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