

test!

The building has a central water pipeline

(supplying drinking water for various purposes)

that runs the complete length of the tower which

ends up as the lightning arrestor. Originally, this

pipeline was fully flanged & bolted without

realizing the fact that tall structures are designed

to be flexible in order to withstand earthquakes &

tremors. Burj Khalifa has been estimated to sway

by about 1½ mtrs (the top floors) in all

directions due to the ambient atmosphere at that

height. This would eventually, without doubt, rip

off the bolts and tear the pipeline, which would

have caused major damage & property loss.

It was subsequently decided to replace the

flanging by welding & this is where Metrode

Superoot came in. We were approached among a

few other brands to offer a safe & reliable

solution. As a prerequisite governed by

SAMSUNG (the main EPC contractor), the

primary concern was to keep up to a minimal

timescale & hence, the basic idea was to avoid

carrying purging gas cylinders up in the tower.

Superoot 316L is designed specifically for

situations where it is impractical to apply back-

purge for the TIG root run, or to gain the

economic benefit of eliminating back-purge. We

supplied samples which proved to be ideal for the

task and a total of 200kgs was eventually used to

complete the project.

The wire was supplied via our distributor

Technical Parts who are based in Dubai.

Superoot 316L AWS A5.22 R316LT1-5

Specifications BS EN ISO 17633-B TS316L-RI1

Power Generation – MT304H

Metrode continues to build on this already well

established position in the power generation

market by introducing a new solid wire, Metrode

MT304H, for welding Super 304H tube. The

super 302H alloy is designed for use as a

superheater and reheater boiler tubing in the

latest generation of Ultra Super Critical (USC)

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cool fired power plant. The alloy already appears

in European (EN10216-5: X10CrNiCuNb 18 9 3)

and USA (ASTM A213: S30432) specifications but

there is not yet any specifications for the welding

wire.

The alloy has Cu, Nb and N additions to improve

creep performance at service temperatures of

approximately 600°C, although the relevant

ASME code case specifies allowable stresses up

to 815°C. The wire is currently available at 2.4

mm diameter manual TIG wire and will shortly be

available as small diameter wire for orbital tube

welding.

Essen – Germany, India & China!

Last year Metrode took part in the ‘Olympic

Games’ of the welding industry at Essen in

Germany and for the first time it was a team

event! We joined Lincoln Electric and were part

of their stand. The new ‘team’ performed well

and we both reported an excellent show with

plenty of new leads to follow up after the event.

In February this year we took part in our first

Essen India

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Raghav Srivastava represented us at the show

and reported that some useful new leads were

gained and existing customers also visited to

discuss current business.

And to complete the set we exhibited for the

11th time at Beijing Essen Welding & Cutting Fair

in May. Together with its mother show

"Schweissen & Schneiden" in Essen, Germany it

now ranks in the top two professional welding

and cutting shows around the world.

STORAGE AND HANDLING – AN UPDATE

To ensure that welding consumables are maintained

in an optimum condition it is important that they are

stored and handled correctly. This document

summarises the requirements for the different

consumables and processes.

General storage recommendations for all

consumable are >18°C and <60% relative humidity.

MMA Electrodes

All Metrode MMA electrodes are supplied in

hermetically sealed metal tins. The metal tins have

a ring pull and provide an excellent and efficient

form of packaging for MMA electrodes. Packaging

waste is minimal and the steel tin can easily be

recycled with normal steel scrap.

The tins are hermetically sealed and meet the

requirements of AWS A5.5 paragraph 22.2 for

hermetically sealed containers. If unopened, and

appropriately stored, this packaging will maintain the

electrodes in the as-packed condition for an

indefinite period of time.

Once opened the tins can be closed using the plastic

lid supplied and should be stored at >18°C and

<60% relative humidity.

Low Alloy Low Hydrogen

MMA electrodes can be used direct from the tin and

for most applications will provide satisfactory

performance. For critical applications, and for

electrodes that have been exposed, the electrodes

should be redried as follows: 250-300°C for 1-2

hours to ensure hydrogen less than 10ml/100g, and

at 300-350°C to ensure hydrogen less than

5ml/100g. A maximum of three redrying cycles

and/or ten hours total time at temperature is

recommended to avoid permanent flux damage.

Temperatures during redrying should not exceed

420°C.

Stainless Steel

Electrodes can be used directly from freshly opened

tins, without need for redrying treatment. Storage of

electrodes on the shopfloor, during usage, should be

in the tins or a suitable container, eg heated quiver

(~50°C). Electrodes are capable of being stored in

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this manner for periods substantially longer than a

typical eight hour working shift, without risk of flux

coating moisture regain to a level where there is a

risk of weld porosity.

At the end of a working shift, tins should be resealed

using the plastic lid and returned to storage under

recommended conditions of 18°C minimum ambient

temperature and 60% relative humidity.

Excessive exposure of electrodes to humid

conditions, will promote moisture pick-up and risk of

weld porosity. In situations where this is suspected,

or weld porosity is encountered, electrodes can be

restored to the as-packed condition by redrying for

1-2 hours at 200-300°C.

A maximum of three redrying cycles and/or ten

hours total time at temperature is recommended to

avoid permanent flux damage. Temperatures during

redrying should not exceed 400°C.

SOLID WIRES

Solid TIG wires are supplied in 2.5kg or 5kg tubes,

and MIG wires are supplied on 12.5kg or 15kg

spools (either plastic or metal baskets). The solid

wires that may be susceptible to rusting (mild steel

and low alloy) are copper coated. Under appropriate

storage conditions solid wires do not present any

handling difficulties.

MIG wires supplied on 15kg wire baskets need to be

properly handled because if they are lifted by one

rim it can bend the basket and lead to feeding

problems.

FLUX CORED WIRES

Flux cored wires need to be stored correctly to

prevent moisture pick-up, which may lead to

porosity. As supplied the wires are adequately

protected for moisture pick-up to not present a

problem, but once opened part-used spools need to

be correctly stored. It is recommended that spools

are removed from machines overnight and put in a

controlled store. If a part spool is to be stored for

any period of time it should be adequately protected

(in a plastic bag with desiccant) and held in a

controlled store.

Care is required when handling mild steel and low

alloy wires because handling of the wire surface can

result in rust marks if the wire is then stored for a

prolonged period. If the wire is to be used

immediately handling the wire surface presents no

problems but if a part spool is to be stored for any

period of time avoid touching the wire surface with

bare hands.

SUBMERGED ARC FLUX

Submerged arc fluxes are supplied in metal drums,

but for most applications it is recommended that the

flux should be dried prior to use.

Metrode’s Submerged Arc Welding Fluxes

There have been a number of changes to the

submerged arc welding fluxes that are currently

available from Metrode.

The following is a list of the currently available

fluxes and their main applications. There are also

individual data sheets on all of the fluxes which

provide more detailed information about the fluxes

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but if you wish to discuss specific applications please

contact the Technical Department.

LA436 Flux

This is a new flux that has recently been introduced

into the range. It is intended for general purpose

use with 1CrMo, 2CrMo and 1NiMo low alloy wires

where there is no requirement for low temperature

impact properties.

LA491 Flux

This flux has been used extensively for welding P91

creep resisting steel using 9CrMoV-N wire. This flux

is still available for customers who have been using

this flux in conjunction with the 9CrMoV-N wire.

The flux also has a secondary use which is for

welding with the ER308LCF and ER316LCF wires for

LNG projects and other applications requiring

cryogenic properties.

LA492 Flux

This new flux has been introduced for welding P91

and P92 steels using the 9CrMoV-N and 9CrWV

wires respectively. LA492 provides similar

mechanical properties to the LA491 flux but has

better slag release and is the flux we would offer for

new customers and projects wishing to weld P91

and P92 steel.

Examples of applications involving SSB flux.

LA424 Flux

This is a specialist flux for high speed fillet welding,

mainly with CrMo alloys.

SSB Flux

This is a long standing Metrode flux and one that is

still recommended for use with duplex, ER329N, and

superduplex, Zeron 100X, wires. It can also be used

for a wide range of other stainless steel wires

although there is now an alternative flux available

which we would recommend for applications

involving the standard 300 series stainless steel

wires, see Metrode SS300 flux.

SS300 Flux

This is a new flux that has been introduced for use

with the standard 300 series stainless steel wires:

308S92, 316S92 and 309S92. This is the flux we

would now recommend for use with all of the

standard stainless steel wires.

The flux also has other potential applications

including duplex, superduplex and possibly nickel

base wires. These uses will be investigated further

in the future.

NiCr Flux

This is the standard flux we recommend for use with

nickel base wires for joining applications. It is very

high basicity, producing excellent metallurgical

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integrity but this does mean that it does not have

such good slag release as some other fluxes,

particularly when welding with the 62-50 wire. The

limitation in slag release is compensated for by the

high integrity of the deposit and the minimal risk of

hot cracking, even in highly restrained joints.

NiCu Flux

This is a flux that only has limited use because it is

only used with the 65NiCu wire.

L2N Flux

L2N is the only fused flux in Metrode’s range, which

has advantages with respect to the resistance to

moisture pick-up. The flux can be used with low

alloy and stainless steel wires, and also with nickel

base wires for cladding applications.

Cladding with 62-50 wire and L2N flux.

New Decade – new packaging

Metrode will be introducing some exciting new

packaging over the next few months. Our TIG

wires will gradually start to be delivered in new

Reflex Blue, rectangular shaped section, two

piece tubes. The pack weights will not change

from our popular 2.5 and 5.0 kg tubes.

This will be a phased introduction over the

coming months and wires will continue to be

supplied

We also have a new inner carton for our limited

range of low alloy MMA electrodes supplied in

cardboard packs.

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The American Way

Metrode in the guise of John Stoll, recently teamed up with Bill Newell of Euroweld to hold 3 educational symposium’s on a range of subjects. They took place at Beaumont, Corpus Christi and Houston at the end of February.

• The Challenges of Welding Chrome-Molys...Why Technique & Workmanship Matter!

• Altering Welding Consumables to Meet Specialized Needs!

• Dispelling Myths Associated with Current Welding & Consumable Technology!

• Welding P91 - An Update!

A total of 91 of the top QA/QC welding people along the Gulf Coast attended the events and they were all decision makers and WPS qualifiers and writers. All three events were universally well received, this is a typical comment: -

“Just wanted to let you know I thought the class subject and presentation was excellent. The seminar covered actual welding applications we deal with from day to day. I have a couple of young engineers that need to attend this course or maybe attend the next class. Thanks for the invite.”

New People

The customer care team has been joined by

Ritu Srivastava and we would like to

welcome her to the Metrode team.

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Metrode Products Ltd Launches

RCC-M Welding Consumable

Programme

Stainless steel, RCC-M tested and certified

“nuclear grade” MMA and TIG welding

consumables delivered from stock

Founded in 1963, Metrode has always been at

the forefront when it comes to manufacturing

and supplying high quality welding

consumables, particularly in those industries

that require the highest integrity from their

welding consumables.

The nuclear, (French) RCC-M code driven

industry, is one of those industries. In order to

satisfy requirements of those fabricators active

in the nuclear welding industry, Metrode

Products launches a new RCC-M consumable

program.

Not all fabrication work can be scheduled many

months in advance, allowing for production and

testing of both base materials and welding

consumables. This is particularly true for

maintenance and repair work and general

fabrication work that need quick turn-around

time.

That is why Metrode is now launching a new

program to deliver, from stock, fully tested and

certified stainless welding consumables

according to RCC-M Add 2007 Section IV.

Metrode RCC-M Consumable Range

The consumable range will include historically

proven stainless steel products. An overview of

the available products is shown in table 1.

All products will be supplied with the required

product traceability and certification. Upon

request specific RCC-M datasheets can be made

available.

Trade name EN Classification RCC-M

Data Sheet

Ultramet 308L(N) E 19 9 L R 32 S 2920

TIG 308S92(N) W 19 9 L S 2910

Ultramet 316L(N) E 19 12 3 L R 32 S 2925

TIG 316S92(N) W 19 12 3 L S 2915

Ultramet 309L(N) E 23 12 L R 32 S 2930

TIG 309S92(N) W 23 12 L *

Available Upon Request

SAW 308S92(N) S 19 9 L S 2940

SAW 316S92(N) S 19 12 3 L S 2945

SAW 309S92(N) S 23 12 L S 2950

Flux SS300(N) S A AF 2 64 AC

Table 1 Overview of available RCC-M consumables (* No

relevant RCC-M data sheet).

Stick electrodes.

Ultramet stick electrodes have all the benefits of

an advanced rutile flux design. This includes

optimum versatility; downhand welding with

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high cosmetic finish and weld metal integrity;

and all-positional welding with the 2.5/3.2mm

electrodes including fixed pipe work. Recovery is

about 110% with respect to core wire, 65% with

respect to whole electrode.

All Ultramet electrodes have a moisture resistant

coating ensuring porosity-free welds, even under

less favourable (moisture) exposure conditions.

As per Metrode’s standard, all electrodes have

the batch number imprinted on the coating for

optimum traceability.

Solid wires

All 3XXS92(N) wires, for both TIG - and SA

Welding have low carbon and low silicon

content. TIG wires are cleaned to prevent weld

pool contamination.

All TIG wires have the batch number stamped on

both ends of the TIG wire providing optimum

traceability, even when the welder cuts the wire

in half.

Figure 1 Sizewell I Nuclear power plant UK.

SA welding flux

For Submerged Arc Welding applications

Metrode recommends its agglomerated flux

SS300-N. This Aluminate Fluoride type flux with

a basicity index (Boniszewski) of 1.6 provides the

right balance between mechanical properties

and weldability. SS300-N will provide a self-

releasing slag and is suitable for DC and AC.

Under normal transportation and storage

conditions the flux can be used from the tin

without the need for redrying.

Certification

Metrode’s Quality System conforms to the

requirements imposed by RCC-M. Furthermore,

all required testing on the consumables has

been performed in order to satisfy the RCC-M

requirements.

Every batch of Metrode’s RCC-M consumables is

supplied with a 3.1 certificate with both actual

chemical and mechanical properties meeting the

specific requirements stipulated in RCC-M Add

2007 Section IV. In figure 2 a copy of a

certificate is shown.

Figure 2 Certificate of Ultramet 316L(N)

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By taking all necessary steps to fulfill the RCC-M

code requirements Metrode can guarantee that

its consumables meet the full scope of RCC-M.

Packaging

Metrode has introduced specific packaging

labels for its nuclear certified welding

consumable range. Bright orange labels will be

exclusively used for nuclear certified material

which should allow for easy identification and

avoids mixing with standard consumables at

every stage of the supply chain.

Figure 3 Metrode RCC-M labels

MMA electrodes are supplied in Metrode

traditional metal tins with ring-pull opening. The

tins are hermetically sealed and meet the

definition for hermetically sealed containers

given in AWS A5.5. If unopened, and

appropriately stored, this packaging will

maintain the electrodes in the as-packed

condition for an indefinite period of time.

Electrodes can be used directly from the tin

without the need for redrying. Once opened, the

tins can be closed using the plastic lid supplied

and should be stored at >18°C and <60% relative

humidity. Redrying requirements are given on

the data sheets for individual electrodes.

TIG wires are, as mentioned earlier, individually

marked with grade and batch number on both

ends and conveniently packed in a rugged 2.5kg

PE tube. This provides sufficient product

protection for both in-shop and on-site

applications.

Submerged Arc Welding flux is supplied in 25 kg

robust metal drums and can, under normal

conditions, be used direct from an unopened

drum. Submerged Arc wire is supplied on

industry standard 25kg “stein baskets”.

Typical mechanical properties

Product Rp0,2

[MPa]

Rm

[MPa]

A4

[%]

CVN

[J+20°C]

UM308L(N) 465 600 47 65

(+350°C) 305 410 30 --

TIG 308S92(N) 465 605 48 160

(+350°C) 290 400 30 --

UM316L(N) 500 600 38 65

(+350°C) 340 470 33 --

(+360°C) 340 470 30 --

TIG 316S92(N) 465 605 48 110

(+350°C) 280 410 30 --

(+360°C) 280 410 30 --

UM309L(N) 495 595 41 --

TIG 309S92(N) 450 590 43 --

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Figure 4a & b – Sellafield Nuclear Reprocessing Plant - UK

Typical chemical composition

* Ferrite calculated according to DeLong diagram.

Metrode to go – exhibition programme

30 May - 2 June 2010, Barcelona, Spain

ENC 2010 was a unique networking event for

scientists, nuclear industry representatives and

policy makers, who can consider and discuss

ideas and innovations that will drive the

technological developments of the future.

Following on from a series of seven successful

duplex conferences during the past twenty

Product C Mn Si S P Cr Ni Mo Cu Co N FN *

Ultramet 308L(N) <0.025 0.7 0.6 0.01 0.02 19.5 9.5 0.1 <0.1 0.04 0.08 8

TIG 308S92(N) 0.01 1.7 0.4 0.01 0.015 20 10 0.1 0.15 0.04 0.04 8

Ultramet 316L(N) <0.025 0.7 0.6 0.01 0.02 19.5 12.5 2.6 <0.1 0.04 0.1 8

TIG 316S92(N) 0.01 1.7 0.4 0.01 0.015 19 12.5 2.6 0.15 0.04 0.04 10

Ultramet 309L(N) 0.025 0.8 0.6 0.01 0.02 23.5 12.5 0.2 <0.1 0.04 0.1 16

TIG 309S92(N) 0.01 1.7 0.5 0.01 0.015 23.5 13 0.1 0.1 0.04 0.04 12

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years, the next Duplex Stainless Steel

Conference will be held at the same venue in

Beaune, France, where the legendary and

mostfamous Duplex Conference ever, was held

in 1991. Again the content will be solely

dedicated to duplex stainless steels with a

strong emphasis on new developments such as

lean and hyper duplex stainless steels.

Presentations will be sourced on the

comparison of properties between duplex and

other alloys. Visitors to this upcoming

conference will therefore benefit from the up-

to-date exchange of information on long-term

experiences with duplex stainless steels that

have taken place since the previous Beaune

Conference in 1991. The main topic will be cost

saving and life-cycle aspects of nitrogen-

containing duplex stainless steels in a variety of

applications.

Metrode will be presenting an update of the

paper that they presented at the first Beaune

Conference, focused on ‘Corrosion Testing of

Duplex & Superduplex Weld Metal’

June 16-17th

The Atlantic Canada Petroleum Show put the

spotlight the technology, the people, and the

projects of the East Coast region. Over 100

exhibiting companies and 2,000 attendees

came together in the beautiful setting of St.

John’s Newfoundland to source new

technologies, discover new business

opportunities, and explore the latest

innovations.

Sports News

We have been sponsoring the under 8 football

team at Abbey Rangers, based in Chertsey, this

season and having the logo on the shirts seems

to have worked - they won two end of season

tournaments!

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VIP Guests

Article from the Surrey Herald

Keith Palmer shows Philip Hammond our new FCW Plant.

Coalition is trying to protect British

jobs, says Tory MP.

Philip Hammond Conservative MP for

Runnymede and Weybridge, has said it is “more

important than ever” to support local business.

The MP, currently transport secretary in the

Conservative Liberal Democrat coalition

government, was speaking at a meeting at

Metrode Products, in Hanworth Lane, Chertsey,

on Friday. He was visiting the welding

consumerables manufacturing company to

discuss the impact of overseas contracts on

British industry. During his meeting, he met

business managers and had a tour of the

premises.

He said: “I like to visit a local business each

week as I tour my consistuency and I’ve been

hoping to come here since the election.

Supporting local business is important. We are

trying to protect jobs and aid the economy

while we get through this budget deficit.”

The company has been in Chertsey for the past

37 years and is part of US company, Lincoln

Electrical.

Mr Hammond was greeted by general manager

Peter Frost and Runnymede borough valuer Ian

Gifford. Mr Frost said: “I wrote to Mr Hammond

at the turn of the year to discuss some contract

that, if awarded, we were concerned could have

used overseas employment.

“We wanted British workers to be employed

and getting Mr Hammond here is a great

opportunity to tell him about manufacturing in

Britain.

“It is more important for the future of

manufacturing in this country that we not only

hardness theoretical but also practical skills.

For more information on Metrode Products, visit

www.metrode.com.

Metrode Products Limited

Hanworth Lane

Chertsey

Surrey, KT16 9LL UK

www.metrode.com

Email: sales@metrode.com

Email: tech@metrode.com