WELDING CONSUMABLES

CLASSIFICATION,

STORAGE AND HANDLING

R.D.PENNATHURMAILAM INDIA LIMITED

CHOICE OF WELDING CONSUMABLES

• IS MOST IMPORTANT STEP IN ACHIEVING SOUND WELDS TO PERFORM SATISFACTORILY IN SERVICE

• SELECTION BASED ON TECHNICAL ANALYSIS IS THE BEST METHOD

• SELECTION IS TO BE BASED ON BASE MATERIAL,WELDING PROCESS ,SERVICE CONDITION & AVAILABILITY OF CONSUMABLES.

• COMMONLY USED CONSUMABLES ARE ELETRODES,SOLID WIRE,FCAW & WIRE /FLUX COMBINATION FOR SAW PROCESS

TYPE OF WELDING CONSUMABLES

• *FLUX COVERED STICK ELECTRODES• LIGHT COATED• MEDIUM COATED• HEAVY COATED• *BARE SOLID ROD (FILLER ROD)• *BARE SOLID WIRE (ELECTRODE / FILLER ROD)• *FLUX CORED WIRE (ELECTRODE)• *BARE SOLID STRIP (ELECTRODE)• *SHILEDING GAS (IN CYLINDERS)• *SHIELDING FLUX (GRANULAR POWDER)

WELDING PROCESS

GTAW

SMAW

GMAW

FCAW

SAW

GTAW CONSUMABLES

• Gas tungsten arc welding is most commonly used to weld stainless steel and nonferrous materials, such as aluminum and magnesium, but it can be applied to nearly all metals, with notable exceptions being lead and zinc.

• Its applications involving carbon steels are limited not because of process restrictions, but because of the existence of more economical steel welding techniques, such as gas metal arc welding and shielded metal arc welding.

• Furthermore, GTAW can be performed in a variety of other-than-flat positions, depending on the skill of the welder and the materials being welded.

• GTAW requires in principle the filler wire of composition to be achieved

CONSUMABLES FOR SMAW

• Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode coated in flux to lay the weld. An electric current, in the form of either alternating current or direct current from a welding power source is used to form an electric arc between the electrode and the metals to be joined.

• As the weld is formed, the flux coating of the electrode disintegrates, giving off vapors that

serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.

• Because of the versatility of the process and the simplicity of its equipment and operation, shielded metal arc welding is one of the world's most popular welding processes

• The SMAW is most versatile process as flux facilitates addition of alloying element to weld metal & as such with same core wire many composition of weld metal can be obtained.

SCHMATIC REPRESENTATION OF SMAW

• FLUXING AGENTS

• SLAG FORMERS

• ARC STABILISERS

• GAS FORMERS

• SLIPPING AGENTS

• BINDING AGENTS

• DEOXIDISERS AND ALLOYING ELEMNTS

FLUX INGRADIENTS

ADVANTAGES OF FLUX COATING

• TO STRIKE AND MAINTAIN ARC

• TO PROVIDE A GAS SHEILD OVER MOLTEN WELDPOOL

• TO DEOXIDISE AND REFINE WELDMETAL

• TO ADD ALLOYING ELEMENTS IN WELDMETAL

• TO PROVIDE A SLAG BLANKET ON MOLTEN WELDPOOL

• TO INCREASE DEPOSITION EFFICIENCY

GMAW CONSUMABLES

• Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding, is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun.

• A constant voltage, direct current power source is most commonly used with GMAW.

• There are four primary methods of metal transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which has distinct properties and corresponding advantages and limitations.

• Originally developed for welding aluminium and other non-ferrous materials in the 1940s, GMAW was soon applied to steels because it allowed for lower welding time as compared to other welding processes.

• The welding consumable has to have same composition as that of expected of weld metal..Hence,the consumable availability is a major limitation to process application. Most popular application is limited to Corbon steel & Nonferrous material.

GAS METAL ARC WELDING

GMAW SCHMATIC ARRANGEMENT

  GMAW Circuit diagram. (1) Welding torch, (2) Workpiece, (3) Power source, (4) Wire feed unit, (5) Electrode source, (6) Shielding gas supply

GMAW weld area. (1) Direction of travel, (2) Contact tube, (3) Electrode (4) Shielding gas, (5) Molten weld metal, (6) Solidified weld metal, (7) Workpiece.

GMAW WELD AREA

FCAW CONSUMABLES• Flux-cored arc welding (FCAW) is a semi-automatic or automatic arc welding

process. FCAW requires a continuously-fed consumable tubular electrode containing a flux and a constant electric current welding power supply.

• An externally supplied shielding gas is sometimes used, but often the flux itself is relied upon to generate the necessary protection from the atmosphere.

• The process is widely used in production/ construction because of its high welding speed and portability.

• FCAW was first developed in the early 1950’s as an alternative to shielded metal arc welding (SMAW).

• The advantage of FCAW vs. SMAW is that FCAW is continuous consumable process with high productivity.This in combination with addition of alloying elements through flux has made it possible to manufacture various specifiction consumables in economical quantity.

FCAW SCHMATIC REPRESENTATION

SAW CONSUMABLES

• Submerged Arc Welding (SAW) is a common arc welding process.• It requires a continuously fed consumable solid or tubular (flux cored) electrode. • The molten weld and the arc zone are protected from atmospheric contamination

by being “submerged” under a blanket of granular fusible flux .• When molten, the flux becomes conductive, and provides a current path between

the electrode and the work. • This thick layer of flux completely covers the molten metal thus preventing spatter

and sparks as well as suppressing the intense ultraviolet radiation and fumes that are a part of the other welding process..

• SAW is normally operated in the automatic or mechanized mode.• Even though the flux in SAW can be used for alloying element tranfer,the process is

having limitation of positional limitation i.e most suitable for Flat/ Horizontal position welding.

• Extensively used in industries for welding of Long/Circumferential seams of pressure vessels.

                                                                                           

Mechanised SAW Welding - Single Wire

SAW TRAINING UNIT

• IS (Indian)

• AWS/ASME (American)

• DIN (German)

• EN (British)

• National/International Inspection/licenser Specification

Welding consumable standards

CONSUMABLE SELECTION

The Welding consumables for welding of CS, LAS & SS are selected based on guidelines provided in ASME II C. The relevant specification for the same are indicated here below:

SFA 5.1 Carbon Steel Electrodes for Shielded Metal Arc Welding SFA 5.4 Stainless Steel Electrodes for Shielded Metal Arc Welding SFA 5.5 Low-Alloy Steel Electrodes for Shielded Metal Arc Welding SFA 5.9 Bare Stainless Steel Welding Electrodes and Rods SFA 5.17 Carbon Steel Electrodes and Fluxes for Submerged Arc Welding SFA 5.18 Carbon Steel Electrodes and Rods for Gas Shielding Arc Welding SFA 5.20 Carbon Steel Electrodes for Flux Cored Arc Welding SFA 5.22 Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux Cored Rods for Gas Tungsten Arc Welding SFA 5.23 Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding SFA 5.29 Low Alloy Electrodes for Flux Cored Arc Welding SFA 5.01 Filler Metal Procurement Guidelines

TESTING OF ELECTRODES

• PHYSICAL TEST

• CHEMICAL TEST

• MECHNICAL TESTS

PHYSICAL TEST

• UNIFORMITY OF COATING• PROPER BRUSHING OF HOLDING & STRIKING ENDS• CONCENTRIC COATING• STRIKING END FREE OF FLUX & RUST• ELECTRODES NOT DEFORMED• NO DAMAGE TO COATING IN TRANSIT

• FOR COTINUOUS WIRE CHECK SPOOL DAMAGE• UNIFORMITY OF WIRE-LAYER WINDING

• CAST & HELIX

PERFORMANCE CHARACTERS

• UNIFORM COVERING• CONCENTRICITY• GRIP END/ARC END TRIMMING • CUP FORMATION • ARC INTENSITY/STABILITY• SMOOTH ARC• FLUIDITY/VISCOSITY• SLAG/OXIDE INCLUSIONS• MOISTURE ABSORPTION• LOW SPATTER• COVERING THICKNESS• CRATER CRACKING • IDENTIFICATION• SLAG DETATCHABILITY

FACTORS TO BE EVALUATED

• CHEMICAL COMPOSITION

• MECHANICAL PROPERTIES

• NOTCH TOUGHNESS

• ELCTRICAL CHARECTERISTICS

• TYPE OF COVERING

OPTIONAL PARAMETERS

• NOTCH TOUGHNESS REQUIREMENTS

• MOISTURE CONTENT

• DIFFUSIBLE HYDROGEN

SUPPLEMENTARY PARAMETERS

• HARDNESS

• CORROSION RESISTANCE

• FERRITE CONTENT

• HOT TENSILE TEST

• WEAR RESISTANCE

• HOT CRACKING TEST

SPECIFIC TESTS FOR WELDING CONSUMABLES (CS&LAS)

CARBON STEEL CONSUMABLES

• WELDMETAL CHEMISTRY• CVN IMPACT VALUE AT-SPECIFIED LOW TEMP.• TENSILE/YIELD AFTER PWHT• HARDNESS REQUIREMENT

LOW ALLOY STEEL CONSUMABLES

• WELDMETAL CHEMISTRY• TENSILE/YIELD AFTER PWHT• HARDNESS REQUIREMENT• DIFFUSIBLE HYDROGEN CONTENT• CVN IMPACT AS SPECIFIED

SPECIFIC TESTS FOR WELDING CONSUMABLES(SS&NF)

STAINLESS STEELCONSUMABLES

• FERRITE CONTENT• WELDMETAL CHEMISTRY• CORROSION RESISTANCE• CVN IMPACT VALUE AT -196 DEG C

NON FERROUS CONSUMABLES

• WELDMETAL CHEMISTRY• CORROSION RESISTANCE• WELDABILITY

AWS SFA 5.1 CLASSIFICATION FOR CARBON STEEL ELECTRODE

E X X Y Y -1* HZ R

E DESIGNATES AN ELECTRODE X X TENSILE STRENGH IN KSI Y Y WELDING POSITION& TYPE OF COVERING 1 IMPROVED TOUGHNESS HZ DIFFUSIBLE HYDROZEN 4/8/16 R MOISTURE RESISTANCE

*M MILITARY SPEC. AS AGREED TO

MOISURE RESISTANT ELECTRODES

• THE ELECTRODES THAT CAN RESIST PICK OF MOISURE ARE CLASSIFIED WITH SUFFIX “R”

• THE CLASSIFICATION IS BASED ON EVALUATION OF MOISURE AS RECEIVED CONDITION & AFTER EXPOSURE TO ATMOSPHRE AT 80%RH /27 C FOR 9hrs

» MAX. MOISURE CONTENT % BY WEIGHTDESIGNATION AS RECD. AFTER EXPOSUREE7016RE7016-1RE7018R 0.30 0.40E7018-1RE7028-RE7048-RE7018-M 0.10 0.40

E.G. E 70 1 8

AWS CLASSIFICATION FOR

CARBON STEEL ELECTRODE

E-Manual Metal Arc Welding Electrode

70- Minimum UTS of 70 Ksi(70000psi)

1- Usability of electrode in all positions

8- Basic type of covering with Iron powder

TYPES OF COVERING

• 0-HIGH CELLULOSE SODIUM• 1-HIGH CELLULOSE POTASSIUM • 2-HIGH TITANIA SODIUM• 3-HIGH TITANIA POTASSIUM• 4-IRON POWDER,TITANIA• 5-LOW HYDROGEN SODIUM• 6-LOW HYDROGEN POTASSIUM• 7-HIGH IRON OXIDE,IRON POWDER• 8-LOW HYDROGEN POTASSIUM,• IRON POWDER• 9-IRON OXIDE TITANIA POTASSIUM

RUTILE Vs BASIC

• GOOD PERFORMANCE• OPERATES ON AC/DC• GOOD OPERATOR APPEAL• IMPACT AT SUBZERO LOW• REBAKING NOT REQD• .• H2 LEVEL HIGH• POSITIONAL WELDING EASY

• SATISFACTORY PERFORMANCE• NOT WELL ON AC• SATISFACTORY• GOOD IMPACT PROPERTIES• CAN NOT BE USED WITHOUT

REBAKING• H2 CAN BE CONTROLLED• POSSIBLE.HIGHER SKILL LEVEL

REQUIRED

AWS SFA 5.5 2007 CLASSIFICATION FOR ALLOY STEEL ELECTRODE

E XX XX –X* HZ R E DESIGNATES AN ELECTRODE X X TENSILE STRENGH IN KSI X WELDING POSITIONX X TYPE OF COVERING X CHEMICAL COMP. OF WELD METAL HZ DIFFUSIBLE HYDROZEN R MOISTURE RESISTANCE

*M MILITARY SPEC. AS AGREED TO

SUFFIX ALPHABETS INDICATIONS

• A C-Mo STEELS

• B Cr-Mo STEELS

• Ni Ni STEELS• • D Mn-Mo STEELS

• K Mn-Ni-Cr-Mo STEELS

AWS CLASSIFICATION OF LOW ALLOY STEEL ELECTRODE

• E-MANUAL METAL ARC WELDING ELECTRODE

• 80-MINIMUM UTS OF 80KSI(80000 psi)

• 1-USABILITY OF ELECTRODE IN ALL POSITIONS

• 8-BASIC TYPE OF COVERING WITH IRON POWDER

• B2-CHEMICAL COMPOSITION OF 1CHROME - 1/2 MOLY STEEL

E.G. E 80 1 8 B2

AWS CLASSIFICATION OF LOW ALLOY STEEL ELECTRODE

• E-MANUAL METAL ARC WELDING ELECTRODE

• 80-MINIMUM UTS OF 80KSI(80000 psi)

• 1-USABILITY OF ELECTRODE IN ALL POSITIONS

• 6-BASIC TYPE OF COVERING

• G-CHEMICAL COMPOSITION -Ni,Cr &Mo

E.G. E 8016 G

AWS CLASSIFICATION OF LOW ALLOY STEEL ELECTRODE

• E-MANUAL METAL ARC WELDING ELECTRODE

• 80-MINIMUM UTS OF 80KSI(80000 psi)

• 1-USABILITY OF ELECTRODE IN ALL POSITIONS

• 8-BASIC TYPE OF COVERING WITH IRON POWDER

• D3-CHEMICAL COMPOSITION OF ½ MOLY STEEL

E.G. E 80 1 8 D3

AWS CLASSIFICATION OF LOW ALLOY STEEL ELECTRODE

• E-MANUAL METAL ARC WELDING ELECTRODE

• 80-MINIMUM UTS OF 80KSI(80000 psi)

• 1-USABILITY OF ELECTRODE IN ALL POSITIONS

• 8-BASIC TYPE OF COVERING WITH IRON POWDER

• C2-CHEMICAL COMPOSITION OF 2%NICKEL STEEL

E.G. E 80 1 8 C2

SELECTION OF CONSUMABLES FOR SS

FOR JOINING OF SIMILAR MATERIAL

SELECTION BASED ON MATCHING OF MAJOR ALLOYNG ELEMENTS.

CORBON MATCHING ;L OR H TYPE

STABILISED GRADES FOR STABILISED TYPES.

CORROSION &CRYOGENIC APPLICATION IF SPECIFIED TESTED CONSUMABLES FOR SPECIAL APPLICATION

AWS SFA 5.4 2007 CLASSIFICATION FOR STAINLESS STEEL ELECTRODE

E XXX XX X-XX

E DESIGNATES AN ELECTRODE X XX ALLOY COMPOSITION XX ALLOY ADDITION X L-LOW CORBON H-HIGH CORBON XX 15-DCRP ( ALL POSITION )

16-AC/DCRP ( ALL POSITION ) 17-AC/DCRP ( ALL POSITION )25-DCRP(H & F)26-AC/DCRP(H & F )

AWS CLASSIFICATION OF STAINLESS STEEL ELECTRODE

• E-Manual metal arc welding electrode

• 316-Chemical composition of 17 to 20 Chrome,11 to14 Nickel,2 to 3 Moly

• L-low carbon variety

E.G. E 316 L

AWS CLASSIFICATION OF STAINLESS STEEL ELECTRODE

• E-Manual metal arc welding electrode

• 309Mo-Chemical composition of 22 to 25 Chrome,12 to14 Nickel,2 to 3

Moly

• L-low carbon variety

E.G. E 309MOL-16

F

AWS SFA 5.9 2007 CLASSIFICATION FOR BARE STAINLESS STEEL RODS

ER XXX XX X

ER DESIGNATES AN BARE ROD

X XX ALLOY COMPOSITION

XX ALLOY ADDITION

X L-LOW CORBON H-HIGH CORBON

AWS CLASSIFICATION OF STAINLESS STEEL FILLER ROD

• ER-ELECTRODE ROD

• 308-CHEMICAL COMPOSITION OF 19 TO22 CHROME,9 TO 11 NICKEL,0.75 MOLY

• L-LOW CARBON VARIETY

E.g. ER 308 L

AWS CLASSIFICATION OF STAINLESS STEEL FILLER ROD

• ER-ELECTRODE ROD

• 309-CHEMICAL COMPOSITION OF 22%-25% CHROME,12%-14% NICKEL,2%-3% MOLY

• L-LOW CARBON VARIETY

E.g. ER 309 L Mo

AWSSFA 5.11-2007 CLASSIFICATION OF NON FERROUS ELECTRODE

• E-MANUAL METAL ARC WELDING ELECTRODE

• XXXX- ALLOY SPECIFICATION

E.G. E XXXX

AWSSFA 5.11-2007 CLASSIFICATION OF NON FERROUS ELECTRODE

• E-MANUAL METAL ARC WELDING ELECTRODE

• NICU7-CHEMICAL COMPOSITION OF MONEL(70%NICKEL&BALANCE COPPER)

E.G. E Ni Cu 7

AWSSFA 5.11-2007 CLASSIFICATION OF NON FERROUS ELECTRODE

• E-MANUAL METAL ARC WELDING ELECTRODE

• NI Cr Fe3-CHEMICAL COMPOSITION OF INCONEL(60%NICKEL& 13-17% Cr, BALANCE FE)

E.G. E Ni Cr Fe3

ELECTRODES FOR CAST IRON

GENERALLY FOLLOWING TYPES ARE USED

• LOW HYDROGEN TYPE

• CAST IRON DEP.

• NICKEL BASED

• FERRO NICKEL BASED

• MONEL BASED

CI CONSUMABLES

PROPERTY LH/CI NI DEP. FeNi DEP MONEL DEP

MACHINABILITY NO GOOD GOOD GOOD

COLOUR MATCHING NO MATCH OK NO MATCH

STRENGH GOOD LOW SATISFACTORY LOW

TOLERANCE TO IMPURITY

GOOD NOT GOOD SATISFACTORY NOT GOOD

SUITABILITY

RECOMMENDED WHERE

MACHINING

IS NOT REQD.

FOR SMALL REPAIR WORK

BEST FOR ALL JOBS REQUIRING MACHINING

FOR SMALL REPAIR WORK

AWS SFA 5.15-2007 CLASSIFICATION OF ELECTRODES &RODS FOR CAST IRON

• E ELECTRODE

• NI CHEMICAL COMPOSITION OF NICKEL

BASED

• CI CAST IRON

E.G. E Ni - CI

AWS SFA 5.15-2007 CLASSIFICATION OF ELECTRODES &RODS FOR CAST IRON

• E MANUAL METAL ARC WELDING ELECTRODE

• NI Fe CHEMICAL COMPOSITION OF FERRO NICKEL BASED

• CI CAST IRON

E.G. E Ni Fe - CI

AWS SFA 5.15-2007 CLASSIFICATION OF ELECTRODES & RODS FOR CAST IRON

• E ELECTRODE

• NI Fe CHEMICAL COMPOSITION FERRO NICKEL BASED

• T TUBULAR/FCAW

• 3 SELF SHIELDING

• CI CAST IRON

E.G. E Ni Fe T3- CI

AWS SPECIFICATION FOR

BARE RODS

• A5.7-COPPER AND ALLOYS • A5.9-CHROMIUM AND CHROMIUM NICKEL STEELS• A5.10-ALUMINIUM AND ALLOYS• A5.13-SURFACING• A5.14-NICKEL AND ALLOYS• A5.15-CAST IRONS• A5.16-TITANIUM AND ALLOYS• A5.17-CARBON STEEL(SAW)• A5.18-CARBON STEEL(GTAW)• A5.23-LOW ALLOY STEEL(SAW)• A5.28-LOW ALLOY STEEL(GTAW)

CLASSIFICATION SFA 5.18 FOR CORBON STEELBARE WIRE

ER XX S* –X Y N HZ

ER INDICATES BARE WIRE XX TESILE STRENGH IN KSI S SOLID WIRE *C COMPOSITE WIRE X CHEMICAL COMP.(GS SINGLE) Y TYPE OF GAS C-CO2/M-MIXED N SPECIAL APPLICATION HZ HYDROGEN LEVEL AT 4/8/16

AWS CLASSIFICATION OF CARBON STEEL FILLER ROD

• ER-Electrode Rod

• 70-minimum UTS of 70 Ksi

• S-solid Rod

• 2-minimum CVN Impact Value of 20 Ftlb at Minus 20 Deg Fahrenheit

E.g. ER 70 S 2

CLASSIFICATION FOR LAS SFA 5.28 FOR BARE WIRE GMAW

ER XX S* –X HZ

ER INDICATES BARE WIRE

XX TESILE STRENGH IN KSI

S SOLID WIRE

*C COMPOSITE WIRE

X CHEMICAL COMP.(G FOR MULTI PASS &GS SINGLE)

HZ HYDROGEN LEVEL AT 4/8/16

• ER-ELECTRODE ROD

• 90-MINIMUM UTS OF 90KSI

• S-SOLID ROD

• B3-CHEMICAL COMPOSITION OF 2.25 CHROME-1 MOLY STEEL

• L-LOW CARBON VARIETY

AWS Classification of Low Alloy Steel Filler Rod

E.g. ER 90 S B3 L

AWS SFA 5.14-2007 CLASSIFICATION OF NON FERROUS ELECTRODE

• ER- ELECTRODE BARE ROD

• XXXX-ALLOY SPECIFICATION

E.G. ER XXXX

AWS SFA 5.14-2007 CLASSIFICATION OF NON FERROUS FILLER RODS

• ER- ELECTRODE BARE ROD

• NICU7-CHEMICAL COMPOSITION OF MONEL(70%NICKEL&BALANCE COPPER)

E.G. ER Ni Cu 7

AWS CLASSIFICATION OF NON FERROUS FILLER ROD

• ER-Electrode Bare Rod

• NiCr-3-Chemical composition of 70%Nickel and 20%Chromium

E.g. ER NiCr - 3

CARBON STEEL ELECTRODES FOR FLUX CORED ARC WELDING

AWS A5.20-2007

E X X T – XX-JXHX• E-ELECTRODE• X-TENSILE IN KSI• X-POSITION DESIGNATOR• T-FCAW/TUBULAR• X-USABILITY DESIGNATOR• X-SHIELDING GAS C-CO2/M-MIXED• J-20 ftlb AT -40 C• X-D/Q INDICATES SPECIAL MECH.PROPERTIES• HX-HYDROGEN DESIGNATOR

CARBON STEEL ELECTRODES FOR FLUX CORED ARC WELDING

AWS A5.20-2007

E71 T – 1C• E-ELECTRODE

• 7-TENSILE IN KSI(70)

• 1-ALL POSITION

• T-FCAW/TUBULAR

• 1-USABILITY AS PER TABLE 2(MULTIPASS)

• C-SHIELDING GAS C-CO2

E70 T – 3C• E-ELECTRODE

• 7-TENSILE IN KSI(70)

• 0-FLAT/HORIZONTAL POSITION

• T-FCAW/TUBULAR

• 3-USABILITY AS PER TABLE 2(SINGLE PASS)

• X-SHIELDING GAS C-CO2

CARBON STEEL ELECTRODES FOR FLUX CORED ARC WELDING

AWS A5.20-2007

E70 T – 8• E-ELECTRODE

• 7-TENSILE IN KSI(70)

• 0-FLAT/HORIZONTAL POSITION

• T-FCAW/TUBULAR

• 8-USABILITY AS PER TABLE 2(MUTI PASS-SELF SHIELDING)

CARBON STEEL ELECTRODES FOR FLUX CORED ARC WELDING

AWS A5.20-2007

LOW ALLOY STEEL ELECTRODES FOR FLUX CORED ARC WELDING

AWS A5.29-2007

E X X TX – XX-JHX• E-ELECTRODE• X-TENSILE IN KSI• X-POSITION DESIGNATOR• T-FCAW/TUBULAR• X-USABILITY DESIGNATOR• X-CHEMICAL COMPOSITION• X-SHIELDING GAS C-CO2/M-MIXED• J-IMPROVED TOUGHNESS -27JAT 10 C• HX-HYDROGEN DESIGNATOR

LOW ALLOY STEEL ELECTRODES FOR FLUX CORED ARC WELDING

AWS A5.29-2007

E 8 X T1 – Ni1C/M• E-ELECTRODE• 8-TENSILE IN KSI(80)• X-POSITION DESIGNATOR• T-FCAW/TUBULAR• 1-RUTILE TYPE• Ni1-CHEMICAL COMPOSITION-1%Ni• C-CO2 SHIELDING GAS• M-MIXED GAS

LOW ALLOY STEEL ELECTRODES FOR FLUX CORED ARC WELDING

AWS A5.29-2007

E 8X T5 – B2CJH4• E-ELECTRODE• 8-TENSILE IN KSI(80)• X-POSITION DESIGNATOR• T-FCAW/TUBULAR• 5-BASIC TYPE• B2-CHEMICAL COMPOSITION- 2 Cr-1 Mo• C-CO2 SHIELDING GAS • J-IMPROVED TOUGHNESS - 27J AT 10 C• HX-HYDROGEN DESIGNATOR-4ml/100gms OF WELD METAL

STAILESS STEEL ELECTRODES FOR FLUX CORED ARC WELDING

AWS A5.22-2007

E X X XTX-X E-ELECTRODE

XXX-COMPOSITION OF WELD METAL

T-FCAW/TUBULAR

X-POSITIONAL WELDING DESIGNATOR 0-F/H;1-ALL POSITION

X-SHIELDING GAS 1-CO2/ 3-SELF SHIELDING/ 4-80-20 Ar-CO2/ 5-Ar

STAINLESS STEEL ELECTRODES FOR FLUX CORED ARC WELDING

AWS A5.22-2007

E 308T1-1 E-ELECTRODE

308-COMPOSITION OF WELD METAL-18%Cr/8%Ni

T-FCAW/TUBULAR

1-ALL POSITION

1-SHIELDING GAS 1-CO2

STAILESS STEEL ELECTRODES FOR FLUX CORED ARC WELDING

AWS A5.22-2007

E 308T0-3 E-ELECTRODE

308-COMPOSITION OF WELD METAL-18%Cr/8%Ni

T-FCAW/TUBULAR

0-FLAT/HORIZONTAL

3-SELF SHIELDING

STAILESS STEEL FLUX CORED RODS FOR GTAW WELDING

AWS A5.22-2007

R X X XT1-5 R-WELDING ROD

XXX-COMPOSITION OF WELD METAL

T-FCAW/TUBULAR

1- ALL POSITION

5-100% ARGON

STAILESS STEEL FLUX CORED RODS FOR GTAW WELDING

AWS A5.22-2007

R 308LT1-5 R-WELDING ROD

308L-COMPOSITION OF WELD METAL

T-FCAW/TUBULAR

1- ALL POSITION

5-100% ARGON

SAW

• F-SAW FLUX • S- INDICATES FLUX BEING CRUSHED

SLAG/SLAG +VIRGIN FLUX• 7-MINIMUM UTS OF 70 KSI(70000psi)• P- HEAT TREATMENT P-PWHT/A-AS WELDED• 4-MINIMUM CVN IMPACT ENERGY OF 20 Ft Lb

AT MINUS 40°F• EXXX-ELECTRODE WIRE• HX- HYDROGEN DESIGNATOR

E.g. F S7 P 4 EXXX HX

SAW

• F-SAW FLUX

• 7-MINIMUM UTS OF 70 KSI(70000psi)

• A- AS WELDED

• 6-MINIMUM CVN IMPACT ENERGY OF 20 Ft Lb AT MINUS 60°F

• EM12K-ELECTRODE SPECIFICATION

• HX- NOT SPECIFIED

• S-ABSENCE INDICATES VIRGIN FLUX

E.g. F 7 A6 EM12K

SHIELDING GASES

• SELECTION OF SHIELDING GAS IS VITAL FOR GMAW/FCAW

• GAS SELECTION CAN AFFECT ARC CHARACTERISTICS & ALSO AFFECT MECHANICAL PROPERTIES.

• THE GAS PLAYS IMPORTANT ROLE IN MODE OF METAL TRANFER,BEAD PROFILE &PENETRATION.

• THE COMMEN GASES USED ARE CO2,ARGON,HELIUM & MIXED GASES.

COMPARISON OF INERT GASES Ar &He

ARGON• 1.4 TIMES HEAVIER THAN AIR• QUANTUM OF SHIEDING GAS

REQD. IS LOW• DUE TO LOWER THERMAL

CONDUCTIVITY FINGER TYPE PENETRATION

• PRODUCES SPRAY TRANFER

• USED COMMENLY FOR WIDE RANGE OF MATERIAL MOSTLY AS MIXED GAS WITH CO2

HELIUM• 0.14TIMES HEAVIER THAN AIR• QUAMTUM OF SHIELDING GAS REQD.

IS VERY HIGH• DUE TO HIGHER THERMAL

CONDUCTIVITY DEEP BROAD PARABOLIC TYPE PENETRATION

• CAN PRODUCE SPRAY TRANFER ONLY WHEN MIXED WITH ARGON

• USED FOR HIGH CONDUCTIVITY MATERIAL LIKE Cu ,Al etc

ACTIVE GAS-CO2

• USED FOR CORBON & LAS• USED ALSO FOR SS IN FCAW• HIGHER SPED,ADEQUATE PENETRATION AT LOWER COST

ARE ITS SALIENT FEATURES.• FOR SOLID WIRE TRANFER MODE IS EITHER SHORT

CIRCUITING OR GLOBULAR• TRANFER TYPE LEADS TO HIGHER SPATTER & ROUGH BEAD

PROFILE• FOR FCAW SPRAY TRANFER IS ACHIVED HENCE MOST

COMMENLY USED GAS

GAS MIXTURES

• Ar+CO2

• Ar+O2

• Ar+O2+CO2

• Ar+He

• AR+He+O2

• Ar+He+O2+CO2

SHIELDING GASES

Arc Characteristics Penetration Profile Mode Of Transfer Spatter Level Alloy Recovery Material Types

SHIELDING GAS COMPARISONE 81T-1-Ni1 VERTICAL UP @21 KJ/CM

95Ar/5CO2 75Ar/25CO2 50Ar/50CO2 100CO2

TYPICALCHEMICALANALYSIS

CMnSi

.0591.29..44

.0551.29.44

.0421.24.39

.0411.16.31

TYPICALMECH.PROP(Mpa)

YS

UTS

540

603

531

586

502

568

457

565TYPICALIMPACTPROP(J)

0 Deg C

-40Deg C

123

91

125

84

109

48

104

40

BEADSHAPE

FLAT FLAT CONVEX CONVEX

IMPORTANT

Making a Gas DecisionDeciding on a particular shielding gas

should be based on the specific manufacturer’s recommendation. Failure to do so may result in weld metal defects or in an deterioration in Mechanical properties.The manufacture’s guaranteed values are obtainable only when specified technical parameters are followed in full .

STORAGE OF CONSUMABLES

• SHELF LIFE OF WELDING CONSUMABLES DEPENDS ON THE WAY THEY ARE STORED

• IF THE ELECTRODES ARE STORED IN A DRY HUMIDITY CONTROLLED ROOM WITHOUT OPENING THE ORIGINAL PACKING,THEY CAN BE UTILISED EVEN UPTO 2 YEARS FROM DATE OF PACKING.

STORAGE & RECONDITIONING FOR SMAW /FCAW

SMAW• Low Hydrogen Store 100-150 Deg C Recondition at 400 Deg C- 1Hr • Stainless Recondition at 200 Deg C- 1Hr FCAW • Plastic Recondition at 50 Deg C- 48Hr Min• Coils Store 100-125 Deg C Recondition at 150 Deg C- 6-8Hrs• Wire Spool Store 150 Deg C Basket Recondition at 250 Deg C- 2-3Hrs Higher Rebake Temperature , Faster Reconditioning

STORAGE AND DRYING OF CS&LAS CONSUMABLES

• CELLULOSIC TYPE-REDRYING TEMP-70 TO 80 DEG C/HR

• BASIC TYPE-REDRYING TEMP- 260 TO 420 DEG C /2HR ,HOLDING TEMP-30 TO 140 DEG C

REBAKING SCHDULE FOR LH ELECTRODES

• REBAKE CONSUMABLES AT 250-300 C FOR ONE HOUR

• TRANFER THEM TO HOLDING OVEN AT 100 C

• TRANPORT HOLDING OVEN TO WORKING AREA &USE THE SAME FOR FABRICATION

• USE DIFFERENT COMPARTMENTS OF OVEN TO BAKE OTHER SPECIFICATION OF CONSUMABLES.

• CLEAN THE OVEN AT LEAST ONCE A WEEK.

STORAGE&DRYING OF SS&NF CONSUMABLES

• RUTILE TYPE- REDRYING TEMP-120TO150 DEG C /2HR

• SEMI BASIC TYPE-REDRYING TEMP-180 TO 200 DEG C/2HR

• BASIC TYPE-REDRYING TEMP-200 TO 250 DEG C/2HR

VACCUM PACKING

• SPECIAL PURPOSE MACHINES ARE AVILALE FOR VACUUME PACKING ELECTRODES AS WELL AS WIRE SPOOLS.

• IN THIS TYPE OF PACKING AS ALL AIR INSIDE THE PACKING ARE REMOVED,THE CONSUMABLES DO NOT ABSORB ANY MOISTURE

• THEY CAN BE USED WITHOUT REBAKING

• THE PACKING QUANTUM CAN BE VARIED BASED ON SPECIFIC APPLICATION

• HIGHLY RECOMMENDED WHEN REBAKING IS NOT FEASIBLE

SOME COMMENLY ASKED QUESTIONS

The E7018 welding rods I've been buying are now marked E7018 H4R. What does the H4R mean? Are these rods different than the E7018 rods I've used before?

H4R is an optional supplementary designator, as defined in AWS A5.1-91 (Specification for shielded metal arc welding electrodes). Basically, the number after the "H" tells you the hydrogen level and the "R" means it's moisture resistant."H4" identifies electrodes meeting the requirements of 4ml average diffusible hydrogen content in 100g of deposited weld metal when tested in the "as-received" condition."R" identifies electrodes passing the absorbed moisture test after exposure to an environment of 80ºF(26.7ºC) and 80% relative humidity for a period of not less than 9 hours. The H4R suffix is basically just additional information printed on the rod, and does not necessarily mean a change in an electrode previously marked E7018.

Why is hydrogen a concern in welding?

Hydrogen contributes to delayed weld and/or heat affected zone cracking. Hydrogen combined with high residual stresses and crack-sensitive steel may result in cracking hours or days after the welding has been completed. High strength steels, thick sections, and heavily restrained parts are more susceptible to hydrogen cracking. On these materials, we recommend using a low hydrogen process and consumable, and following proper preheat, interpass, and postheat procedures. Also, it is important to keep the weld joint free of oil, rust, paint, and moisture as they are sources of hydrogen

What consumables are better for welding over rusty, dirty steel?

Steel should be cleaned of any oil, grease, paint, and rust before using any arc welding process. However, if complete cleaning cannot be performed, consumables that form a slag, have deeper penetration, are slower freezing, or have higher Silicon and Manganese are recommended for dirty steels

Why are the Charpy impact values from my test welds lower than that printed on your Certificate of Conformance?

The test results on our Certificate of Conformance were obtained from welding an AWS filler metal test plate. Any change in welding procedure will affect Charpy impact values. Below are common practices for welding test plates when Charpy impact specimens are required: • Controlled heat input • Controlled preheat and interpass temperature • Even number of passes per layer • Build-up cap pass to maximum allowed in specification

I'm using E71T-1 flux-cored wire with 75Ar/25CO2. Why am I getting gas marks on the weld surface?

The fast freezing rutile slag on an E71T-1 wire gives it excellent out-of-position characteristics, but can also trap gases under the slag as the weld solidifies, resulting in gas marks. Gas marks are more commonly observed welding at high procedures under a high Argon blend shielding gas. Gas marking and/or can be minimized by:

1. Switching to 100% CO2 shielding gas 2. Lowering the welding current 3. Cleaning the weld joint of paint, rust, and moisture 4. Minimize any wind disturbance 5. Cleaning spatter from inside gas nozzle 6. Increasing the shielding gas flow rate

Why is preheat sometimes required before welding? Preheating the steel to be welded slows the cooling rate in the weld area. This may be necessary to avoid cracking of the weld metal or heat affected zone. The need for preheat increases with steel thickness, weld restraint, the carbon/alloy content of the steel, and the diffusible hydrogen of the weld metal. Preheat is commonly applied with fuel gas torches or electrical resistance heaters

Carbon EquivalentCarbon Equivalent

CECE = C + +Mn20

Cr+Mo+V10

Ni15

+

Preheat TemperaturePreheat Temperature

Tp = 350 ( C ) - 0.25

( C ) = CE ( 1 + 0.005 x t )

CE - Carbon Equivalent t - Thickness in mm

How should uniformity of preheat be measured?

AWS D1.1 Structural Steel Welding Code, Section 5.6 states: Preheat and all subsequent minimum interpass temperatures shall be maintained during the welding operation for a distance at least equal to the thickness of the thickest welded part, but not less than 3 in. [75mm] in all directions from the point of welding. In general, when preheat is specified, the entire part should be thoroughly heated so the minimum temperature found anywhere on that part will meet or exceed the specified preheat temperature.

What is interpass temperature?

Interpass temperature refers to the temperature of the steel just prior to the depositing of an additional weld pass. It is identical to preheat, except that preheating is performed prior to any welding. When a minimum interpass temperature is specified, welding should not be performed when the base plate is below this temperature. The steel must be heated back up before welding continues. A maximum interpass temperature may be specified to prevent deterioration of the weld metal and heat affected zone properties. In this case, the steel must be below this temperature before welding continues.

Do I need an oven to store low hydrogen electrodes?

All low-hydrogen consumables must be dry to perform properly. Unopened hermetically sealed containers provide excellent protection in good storage conditions. Once cans are opened, they should be stored in a cabinet at 120º-150ºC.When the electrodes are exposed to the air, they will pickup moisture and should be redried. Electrodes exposed to the air for less than 1 week with no direct contact with water should be redried as follows:

E7018: 1 hour at 650º-750ºF

E8018, E9018, E10018, E11018: 1 hour at 700º-800ºF

1. If the electrodes come in direct contact with water or have been exposed to high humidity, they should be predried for 1-2 hours at 180º-220ºF first before following the above redrying procedure.

2. Standard EXX18 electrodes should be supplied to welders twice per shift. 3. Low hydrogen electrodes with the suffix "R" have a moisture resistant coating and may be

left out up to 9 hours or as specified by code requirements.

What precautions should I take when welding T-1 steels?

T-1 is a quenched and tempered steel. Welding quenched & tempered steels may be difficult due its high strength and hardenability. The base steel around the weld is rapidly being heated and cooled during welding, resulting in a heat affected zone (HAZ) with high hardness. Hydrogen in the weld metal may diffuse into HAZ and cause hydrogen embrittlement, resulting in delayed underbead or toe cracking outside of the weld. To minimize heat affected zone cracking:

1. Use a low hydrogen consumable, like a -H4 or -H2. 2. Preheat. This slows the cooling rate. Note that excessive preheat may anneal the base

material. 3. Slow cool. More time at elevated temperatures allows the dissolved hydrogen to

escape. 4. Peen the weld beads to minimize residual weld stresses. 5. Use the lowest strength filler metal meeting design requirements. If making fillet welds,

the weld can be oversized to give the specified strength 6. Minimize weld restraint.

What electrode can I use to join mild steel to stainless steel?

Electrode selection is determined from the base metal chemistries and the percent weld admixture. The electrode should produce a weld deposit with a small amount of ferrite (3-5 FN) needed to prevent cracking. When the chemistries are not known, E 312 type electrode, which produces a high ferrite number, is commonly used. What consumable should be used to weld cast iron?

Cast irons are alloys which typically have over 2% carbon plus 1-3% silicon and are difficult to weld. Electrodes with a high percentage of nickel are commonly used to repair cast iron. Nickel is very ductile, making it a good choice to weld on cast iron, which is very brittle. welding with Nickel(99%)l/Ferro Nickel(55%) are the recommended electrodes designed for welding cast iron.

CASE STUDIES & FAILURE ANALYSIS

WITH STICK WELDING(SMAW) PROCESS

ON DIFFERENT TYPES OF MATERIAL

FAILURE OF TEST COUPENS OF DISHED END

PETAL TYPE

HOT PRESSED/COLD SPINNING

THE WPS/PQR ESTABLISHED USING E7018 ELETRODES FOR SA515Gr70 MATERIAL GAVE SATIASFACTORY RESULTS FOR PETAL D.E

THE SAME WPS FOUND TO VARIATION IN RESULT WHEN USED FOR COLD SPUN /HOT PRESSED D.E. WITH WELD JOINT.

ANALYSIS

THE HOT PRESSED ./COLD SPUN D.E.UNDERGOES NORMALISING OPERATION WHICH IS NOT ACCOUNTED IN WPS

WHEN USING E7018 ELECTRODES ,UTS DROPS BY 50-70 N/mm sq WITHNORMALISING OPERATION

FAILURE OF TEST COUPENS OF DISHED END(CONTD)

SOLUTION • IT IS RECOMMENDED TO USE E7018A1 WELDING

CONSUMABLES.

PROPERTIES OF CONSUMABLES WITH TYPICAL H.T. CYCLES.

Sl.No CONSUMALE TYPE

AS WELDED

SR NORMALISED

1 E7018 530 525 480

2 E7018A1 540 535 530

FAILURE OF 5Cr-1/2 Mo SPIRAL HEAT EXCHANGER

PROBLEM:

THE SPIRAL COIL WELD JOINTS WERE FOUND TO BE LEAKING AFTER SHORT SEVICE OF SIX MONTHS

ANALYSIS:

THE WELD JOINTS EXAMINED USING DP INDICATED SEVERE MICRO FISSURING ON ALL THE JOINTS.

THE EXAMINATION OF WPS/PQR INDICATED ROOT RUN BY GTAW & BALANCE BY SMAW OF E 8018-B6 CONSUMABLES.

FAILURE OF 5Cr-1/2 Mo SPIRAL HEAT EXCHANGER(CONTD)• ON EXAMINATION OF CONSUMABLE RECORDS ,BEING 2.5MM

IN SIZE ,NO MECHANICAL TEST RESULS WERE CALLED FOR & HENCE NOT PROVIDED.

REVIEW • TAKING INTO CONSIDERATION TYPE OF BASE MATERIAL

WHICH IS PRONE FOR INTERMEDIATE HARDANABLE MICRO STRUCTURE & MICRO FISSURING UNDER RESTRAIANT, IT WAS RECOMMENDED TO USE E8018-B6 DULY QUALIFIED WITH TEKKAN Y-GROOVE TEST

TEKKEN Y-GROOVE ASSEMBLY

20mm

CROYOGENIC APPLICATION

TYPICAL REQUIREMENT 15 mil LE AT MINUS 196 Deg.C

• LOW CORBON(<0.04),NITROGEN(<0.05),

• FERRITE(2%)

• BASIC SLAG

SMAW “15 “ COATING TYPE

FCAW LIME/FLUORIDE COATING

E308L 15/16 FOR CRYOGENIC APPLICATION(CONTD) PROBLEM• SELECTION OF PROPER CONSUMABLE FOR CRYOGENIC

APPLICATION ANALYSIS• THE CONVENTIONAL E308L-16 ELECTRODES GAVE ERRATIC

RESULTS.• EVENTHOUGH THE E308L-15 ELECTRODES FOUND TO GIVE GOOD

RESULTS, RADIOGRAPHIC RESULTS WERE NOT CONSISTANT• IT WAS POSSIBLE TO OBTAIN GOOD PERFORMANCE AS WELL AS

CONSISTANT RESULT BY MODIFYING THE PRODUCT E308L-16 WITH CONTROLLED FERRITE(<2%)

RESULTS OF E308L-16 BATCH TEST

BATCH CVN AT -196 C LE mil UTS

mpa

%E FN %

A 32.3 17 536 45.4 2

B 40 19.2 543 49 1.5

C 35.3 19 564 47 1

THE RESULTS WITH MODIFIED PRODUCT FOUND SATISFACTORY

CORROSION APPLICATION

• TYPICAL REQUIREMENTS 24 mpy PRAC.B/15MPY ASTM A 262 PRAC. C

• BASIC SLAG,LOW FERRITE(NIL)

• HIGH NICKEL&/OR HIGH MANGANESE

E316LF WITH NIL FERRITE PROBLEM THE E316LF ELETRODES QUALIFIED FOR JOB GAVE MICRO

FISSURING IN ACTUAL FABRICATION PARTICULARLY ON RESTRAIANT JOINTS.

ANALYSIS: THE QUALIFIED CONSUMABLE ,EVENTHOUGH GAVE

SATISFACTORY RESULTS IN L-SEAMS,FOUND TO GIVE MICRO FISSURING IN C-SEAM& NOZZLE JOINTS.

THE CRATER GRINDING THOUGH CONTROLLED THE PROBLEM, IT WAS NOT DESIRED SOLUTION

SOLUTION: BASED ON OBSERVATION & STUDIES ,IT WAS DECIDED

DEVELOP THE E316LF CONSUMABLE CAPABLE ON WITHSTADING HEAVY RESTRAINANT. TO EVALUATE THE CONSUMABLE ,THE THOMAS-SCHFFLER TEST WAS TAKEN AS BASIS

E316LF WITH NIL FERRITE TEST RESULTS OF CORROSION ON MOD.E316LF

BATCH

NO.TEST

DURATIONCORR.RATE

mpyREMARKS NO OF

CRACKS

FERRITE NO.

A 48X5 14 FAIL 5 NIL

B 48X5 10.5 REVIEW 1 NIL

C 48X5 5.5 ACCPT. - NIL

THOMAS SCHFLLER TEST ASSEMBLY

WELDING OF DISSIMILAR STEELS

WELDING OF DISSIMILAR METALS

PROBLEM: FOR WELDING OF CS &LAS TO SS THE COMMON

CONSUMABLES SELECTED LIKE E309/309L/309Mo GAVE PROBLEMS WITH REGARD TO DUCTILITY

ANALYSIS THE COMMONLY AVILABLE CONSUMABLES IN ABOVE

GRADES COMMONLY HAD FERRITE 8-16% THESE CONSUMABLES EVEN THOUGH SUITABLE FOR THIN

SECTIONS,GAVE VERY LOW %E WHEN USED ON THICKER JOINTS/SR APPLICATION

THE REASON FOR ABOVE WAS DUE TO FORMATION OF INTERMEDIATE BAINITE(SIGMA) PHASE

SOLUTION USE MODIFIED CONSUMABLES WITH CONTROLLED FERRITE

OF 6-9% & QUALIFY THE SAME WITH SR AT 680deg C FOR 1HOUR

WHEN WELDING JOINTS THICKER THAN 20mm ,BUTTER THE CS/LAS WITH E309&WELD WITH SUITABLE SSCONSUMABLES.

EFFECT OF POST WELD HEAT TREATMENT ON E309 TYPE CONSUMABLES

POST WELD HT FOR 10 HOURS

POST WELD HT TEMP

C 6

00

°C

D 7

00

°C

A 5

50

°C

B 5

00

°C

% A

GE

E

LO

NG

. W

ITH

R

EF

T

O O

RIG

INA

L%

E 4

8

16

Sl.

No

Type Te

chn

I

c

a

l

Cond

i

t

I

on

Mech. Prop (ASME Specified

Mech. Prop (Actual)

As Welded PWHT As Welded PWHT

UTS N/mm2

%E

UTS N/mm2

%E

UTS N/mm2

% E

Ferrite UTS N/mm2

%E

Ferrite

1 E309/E309MO 550 30 - - 550-650 30 16 650- 750 10 4

2 E310 550 30 - - 550-650 30 - 550- 650 30 -

3 ENiCrFe3 550 30 - - 550-650 30 - 550- 6O0 30 -

4 E309/E309MO(Modified)

550 30 - - 550-650 30 8 580- 680 25 6

TYPICAL MECHANICAL PROPERTIES OF WELDING CONSUABLES STEEL WELDING USED FOR DISSIMILAR

Undiluted E309 deposit

CS TO SS WELDING WITHE309 TYPECONSUMABLES

CS TO SS WIELDINGWITH CS SIDE BUTTERING

E309 BUTTERINGSS18/8 TYPEWELD METAL

4020 10

PROBLEMS RELATED

TO CLAD STEEL WELDING

Barrier layer locationMISMATCH OF 1.2MM-CONVENTIONAL EDGE PREPARATION

1-2MM

Contamination of high alloy steel With CS/LAS

5mm

STRIP BACK & HIGH ALLOY WELD

NOZZLE TO SHELL WELD

FIRST SIDE

BASE METAL WELDINGBG &SECOND SIDE BASE MEATL WELDING

BARRIER LAYER

FIRST LAYER

SEQUENCE OF WELDING

COMMON TYPES OF EDGE PREPARATIONS

3mm5mm

3mm

LEVEL OF BARRIER LAYER 5mm DEPTH

CS/LAS WELDING TO BE RESTRITED 1MM BELOW ORIGINAL BARRIER LAYER

REPAIR WELDING

REPAIR FROM CS/LAS SIDE T-Thickness

a-Clad thickness

b-High alloy steel dep. Depth

c-Balance CS/LAS weld metal

d-Gouging depth

BALANCE CS/LAS}WELD METAL }

t- (d+b)

THANK YOU