welding consumables

WELDING CONSUMABLES

CLASSIFICATION,

STORAGE AND HANDLINGR.D.PENNATHURMAILAM INDIA LIMITED

CHOICE OF WELDING CONSUMABLESIS 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 PROCESSGTAW

SMAW

GMAW

FCAW

SAW

GTAW CONSUMABLESGas 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 SMAWShielded 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.

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DescriptionRetrieved from [1] on en:March 20, en:2005 by Spangineer. Photo taken by Justin McGarry of Hull Technician Chris B. MillonesSourceOriginally from en.wikipedia; description page is/was here.Date2005-03-21 (original upload date)AuthorOriginal uploader was Spangineer at en.wikipediaPermission (Reusing this image)PD-USGOV-MILITARY-NAVY.

This image is a work of a sailor or employee of the U.S. Navy, taken or made during the course of the person's official duties. As a work of the U.S. federal government, the image is in the public domain.

Date/Timecurrent20:55, 14 June 2007

SCHMATIC REPRESENTATION OF SMAW

FLUX INGRADIENTSFLUXING AGENTS

SLAG FORMERS

ARC STABILISERS

GAS FORMERS

SLIPPING AGENTS

BINDING AGENTS

DEOXIDISERS AND ALLOYING ELEMNTS

ADVANTAGES OF FLUX COATINGTO 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 CONSUMABLESGas 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 CONSUMABLESFlux-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 1950s 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 CONSUMABLESSubmerged 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 5.1Carbon Steel Electrodes for Shielded Metal Arc Welding SFA 5.4Stainless Steel Electrodes for Shielded Metal Arc Welding SFA 5.5Low-Alloy Steel Electrodes for Shielded Metal Arc Welding SFA 5.9Bare Stainless Steel Welding Electrodes and Rods SFA 5.17Carbon Steel Electrodes and Fluxes for Submerged Arc Welding SFA 5.18Carbon Steel Electrodes and Rods for Gas Shielding Arc Welding SFA 5.20Carbon Steel Electrodes for Flux Cored Arc Welding SFA 5.22Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux Cored Rods for Gas Tungsten Arc Welding SFA 5.23Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding SFA 5.29Low Alloy Electrodes for Flux Cored Arc Welding SFA 5.01Filler Metal Procurement Guidelines

TESTING OF ELECTRODES

PHYSICAL TEST

CHEMICAL TEST

MECHNICAL TESTS

PHYSICAL TESTUNIFORMITY OF COATINGPROPER BRUSHING OF HOLDING & STRIKING ENDSCONCENTRIC COATINGSTRIKING END FREE OF FLUX & RUSTELECTRODES NOT DEFORMEDNO DAMAGE TO COATING IN TRANSIT

FOR COTINUOUS WIRE CHECK SPOOL DAMAGEUNIFORMITY OF WIRE-LAYER WINDINGCAST & HELIX

PERFORMANCE CHARACTERSUNIFORM COVERINGCONCENTRICITYGRIP END/ARC END TRIMMING CUP FORMATION ARC INTENSITY/STABILITYSMOOTH ARCFLUIDITY/VISCOSITYSLAG/OXIDE INCLUSIONSMOISTURE ABSORPTIONLOW SPATTERCOVERING THICKNESSCRATER CRACKING IDENTIFICATIONSLAG DETATCHABILITY

FACTORS TO BE EVALUATEDCHEMICAL COMPOSITION

MECHANICAL PROPERTIES

NOTCH TOUGHNESS

ELCTRICAL CHARECTERISTICS

TYPE OF COVERING

OPTIONAL PARAMETERS NOTCH TOUGHNESS REQUIREMENTS

MOISTURE CONTENT

DIFFUSIBLE HYDROGEN

SUPPLEMENTARY PARAMETERSHARDNESS

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 CHEMISTRYTENSILE/YIELD AFTER PWHT HARDNESS REQUIREMENT DIFFUSIBLE HYDROGEN CONTENTCVN 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

EDESIGNATES AN ELECTRODEX XTENSILE STRENGH IN KSIY YWELDING POSITION& TYPE OF COVERING1IMPROVED TOUGHNESSHZDIFFUSIBLE HYDROZEN 4/8/16RMOISTURE RESISTANCE

*MMILITARY SPEC. AS AGREED TO

MOISURE RESISTANT ELECTRODESTHE ELECTRODES THAT CAN RESIST PICK OF MOISURE ARE CLASSIFIED WITH SUFFIX RTHE 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 WEIGHTDESIGNATIONAS RECD.AFTER EXPOSUREE7016RE7016-1RE7018R 0.300.40E7018-1RE7028-RE7048-RE7018-M 0.100.40

E.G. E 70 1 8 AWS CLASSIFICATION FOR CARBON STEEL ELECTRODE

E-Manual Metal Arc Welding Electrode70- Minimum UTS of 70 Ksi(70000psi)1- Usability of electrode in all positions8- Basic type of covering with Iron powder

TYPES OF COVERING0-HIGH CELLULOSE SODIUM1-HIGH CELLULOSE POTASSIUM 2-HIGH TITANIA SODIUM3-HIGH TITANIA POTASSIUM4-IRON POWDER,TITANIA5-LOW HYDROGEN SODIUM6-LOW HYDROGEN POTASSIUM7-HIGH IRON OXIDE,IRON POWDER8-LOW HYDROGEN POTASSIUM, IRON POWDER9-IRON OXIDE TITANIA POTASSIUM

RUTILE Vs BASICGOOD PERFORMANCEOPERATES ON AC/DCGOOD OPERATOR APPEALIMPACT AT SUBZERO LOWREBAKING NOT REQD.H2 LEVEL HIGHPOSITIONAL WELDING EASYSATISFACTORY PERFORMANCENOT WELL ON ACSATISFACTORYGOOD IMPACT PROPERTIESCAN NOT BE USED WITHOUT REBAKINGH2 CAN BE CONTROLLEDPOSSIBLE.HIGHER SKILL LEVEL REQUIRED

AWS SFA 5.5 2007 CLASSIFICATION FOR ALLOY STEEL ELECTRODE E XX XX X* HZ REDESIGNATES AN ELECTRODEX XTENSILE STRENGH IN KSIXWELDING POSITIONXX TYPE OF COVERINGXCHEMICAL COMP. OF WELD METALHZDIFFUSIBLE HYDROZENRMOISTURE RESISTANCE

*MMILITARY SPEC. AS AGREED TO

SUFFIX ALPHABETS INDICATIONS

AC-Mo STEELS

BCr-Mo STEELS

NiNi STEELS DMn-Mo STEELS

KMn-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 STEELE.G. E 80 1 8 B2





6-BASIC TYPE OF COVERING

G-CHEMICAL COMPOSITION -Ni,Cr &MoE.G. E 8016 G






D3-CHEMICAL COMPOSITION OF MOLY STEELE.G. E 80 1 8 D3






C2-CHEMICAL COMPOSITION OF 2%NICKEL STEELE.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

EDESIGNATES AN ELECTRODEX XXALLOY COMPOSITIONXXALLOY ADDITIONXL-LOW CORBON H-HIGH CORBONXX15-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 varietyE.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 varietyE.G. E 309MOL-16

AWS SFA 5.9 2007 CLASSIFICATION FOR BARE STAINLESS STEEL RODS ER XXX XX X

ERDESIGNATES AN BARE ROD

X XXALLOY COMPOSITION

XXALLOY ADDITION

XL-LOW CORBON H-HIGH CORBON

AWS CLASSIFICATION OF STAINLESS STEEL FILLER RODER-ELECTRODE ROD

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

L-LOW CARBON VARIETYE.g. ER 308 L

AWS CLASSIFICATION OF STAINLESS STEEL FILLER RODER-ELECTRODE ROD

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

L-LOW CARBON VARIETYE.g. ER 309 L Mo

AWSSFA 5.11-2007 CLASSIFICATION OF NON FERROUS ELECTRODEE-MANUAL METAL ARC WELDING ELECTRODE

XXXX- ALLOY SPECIFICATIONE.G. E XXXX


NICU7-CHEMICAL COMPOSITION OF MONEL(70%NICKEL&BALANCE COPPER)E.G. E Ni Cu 7


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

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

NICHEMICAL COMPOSITION OF NICKEL BASED

CICAST IRON

E.G. E Ni - CI

AWS SFA 5.15-2007 CLASSIFICATION OF ELECTRODES &RODS FOR CAST IRONEMANUAL METAL ARC WELDING ELECTRODE

NI Fe CHEMICAL COMPOSITION OF FERRO NICKEL BASED

CICAST 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

TTUBULAR/FCAW

3SELF SHIELDING

CICAST IRON

E.G. E Ni Fe T3- CI

AWS SPECIFICATION FOR BARE RODS A5.7-COPPER AND ALLOYS A5.9-CHROMIUM AND CHROMIUM NICKEL STEELSA5.10-ALUMINIUM AND ALLOYSA5.13-SURFACINGA5.14-NICKEL AND ALLOYSA5.15-CAST IRONSA5.16-TITANIUM AND ALLOYSA5.17-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

ERINDICATES BARE WIREXXTESILE STRENGH IN KSISSOLID WIRE*CCOMPOSITE WIREXCHEMICAL COMP.(GS SINGLE)Y TYPE OF GAS C-CO2/M-MIXEDNSPECIAL APPLICATIONHZHYDROGEN LEVEL AT 4/8/16

AWS CLASSIFICATION OF CARBON STEEL FILLER RODER-Electrode Rod70-minimum UTS of 70 KsiS-solid Rod2-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

ERINDICATES BARE WIRE

XXTESILE STRENGH IN KSI

SSOLID WIRE

*CCOMPOSITE WIRE

XCHEMICAL COMP.(G FOR MULTI PASS &GS SINGLE)

HZHYDROGEN LEVEL AT 4/8/16

AWS Classification of Low Alloy Steel Filler RodER-ELECTRODE ROD

90-MINIMUM UTS OF 90KSI

S-SOLID ROD

B3-CHEMICAL COMPOSITION OF 2.25 CHROME-1 MOLY STEEL

L-LOW CARBON VARIETYE.g. ER 90 S B3 L

AWS SFA 5.14-2007 CLASSIFICATION OF NON FERROUS ELECTRODEER- ELECTRODE BARE ROD

XXXX-ALLOY SPECIFICATIONE.G. ER XXXX

AWS SFA 5.14-2007 CLASSIFICATION OF NON FERROUS FILLER RODSER- 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-JXHXE-ELECTRODEX-TENSILE IN KSIX-POSITION DESIGNATORT-FCAW/TUBULARX-USABILITY DESIGNATORX-SHIELDING GAS C-CO2/M-MIXEDJ-20 ftlb AT -40 CX-D/Q INDICATES SPECIAL MECH.PROPERTIESHX-HYDROGEN DESIGNATOR

CARBON STEEL ELECTRODES FOR FLUX CORED ARC WELDING AWS A5.20-2007 E71 T 1CE-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 3CE-ELECTRODE


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 8E-ELECTRODE


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-JHXE-ELECTRODEX-TENSILE IN KSIX-POSITION DESIGNATORT-FCAW/TUBULARX-USABILITY DESIGNATORX-CHEMICAL COMPOSITIONX-SHIELDING GAS C-CO2/M-MIXEDJ-IMPROVED TOUGHNESS -27JAT 10 CHX-HYDROGEN DESIGNATOR

LOW ALLOY STEEL ELECTRODES FOR FLUX CORED ARC WELDING AWS A5.29-2007 E 8 X T1 Ni1C/ME-ELECTRODE8-TENSILE IN KSI(80)X-POSITION DESIGNATORT-FCAW/TUBULAR1-RUTILE TYPENi1-CHEMICAL COMPOSITION-1%NiC-CO2 SHIELDING GASM-MIXED GAS

LOW ALLOY STEEL ELECTRODES FOR FLUX CORED ARC WELDING AWS A5.29-2007 E 8X T5 B2CJH4E-ELECTRODE8-TENSILE IN KSI(80)X-POSITION DESIGNATORT-FCAW/TUBULAR5-BASIC TYPEB2-CHEMICAL COMPOSITION- 2 Cr-1 MoC-CO2 SHIELDING GAS J-IMPROVED TOUGHNESS - 27J AT 10 CHX-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

SAWF-SAW FLUX S- INDICATES FLUX BEING CRUSHED SLAG/SLAG +VIRGIN FLUX7-MINIMUM UTS OF 70 KSI(70000psi)P- HEAT TREATMENT P-PWHT/A-AS WELDED4-MINIMUM CVN IMPACT ENERGY OF 20 Ft Lb AT MINUS 40FEXXX-ELECTRODE WIREHX- HYDROGEN DESIGNATORE.g. F S7 P 4 EXXX HX

SAWF-SAW FLUX

7-MINIMUM UTS OF 70 KSI(70000psi)

A- AS WELDED

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

EM12K-ELECTRODE SPECIFICATION

HX- NOT SPECIFIED

S-ABSENCE INDICATES VIRGIN FLUXE.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 ARGON1.4 TIMES HEAVIER THAN AIRQUANTUM OF SHIEDING GAS REQD. IS LOWDUE TO LOWER THERMAL CONDUCTIVITY FINGER TYPE PENETRATIONPRODUCES SPRAY TRANFER

USED COMMENLY FOR WIDE RANGE OF MATERIAL MOSTLY AS MIXED GAS WITH CO2 HELIUM0.14TIMES HEAVIER THAN AIRQUAMTUM OF SHIELDING GAS REQD. IS VERY HIGHDUE TO HIGHER THERMAL CONDUCTIVITY DEEP BROAD PARABOLIC TYPE PENETRATIONCAN PRODUCE SPRAY TRANFER ONLY WHEN MIXED WITH ARGONUSED FOR HIGH CONDUCTIVITY MATERIAL LIKE Cu ,Al etc

ACTIVE GAS-CO2

USED FOR CORBON & LASUSED ALSO FOR SS IN FCAWHIGHER SPED,ADEQUATE PENETRATION AT LOWER COST ARE ITS SALIENT FEATURES.FOR SOLID WIRE TRANFER MODE IS EITHER SHORT CIRCUITING OR GLOBULARTRANFER TYPE LEADS TO HIGHER SPATTER & ROUGH BEAD PROFILEFOR FCAW SPRAY TRANFER IS ACHIVED HENCE MOST COMMENLY USED GAS

GAS MIXTURESAr+CO2

Ar+O2

Ar+O2+CO2

Ar+He

AR+He+O2

Ar+He+O2+CO2

SHIELDING GASESArc CharacteristicsPenetration ProfileMode Of TransferSpatter LevelAlloy RecoveryMaterial Types

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

95Ar/5CO2

75Ar/25CO2

50Ar/50CO2

100CO2

TYPICAL

CHEMICAL

ANALYSIS

C

Mn

Si

.059

1.29.

.44

.055

1.29

.44

.042

1.24

.39

.041

1.16

.31

TYPICAL

MECH.

PROP(Mpa)

YS

UTS

540

603

531

586

502

568

457

565

TYPICAL

IMPACT

PROP(J)

0 Deg C

-40Deg C

123

91

125

84

109

48

104

40

BEAD

SHAPE

FLAT

FLAT

CONVEX

CONVEX

IMPORTANTMaking a Gas DecisionDeciding on a particular shielding gas should be based on the specific manufacturers recommendation. Failure to do so may result in weld metal defects or in an deterioration in Mechanical properties.The manufactures 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 SMAWLow 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 MinCoils Store 100-125 Deg C Recondition at 150 Deg C- 6-8HrsWire 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 80F(26.7C) 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:Switching to 100% CO2 shielding gas Lowering the welding current Cleaning the weld joint of paint, rust, and moisture Minimize any wind disturbance Cleaning spatter from inside gas nozzle 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

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 120-150C.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: 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 180-220F first before following the above redrying procedure. Standard EXX18 electrodes should be supplied to welders twice per shift. 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.

E7018:1 hour at 650-750FE8018, E9018, E10018, E11018:1 hour at 700-800F

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: Use a low hydrogen consumable, like a -H4 or -H2. Preheat. This slows the cooling rate. Note that excessive preheat may anneal the base material. Slow cool. More time at elevated temperatures allows the dissolved hydrogen to escape. Peen the weld beads to minimize residual weld stresses. Use the lowest strength filler metal meeting design requirements. If making fillet welds, the weld can be oversized to give the specified strength 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 ENDPETAL TYPEHOT PRESSED/COLD SPINNINGTHE WPS/PQR ESTABLISHED USING E7018 ELETRODES FOR SA515Gr70 MATERIAL GAVE SATIASFACTORY RESULTS FOR PETAL D.ETHE SAME WPS FOUND TO VARIATION IN RESULT WHEN USED FOR COLD SPUN /HOT PRESSED D.E. WITH WELD JOINT.ANALYSISTHE HOT PRESSED ./COLD SPUN D.E.UNDERGOES NORMALISING OPERATION WHICH IS NOT ACCOUNTED IN WPSWHEN 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.NoCONSUMALE TYPEAS WELDEDSRNORMALISED1E70185305254802E7018A1540535530

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 MONTHSANALYSIS: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 ASSEMBLY20mm

CROYOGENIC APPLICATION TYPICAL REQUIREMENT 15 mil LE AT MINUS 196 Deg.C

LOW CORBON(

E308L 15/16 FOR CRYOGENIC APPLICATION(CONTD) PROBLEM SELECTION OF PROPER CONSUMABLE FOR CRYOGENIC APPLICATION ANALYSISTHE CONVENTIONAL E308L-16 ELECTRODES GAVE ERRATIC RESULTS.EVENTHOUGH THE E308L-15 ELECTRODES FOUND TO GIVE GOOD RESULTS, RADIOGRAPHIC RESULTS WERE NOT CONSISTANTIT WAS POSSIBLE TO OBTAIN GOOD PERFORMANCE AS WELL AS CONSISTANT RESULT BY MODIFYING THE PRODUCT E308L-16 WITH CONTROLLED FERRITE(

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 FERRITEPROBLEMTHE 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 SOLUTIONSOLUTION: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 FERRITETEST RESULTS OF CORROSION ON MOD.E316LFTHOMAS 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 ANALYSISTHE 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 APPLICATIONTHE 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 1HOURWHEN WELDING JOINTS THICKER THAN 20mm ,BUTTER THE CS/LAS WITH E309&WELD WITH SUITABLE SSCONSUMABLES.

EFFECT OF POST WELD HEAT TREATMENT ON E309 TYPE CONSUMABLESPOST WELD HT FOR 10 HOURSPOST WELD HT TEMPC 600 CD 700 C

A 550 CB 500 C % AGE ELONG. WITH REF TO ORIGINAL%E4816

TYPICAL MECHANICAL PROPERTIES OF WELDING CONSUABLES STEEL WELDING USED FOR DISSIMILAR Undiluted E309 depositCS TO SS WELDING WITHE309 TYPECONSUMABLESCS TO SS WIELDINGWITH CS SIDE BUTTERINGE309 BUTTERINGSS18/8 TYPEWELD METAL402010

Sl.NoTypeTechnIcalConditIonMech. Prop (ASME SpecifiedMech. Prop (Actual)

As Welded PWHTAs Welded PWHT

UTS N/mm2%EUTS N/mm2%EUTS N/mm2% EFerrite UTS N/mm2%EFerrite1E309/E309MO55030--550-6503016650- 7501042E31055030--550-65030-550- 65030-3ENiCrFe355030--550-65030-550- 6O030-4E309/E309MO(Modified)55030--550-650308580- 680256

PROBLEMS RELATED

TO CLAD STEEL WELDING

Barrier layer locationMISMATCH OF 1.2MM-CONVENTIONAL EDGE PREPARATION1-2MMContamination of high alloy steel With CS/LAS5mmSTRIP BACK & HIGH ALLOY WELDNOZZLE TO SHELL WELDFIRST SIDE BASE METAL WELDINGBG &SECOND SIDE BASE MEATL WELDINGBARRIER LAYERFIRST LAYERSEQUENCE OF WELDING

COMMON TYPES OF EDGE PREPARATIONS3mm5mm3mmLEVEL OF BARRIER LAYER 5mm DEPTHCS/LAS WELDING TO BE RESTRITED 1MM BELOW ORIGINAL BARRIER LAYERREPAIR WELDINGREPAIR FROM CS/LAS SIDET-Thickness

a-Clad thickness

b-High alloy steel dep. Depth

c-Balance CS/LAS weld metal

d-Gouging depthBALANCE CS/LAS}WELD METAL }t- (d+b)

THANK YOU

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