BARACUDA WELDING TRIALS

CONDUCTED 2004

AS WELDED

BY

DAVID J. KEATS

FILLET WELD EXAMINATION REPORTS

CONDUCTED

BY

BODYCOTE MATERIALS TESTING

The following document details the reports/findings of various wet fillet welds, which were made using our Barracuda Gold underwater welding electrodes. The details contained have been extracted from the Hammerhead wet-spot welding ‘Smart’ report and represents typical wet weld quality, as performed by a skilled welder, on plain carbon steel to BSEN 10 025-275JR specification.

TENSILE STRENGTH PROPERTIES

D1 – SINGLE PASS WET WELD - 3.2MM ON 8.0MM PLATE D1.1 – SINGLE PASS WET WELD - (REPEATED) D1.2 – THREE PASS WET WELD - 3.2MM ON 8.0MM PLATE D1.3 – THREE PASS WET WELD - (REPEATED) D2 – THREE PASS WET WELD - 4.0MM ON 10.0MM PLATE D2.1 – THREE PASS WET WELD - (REPEATED) D2.2 – SINGLE PASS WET WELD - 4.0MM ON 10.0MM PLATE D2.3 – SINGLE PASS WET WELD - (REPEATED)

MACRO PHOTOS & HARDNESS SURVEYS

E1 – SINGLE PASS WET WELD - 3.2MM ON 8.0MM PLATE E1.1 – THREE PASS WET WELD - 3.2MM ON 8.0MM PLATE F1 – THREE PASS WET WELD- 4.0MM ON 10.0MM PLATE F1.1 – SINGLE PASS WET WELD - 4.0MM ON 10.0MM PLATE GRAPH SHOWING WELD STRENGTH PROPERTIES FOR ALL ‘D’ WELDS

Sample D1 & D1.1 - Single pass fillet weld using 3.2mm Barracuda electrodes on 8.0mm plate in H-V position.

Photo 1-2 shows joint preparation and as welded joint.

Photo 3-4 shows weld after tensile testing. The welding parameters were set as follows. Amps: 160-165 Volts: 28-30 Polarity: DC –Ve electrode ROL: 190mm/min Arc Energy: 1.42-1.57kJ/mmS-1 These welds were subjected to tensile tests; see test report numbers S401923 & S402301 for further details. NOTE: welds made under winter weather conditions, with typical air temperatures of 0-1oC recorded.

Sample D1.2 & D1.3 - Multipass fillet weld made using 3.2mm Barracuda electrodes on 8.0mm plate in H-V position.

Photo 1-2 shows joint/preparation and as welded joint.

Photo 3-4 shows weld after tensile test. The welding parameters were set as follows: Root Pass (1st pass) Fill & Cap (2nd and 3rd pass) Amps: 160-165 150-155 Volts: 28-30 28-30 Polarity: DC –Ve electrode DC-Ve electrode ROL: 190mm/min 190-250mm/min Arc Energy: 1.41-1.57kj/ mmS-1 1.18-1.33kj/ mmS-1 These welds were subjected to tensile tests; see test report numbers S401924 & S402322 for further details. NOTE: welds made under winter weather conditions, with typical air temperatures of 0-1oC recorded.

Sample D2 & D2.1 - Multipass fillet weld made underwater using 4.0mm Barracuda electrodes on 10mm plate in H-V position.

Photo 1-2 shows joint/preparation and as welded joint.

Photo 3-4 shows weld after tensile testing. The welding parameters were set as follows: Root Pass (1st pass) Fill & Cap (2nd and 3rd pass) Amps: 190-195 180-190 Volts: 28-32 28-32 Polarity: DC –Ve electrode DC-Ve electrode ROL: 175m/min 190-250mm/min Arc Energy: 1.83kj/ mmS-1 1.48-1.59kj/ mmS-1 These welds were subjected to tensile tests; see test report numbers S402302 & S402303 for further details. NOTE: welds made under winter weather conditions, with typical air temperatures of 0-1oC recorded.

Sample D2.2 & D2.3 - Single pass fillet weld using 4.0mm Barracuda electrodes on 10mm plate in H-V position.

Photo shows joint/preparation and as welded joint.

Photo shows weld after tensile test. The welding parameters were set as follows: Amps: 190-195 Volts: 28-32 Polarity: DC –Ve electrode ROL: 180mm/min Arc Energy: 1.64 – 1.77 - kJ/mmS-1 These welds were subjected to tensile tests; see test report numbers S402304 & S402305 for further details. NOTE: welds made under winter weather conditions, with typical air temperatures of 0-1oC recorded.

Sample E1, E1.1, F1 & F1.1 - Single & multipass fillet weld made using 3.2 and 4.0mm Barracuda electrodes on 8.0 and 10.0mm plate in H-V position.

Shows general weld/joint preparation. The welding parameters were set as follows: Root Pass (1st pass) Fill & Cap (2nd and 3rd pass) 3.2mm 4.0mm Amps: 160-165 180-195 Volts: 28-30 28-32 Polarity: DC –Ve electrode DC-Ve electrode ROL: 190-210mm/min 190-230mm/min Arc Energy: 1.41 – 1.45kj/mmS-1 1.59 – 1.64kj/mm S-1 Welds were subjected to macro and hardness surveys; see report s S405256, S401927, S402314, and S402315.