1

SAW.02.1.NF

Submerged Arc Welding

Fluxes, wires

and

wire/flux combinations

Content

Submerged arc welding fluxes

Classifications

Submerged arc welding wires

Wire Flux Combinations

SAW.02.2.NF SAW.02.3.NF

Not used flux Slag

Weld

Weld cross section

Solidified weld metal

Electrode (wire)

Welding flux

Backing strip (steel or ceramic)

Liquid slag

Liquid steel

Principle Submerged Arc Welding

Workpiece

SAW.02.4.NF

Function of welding flux

Protects the weld pool against oxidizing

influence (effects) of air

Control weld bead shape

Provides wetting action

Cleaning of weld pool

Stabilize the arc

Ionizes the arc

Control the composition and metallurgy of

the weld deposit

Prevent a too fast weld pool cooling SAW.02.5.NF

Sub Arc Welding Fluxes

Compare it with electrode coating

Comparison:

function flux = function electrode coating

Differences:

SAW flux : as bulk

Electrode coating : baked to solid core wire SAW.02.6.NF

Based on manufacturing method of

welding fluxes, we distinguish:

Fused fluxes

Agglomerated fluxes

Through the production method, both

weldability and mechanical properties

of the welding fluxes are strongly

influencend

Sub Arc Welding Fluxes

SAW.02.7.NF

Designation according to their chemical structure

Agglomerated fluxes

Manganese

Silicate

type

Calcium

Silicate

type

Fluorite

Basic

type

Aluminate

types

Aluminate-

Rutile

type

Aluminate-

Basic

type

SAW.02.8.NF

Main components in welding flux

Designation

Manganese-silicate

Calcium-silicate

Aluminate-rutile

Aluminate-basic

Fluorite-basic

Main components

MnO + SiO2

CaO + MgO + SiO2

Al2O3 + TiO2

Al2O3 + CaO + MgO

Al2O3

CaO + MgO + MnO + CaF2

SiO2

CaF2

> 50%

> 60%

> 45%

> 45%

20%

> 50%

20%

15%

SAW.02.9.NF

Typical chemical composition of some

Lincoln Europe Sub Arc fluxes

780 960 P230 P240

SiO2 17 20 20 13

Al2O3 39 * 30 * 23 * 18

CaO 6 2 * 20 * 29 *

MgO 1 20 * 22 * 33 *

MnO 13 10 5 -

F (CaF2) 3 10 3 11 *

Fe2O3 7 1 -

TiO2 11 * 2 2 -

2

SAW.02.10.NF

Basicity according Boniszewski

CaO + MgO + BaO + CaF2 + K2O + Na2O +

SiO2 +

MnO + FeO

2

Al2O3 + TiO2 + ZrO2

2

Basic oxides

Acid oxides =

A common formula for calculating the

basicity of a welding flux is:

SAW.02.11.NF

According Boniszewski’s formula, Lincoln’s

fluxes have the following basicity

Flux Basicity Description

P240 3.0

Highly basic 8500 2.8

888 2.6

P230 1.6

Basic P2000/2007/2000S 1.6

7000 1.5

860 1.1 Neutral

960 1.0

761 0.8

Medium acid 780/781 0.7

980 0.6

782 0.4 High acid SAW.02.12.NF

Welding flux if excellent slag release is

required (e.g. fillet welding or narrow joints)

Welding flux for welding base materials

which require good mechanical

properties (e.g. high impact values)

Flux can be alloyed

Agglomerated flux

SAW.02.13.NF

Characteristics of Silicate fluxes

MS type

often give a high Mn content in the weld metal

high level of oxigen in weld metal due to oxidizing capacity

are universally used up to 520 N/mm2 tensile

less prone to rusted plate

usually in combination with S1 - S3, S1Si - S3Si and S2Mo wire

CS type

differences in Si content increase in weld metal

have high current carrying capacity

not to be used for multi-pass technique

less suitable for rusty plate

at high

silicate

levels

SAW.02.14.NF

Characteristics of Aluminate fluxs

AR type

less prone to rusted plate

suitable for fillet welding

can be applied to rusty plate in combina-tion with

a low Mn containing wire

AB type

good mechanical properties

suitable for multi-pass technique

low oxygen content in deposit weld metal

(~ 400 ppm)

SAW.02.15.NF

Characteristics of Fluorite fluxes

FB type

excellent mechanical properties

lowest oxygen content in weld metal and

therefore (include) excellent mechanical

properties

Mn burn-off, because no MnO can be reduced

suitable for multi-pass technique

SAW.02.16.NF

Characteristical properties of the

different welding fluxes Property MS CS AR AB FB

Current capacity +++ +++ ++ ++ +

Weldability on AC +(+) ++ +++ ++ (++)

Sensitivity to porosity +++ ++ ++ ++ ++

Suitable for fillet welding + ++ +++ ++ +

Bridging capacity + ++ +++ ++ ++

Welding speed ++ ++ +++ ++ +

Slag detachability + +++ +++ ++ ++

Weld bead profile +++ +++ +++ ++ +

Crack resistance + + + ++ +++

Mechanical properties + + + ++ +++

+ = normal ++ = good +++ = excellent SAW.02.17.NF

Choice of Agglo welding fluxes

Can also divided into:

Acid vs Basic

Active vs Neutral

SAW.02.18.NF

Acid fluxes

Advantages excellent weldability and weld bead profile on AC / DC

higher crack resistance

good porosity resistance caused by rust / “ Arc-blow”

good slag detachability at fillet welding and in narrow grooves

ability to increase welding speed or productivity

high current carrying capacity

mostly lower mechanical properties

mostly low in price

Application: excellent for single-pass technique

In multi-pass technique up to max. 20-25 mm thickness at right wire selection (S1 - S2 - S2Mo)

3

SAW.02.19.NF

Basic fluxes

Characteristics

excellent mechanical properties (especially toughness)

usually expensive

Weldability lesser (less attractive weld bead profile?)

lesser slag detachability in narrow joints?

lower current carrying capacity and only DC weldable

sensitive to moisture absorption (hygroscopic) but an extremely low H2 level is possible

available as Si/Mn, pick-up , burn-off and neutral

Application:

excellent for multi-pass technique

where it is actually necessary because of the mechanical properties (notch toughness)

SAW.02.20.NF

Active fluxes

Characteristics

Active refers to characteristics of the flux

Active has nothing to do with basicity

contain Si and/or Mn

Desoxidizers be added to obtain an increased

resistance to porosity and cracks due to

contaminations

weld metal chemical composition changed with varying

arc voltage

needs better control welding param. compared to neutral fluxes

Application:

mainly in single-pass technique on rusty plate SAW.02.21.NF

Active fluxes

Characteristics

Active refers to characteristics of the flux

Active has nothing to do with basicity

Special active flux available : Carbon Active

Carbon burn-off across the arc is compensated

812-SRC

High basic carbon active flux

Application:

AISI 4130 / 4140 welded with LNS 164 (Mn1NiMo)

Subsea components with PWHT

SAW.02.22.NF

Neutral fluxes

Characteristics

indicate no significant difference in weld metal

composition by variation of arc voltage

little or none deoxidizing elements

desoxidizing elements should come from the wire

rusty plate can cause porosity

weld metal mechanical properties can change by

changing welding parameters such as penetration,

heat input and number of layers

Application:

excellent for multi-pass technique in heavy plate SAW.02.23.NF

Lincoln Electric; 3 types of fluxes

Active 700-series for single pass technique

If multi-pass welding, it is necessary to use L60 wire (LNS 143 (S1)) and max. 25 mm plate thick.

Neutral 800/900-series + P 230 en P 240 for multi-pass

(run) welding (technique)

Alloyed (A-xxx-10)

Cheap to produce

Alloyed solid and tubular cored wires are expensive to produce

Chemical composition depence on the welder (arc-voltage)

SAW.02.24.NF

Lincoln Electric; 3 types of fluxes

General

Use an active fluxes for fillet welding

and a neutral fluxes for full pen welding

joints (multi-layer technique)

Use a high basic neutral flux if:

high mechanical properties are required

if very thick-walled restraint constructions

should be welded

if heavy wall cast structures should be

welded

Lincoln Europe welding fluxes

761

780

781

782

SAW.02.25.NF

802

860

888

P230

P240

812-SRC

P2000

P2007

P2000S

P7000

P223

995N

998N

etc.

SAW.02.26.NF

Lincoln Electric welding fluxes

Active fluxes are:

Lincolnweld 761

Lincolnweld 780

Lincolnweld 781

Lincolnweld 782

EN 760:

S A CS/MS 1 88 AC H5

S A AR/AB 1 78 AC H5

S A ZS 1 87 AC H5

S A AR/AB 1 76 AC H5

SAW.02.27.NF

Lincoln Electric welding fluxes

Neutral fluxes are:

Lincolnweld 802

Lincolnweld 860

Lincolnweld 888

Lincolnweld 812-SRC

Lincolnweld 8500

P 230

P 240

P 2000 (P2007)

P 2000S

S A CS 1 55 DC H5

S A AB 1 56 AC H5

S A FB 1 66 AC H5

S A FB 1 XX AC H5

S A FB 1 54 AC H5

S A AB 1 67 AC H5

S A FB 1 55 AC H5

S A AF 2 64 DC(AC) H5

S A AF 2 64 Cr DC H5

4

SAW.02.28.NF

Lincoln Electric welding fluxes

Neutral, special applications:

Lincolnweld 960

Lincolnweld 980

Hardfacing:

A-XXX-10 (alloyed)

Lincolnweld 802

Pipe Mill:

Lincolnweld 760 pipe, 995N, 998N, P223

S A AB 1 66 AC H5

S A AR/AB 1 57 AC H5

S A CS 1 55 DC H5

SAW.02.29.NF

Flux belongs to the wire

Follow strictly the flux manufacturer instructions for

which wires can be used for a certain flux and which

properties can be expected

The reverse is also true; the wire must

match not only the particular characteristics of

the flux in question, but also the steel that have

to be welded

This process of matching is done by means of the

composition of the wire, the principal factors being

Mn and Si contents, whilst Mo, Ni and Cr contents are

sometimes also used to adjust the wire composition

Sub Arc Wires

Wire EN 756 AWS A5.17 C Mn Si

L60 (LNS 143) S1 EL 12 0.1 0.5 0.06

LNS 135 S2 EM 12 0.1 1 0.1

L61 (LNS 129) S2Si EM12K 0.1 1 0.25

LNS 133U (L50M) S3Si EH 12K 0.1 1.7 0.20

LNS 136 S4 EH 14 0.1 2 0.10

Sub arc wires, un-alloyed

Wire EN 756 A5.23 C Mn Si Cr Ni Mo Others

L70 S2Mo EA1 0.1 0.8 0.15 0.5

LNS 140A S2Mo EA2 0.1 1 0.15 0.5

LNS 141 S3Mo EA4 0.1 1.5 0.20 0.5

LNS 140 S4Mo EA3 0.1 1.9 0.10 0.5

LNS 140TB - EG 0.06 1 0.2 0.5

LNS 150 (LA92) S CrMo1 EB2 0.12 0.9 0.15 1.2 0.5

LNS 151 (LA93) S CrMo2 EB3 0.1 0.6 0.15 2.6 1.0

LNS 502 S CrMo5 EB6 0.08 0.5 0.35 5.7 0.6

LNS 9Cr(P91) S CrMo91 EB9 0.1 0.7 0.2 9 0.9 1 V, Nb, N

LNS 160 S2Ni1 ENi1 0.1 1 0.1 1.2

LNS 162 S2Ni2 ENi2 0.1 1 0.15 2.2

LNS 175 S2Ni3 ENi3 0.05 1 0.15 3.5

LNS 163 S0 EG 0.1 1 0.25 0.9 0.6Cu

LNS 164 (LA84) S3Ni1Mo EF3 0.1 1.6 0.1 0.9 0.5

LNS 165 (LA85) SZ EG 0.1 1.4 0.20 1.0 0.2

LNS 167 S2Ni1Mo EF1* 0.3 1 0.20 0.9 0.5

LNS 168 S3Ni2.5CrMo - 0.1 1.5 0.04 0.3 2.4 0.4

Sub arc wires, low-alloyed

High-alloyed EN 12072 AWS A5.9 C Mn Si Cr Ni Mo Others

LNS 304L S 19 9 L ER308L 0.01 1.8 0.4 20 10 0.1

LNS 307 S 18 8 Mn ER307 0.07 7 0.6 19 9

LNS 309L S 23 12 L ER309L 0.01 1.8 0.4 24 12 0.1

LNS 316L S 19 12 3 L ER316L 0.01 1.8 0.4 19 12 2.8

LNS 318 S 19 12 3 Nb ER318 0.04 1.8 0.4 19 12 2.8 0.6Nb

LNS 347 S 19 9 Nb ER347 0.04 1.6 0.4 19 10 0.1 0.6Nb

LNS 4455 S 20 16 3 Mn L - 0.01 7.5 0.4 20 16 2.8 0.15N

LNS 4462 S 22 9 3 N L ER2209 0.01 1.6 0.5 23 9 3 0.16N

LNS 4500 S 20 25 5 Cu L ER385 0.01 1.8 0.3 20 25 5 1.5Cu

Zeron100X S 25 9 4 N L ER2553 0.01 0.7 0.3 25 9 4 W,Cu,N

LNS Ni-base ISO 18274 AWS A5.14

NiCro 60/20 S Ni 6625 ERNiCrMo-3 0.03 0.2 0.1 22 65 9 Nb, Fe

NiCro 70/19 S Ni 6082 ERNiCr-3 0.03 3 0.1 73 21 Nb

NiCroMo 59/23 S Ni 6059 ERNiCrMo-13 0.01 0.5 0.1 59 23 16 Fe

NiCroMo 60/16 S Ni 6276 ERNiCrMo-4 0.01 0.5 0.0 16 58 16 W, Fe

Sub arc wires high-alloyed and Ni-base

Wire EN 756 AWS

A5.17 C Mn Si Cr Ni Mo

LNS T55 S0 EC1 0.07 1.9 0.7 - - -

LAC 690 S0 ECM3 0.07 1.5 0.4 0.4 2.6 0.4

Sub arc wires, Flux Cored

SAW.02.34.NF SAW.02.35.NF SAW.02.36.NF

AWS & ASME classification system

Indicates Submerged

Arc Welding

process

Mechanical properties

Condition after welding

A: as welded

P: PWHT

F 7 A 2 - EM12K

Minimum impact

temperature

Electrode classifi-

cation

5

SAW.02.37.NF

AWS A5.17

SAW.02.38.NF

AWS A5.23 (2008)

Elec t rode c la ssi f i c at ion

EC = c om p osi t e e le c t r ode

E = s ol id elec t r od e

Mee ts req . of di f fu sible h yd rogen o f de-

pos i te d w e ld met a l < 2, , 8, 16 m l /100g4

Im p act @ °F, min. 27 J ou l e (20 f t .lb f )

Minim u m ten s i le st re n g t h in p s i x 1 0,0 00 o f t h e de po sited w eld m e t a l (7-13 )

Ind i c at es s u bm erg ed a rc f lux

Cond it i on of h ea t t r ea tm en t :

A = as w elded

P = Pos t Weld He at Tr ea t m en t

F9P6-EB3R-B3R H4

Spec i f ic a t ion for l ow -a l l oy s t ee l elec t rode s

an d f lu xes for Subm erged Arc Weld ing

N F-2 010

De signa t e s the c h emic a l c om po si t ion o ft he d ep os i te d w e ld met a l

Op t ion a l for sp e c ial l im i ts on r e sidu a ls :

N : for n uc le ar a p p l ic a t io nsR: for s pe c ial r eq . ste p c ool ing ap pl i c a t ions ("X" fac t o r )

LNS 151 / P240 or flux 888

Digit0

245

81015

6

°F0

- 20- 40- 50

- 80- 100- 150

- 60

°C- 18

- 29- 40- 46- 51

- 62- 73- 101

[ksi]

F7F8

F10F11

F12F13

F9

[ksi]

5868

8898

108118

78

[MPa]

515550

690760

830900

620

[MPa]

400470

610680

750815

540

Tensile Rm Yield (Rp0.2)

SAW.02.39.NF

Welding technique

ov

erl

ap

overdiktereinforcement

overdikte

reinforcement

hoek van aanvloeien

90°

2-3 mm2-3 mm

opmenging

dilution~30%

SAW.02.40.NF

Two-run technique Possible requirements of the joint are:

ov

erl

ap

overdiktereinforcement

overdikte

reinforcement

hoek van aanvloeien

90°

SAW.02.41.NF

Two-run technique

SAW.02.42.NF

Two-run technique

End result depends on:

Choice of wire/flux combination

To be welded steel quality

Heat Input (t 8/5)

Means choice of wire/flux combination is

of most importance and must:

have good wetting properties

have no risk for porosity

must give in some application good impact

properties

SAW.02.43.NF

Laag / tegenlaag techniek Two-run technique (Square butt welding)

LNS 140A/P230

Temperature [°C]

Welding parameters:

700 A – 28 V – 80 cm/min

Imp

act

(IS

O-V

) in

Jo

ule

SAW.02.44.NF

Multi-run technique

2-3 mm2-3 mm

opmenging

dilution~30%

SAW.02.45.NF

Multi-pass technique

End result depends on:

Choice of wire/flux combination

Used bead sequence

Used Heat Input (t 8/5)

Much less on quality of welded steel

6

SAW.02.46.NF

Multi-pass technique

Neutral or nearly neutral welding

flux, which depends on choice of

wire:

- 20°C CMn

- 40°C CMn (possibly with Ni)

- 60°C CMn + Ni (1 - 2 - 3 - 3,5%)

for increased strength (high yield) with

alloying elements as, Mn - Mo - Ni

and Cr (low percentages)

SAW.02.47.NF

Multi-run technique Impact – f (consumable. and heat treatment)

-100 -80 -60 -40 -20

Test temperature [°C]

Imp

act

val

ue

(IS

O-V

) in

Jo

ule

150

100

50

CMn1% Ni

2% Ni

3% Ni

AW

PWHT

SAW.02.48.NF

Choice wire/flux combination = f (req.)

LNS 133U

P240

Wire / Flux combination

Tra

nsit

ion

te

mp

era

ture

[°C

]

-90

LNS 160

P230

LNS 162

P230

LNS 162

P240

LNS 175

P240

Required: 27 Joule

Required: 39 Joule

-30

-40

-50

-60

-70

-80

SAW.02.49.NF SAW.02.50.NF

Basic guidelines (1)

700-series

761

universal applicable, 780 is first choice

780

781

782 for high travel speed, thin plate

782FG (boiler tanks, membrane wall)

SAW.02.51.NF

Basic guidelines (2)

800-series

802 Only for hardfacing applications

860 Most used (popular) neutral flux

888 If high mechanical properties are

8500 required

P240

SAW.02.52.NF

Basic guidelines (3)

900-series

960 Weldability of 780 and mechanical

properties of 860

Multi purpose flux for fillet welding as

well as multi-pass technique

SAW.02.53.NF

Frequent used W-F Combo’s

L61-860 Economy solution

L61-P230 General construction -20°

L50M-P230 General construction -40°C

LNS 150-782FG Membrane wall – high speed

LNS 165-P240 LT -80°C / CTOD -50°C

LNS 164-812-SRC Subsea / PWHT 4130 etc

LNS T55-860 Productivity -30°C

LNS T55-P230 Productivity -40°C

LNS T55-8500 Productivity -50°C

LAC 690-888 S690 -60°C 5Y69MH5

SAW - Wires

Brand name AWS EN

EM13K

EL12 S1 420 350

EL12 S1 TR 0 0°C TR 0 - 20°C

EM12* S2 TR 0 420/0 TR 0 350/20 TR 20 380/40

EM12K S2Si 420 380 380 380 420

EM12K S2Si TR 0 0°C TR 0 - 20°C TR 0 0°C - 60°C - 40°C

EH12K S3Si 420 420 420 420 420

EH12K S3Si - 20°C - 20°C - 60°C - 50°C - 60°C

EA1 S2Mo 420 420 460 460

EA1 S2Mo TR 20 - 20°C TR 20 - 20°C - 40°C TR 40 - 40°C

EG S0 TR 40 TR 60

EM14K

ENi1K

ENi1 S2Ni1 420 - 50°C 460 - 50°C 460 - 60°C

ENi2 S2Ni2 460 - 60°C 460 - 60°C

EF2

EF1* S3Ni1Mo 500 - 40°C

ENi5

ENi5 S0 500 - 60°C 500 - 60°C

EA3K (S3MoSi)

EF1* S2Ni1Mo 500 - 40°C

S3Ni1.5Mo 550 - 30°C

EB2

EB2 CrMo1 P 11 P 11

EB3

EB3 CrMo2 P 22 P 22

EM2 (S3Ni1.7Mo) NF/21-08-2003

LNS T55 EC1 H4 S0 500 - 30°C 500 - 50°C 500 - 40°C

LNS T690-H ECM3 H4 S0 690 - 40°C

Wire / Flux combinations for un- and low alloyed steel

LNS 151

LA-100

LNS 150

LNS 168

LA-92

LA-93

LNS 167

LNS 165

LA-90

LNS 164 (80Y)

LA-85

LA-82

-

LNS 162

LNS 160

LA-75

LA-71

LA-81

LNS 140TB

L-70

LNS 140A

L-S3 (L-50M)

LNS 133U

L-61

LNS 129

LNS 143

LNS 135

L-50

L-60

P 240Classification

AR 1 78 FB 1 55

780 860 960

AB 1 56 AB 1 66

8500 P 230

FB 1 54 AB 1 55

Yield Strength

Impact @ ...°C

TR = Two Run

40 = - 40°C

Linc oln S mitweld

Sub arc wire/flux combinations