metrode news summer 2010 - oxide.co.il · in european (en10216-5: x10crnicunb 18 9 3) and usa (astm...
TRANSCRIPT
Metrode
News
Summer
2010
In this issue: -
Superoot 316L
application story
Power generation
MT304H
Essen worldwide
Storage & Handling
Submerged arc flux
New packaging
USA symposium’s
New people
New RCC-M range
Exhibition News
Sports News
Local MP visits
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Metrode Superoot Flux Cored TIG –
A tall story
Burj Khalifa (Arabic: "Khalifa Tower"), formerly
known as Burj Dubai prior to its inauguration, is
a skyscraper in Dubai, United Arab Emirates, and
the tallest man-made structure ever built, at
828 m (2,717 ft) Construction began on 21
September 2004, with the exterior of the
structure completed on 1 October 2009. The
building officially opened on 4 January 2010 and
just over a week later some spectacular storms
gave the buildings lighting arrestor a pretty stern
test!
The building has a central water pipeline
(supplying drinking water for various purposes)
that runs the complete length of the tower which
ends up as the lightning arrestor. Originally, this
pipeline was fully flanged & bolted without
realizing the fact that tall structures are designed
to be flexible in order to withstand earthquakes &
tremors. Burj Khalifa has been estimated to sway
by about 1½ mtrs (the top floors) in all
directions due to the ambient atmosphere at that
height. This would eventually, without doubt, rip
off the bolts and tear the pipeline, which would
have caused major damage & property loss.
It was subsequently decided to replace the
flanging by welding & this is where Metrode
Superoot came in. We were approached among a
few other brands to offer a safe & reliable
solution. As a prerequisite governed by
SAMSUNG (the main EPC contractor), the
primary concern was to keep up to a minimal
timescale & hence, the basic idea was to avoid
carrying purging gas cylinders up in the tower.
Superoot 316L is designed specifically for
situations where it is impractical to apply back-
purge for the TIG root run, or to gain the
economic benefit of eliminating back-purge. We
supplied samples which proved to be ideal for the
task and a total of 200kgs was eventually used to
complete the project.
The wire was supplied via our distributor
Technical Parts who are based in Dubai.
Superoot 316L AWS A5.22 R316LT1-5
Specifications BS EN ISO 17633-B TS316L-RI1
Power Generation – MT304H
Metrode continues to build on this already well
established position in the power generation
market by introducing a new solid wire, Metrode
MT304H, for welding Super 304H tube. The
super 302H alloy is designed for use as a
superheater and reheater boiler tubing in the
latest generation of Ultra Super Critical (USC)
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cool fired power plant. The alloy already appears
in European (EN10216-5: X10CrNiCuNb 18 9 3)
and USA (ASTM A213: S30432) specifications but
there is not yet any specifications for the welding
wire.
The alloy has Cu, Nb and N additions to improve
creep performance at service temperatures of
approximately 600°C, although the relevant
ASME code case specifies allowable stresses up
to 815°C. The wire is currently available at 2.4
mm diameter manual TIG wire and will shortly be
available as small diameter wire for orbital tube
welding.
Essen – Germany, India & China!
Last year Metrode took part in the ‘Olympic
Games’ of the welding industry at Essen in
Germany and for the first time it was a team
event! We joined Lincoln Electric and were part
of their stand. The new ‘team’ performed well
and we both reported an excellent show with
plenty of new leads to follow up after the event.
In February this year we took part in our first
Essen India
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Raghav Srivastava represented us at the show
and reported that some useful new leads were
gained and existing customers also visited to
discuss current business.
And to complete the set we exhibited for the
11th time at Beijing Essen Welding & Cutting Fair
in May. Together with its mother show
"Schweissen & Schneiden" in Essen, Germany it
now ranks in the top two professional welding
and cutting shows around the world.
STORAGE AND HANDLING – AN UPDATE
To ensure that welding consumables are maintained
in an optimum condition it is important that they are
stored and handled correctly. This document
summarises the requirements for the different
consumables and processes.
General storage recommendations for all
consumable are >18°C and <60% relative humidity.
MMA Electrodes
All Metrode MMA electrodes are supplied in
hermetically sealed metal tins. The metal tins have
a ring pull and provide an excellent and efficient
form of packaging for MMA electrodes. Packaging
waste is minimal and the steel tin can easily be
recycled with normal steel scrap.
The tins are hermetically sealed and meet the
requirements of AWS A5.5 paragraph 22.2 for
hermetically sealed containers. If unopened, and
appropriately stored, this packaging will maintain the
electrodes in the as-packed condition for an
indefinite period of time.
Once opened the tins can be closed using the plastic
lid supplied and should be stored at >18°C and
<60% relative humidity.
Low Alloy Low Hydrogen
MMA electrodes can be used direct from the tin and
for most applications will provide satisfactory
performance. For critical applications, and for
electrodes that have been exposed, the electrodes
should be redried as follows: 250-300°C for 1-2
hours to ensure hydrogen less than 10ml/100g, and
at 300-350°C to ensure hydrogen less than
5ml/100g. A maximum of three redrying cycles
and/or ten hours total time at temperature is
recommended to avoid permanent flux damage.
Temperatures during redrying should not exceed
420°C.
Stainless Steel
Electrodes can be used directly from freshly opened
tins, without need for redrying treatment. Storage of
electrodes on the shopfloor, during usage, should be
in the tins or a suitable container, eg heated quiver
(~50°C). Electrodes are capable of being stored in
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this manner for periods substantially longer than a
typical eight hour working shift, without risk of flux
coating moisture regain to a level where there is a
risk of weld porosity.
At the end of a working shift, tins should be resealed
using the plastic lid and returned to storage under
recommended conditions of 18°C minimum ambient
temperature and 60% relative humidity.
Excessive exposure of electrodes to humid
conditions, will promote moisture pick-up and risk of
weld porosity. In situations where this is suspected,
or weld porosity is encountered, electrodes can be
restored to the as-packed condition by redrying for
1-2 hours at 200-300°C.
A maximum of three redrying cycles and/or ten
hours total time at temperature is recommended to
avoid permanent flux damage. Temperatures during
redrying should not exceed 400°C.
SOLID WIRES
Solid TIG wires are supplied in 2.5kg or 5kg tubes,
and MIG wires are supplied on 12.5kg or 15kg
spools (either plastic or metal baskets). The solid
wires that may be susceptible to rusting (mild steel
and low alloy) are copper coated. Under appropriate
storage conditions solid wires do not present any
handling difficulties.
MIG wires supplied on 15kg wire baskets need to be
properly handled because if they are lifted by one
rim it can bend the basket and lead to feeding
problems.
FLUX CORED WIRES
Flux cored wires need to be stored correctly to
prevent moisture pick-up, which may lead to
porosity. As supplied the wires are adequately
protected for moisture pick-up to not present a
problem, but once opened part-used spools need to
be correctly stored. It is recommended that spools
are removed from machines overnight and put in a
controlled store. If a part spool is to be stored for
any period of time it should be adequately protected
(in a plastic bag with desiccant) and held in a
controlled store.
Care is required when handling mild steel and low
alloy wires because handling of the wire surface can
result in rust marks if the wire is then stored for a
prolonged period. If the wire is to be used
immediately handling the wire surface presents no
problems but if a part spool is to be stored for any
period of time avoid touching the wire surface with
bare hands.
SUBMERGED ARC FLUX
Submerged arc fluxes are supplied in metal drums,
but for most applications it is recommended that the
flux should be dried prior to use.
Metrode’s Submerged Arc Welding Fluxes
There have been a number of changes to the
submerged arc welding fluxes that are currently
available from Metrode.
The following is a list of the currently available
fluxes and their main applications. There are also
individual data sheets on all of the fluxes which
provide more detailed information about the fluxes
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but if you wish to discuss specific applications please
contact the Technical Department.
LA436 Flux
This is a new flux that has recently been introduced
into the range. It is intended for general purpose
use with 1CrMo, 2CrMo and 1NiMo low alloy wires
where there is no requirement for low temperature
impact properties.
LA491 Flux
This flux has been used extensively for welding P91
creep resisting steel using 9CrMoV-N wire. This flux
is still available for customers who have been using
this flux in conjunction with the 9CrMoV-N wire.
The flux also has a secondary use which is for
welding with the ER308LCF and ER316LCF wires for
LNG projects and other applications requiring
cryogenic properties.
LA492 Flux
This new flux has been introduced for welding P91
and P92 steels using the 9CrMoV-N and 9CrWV
wires respectively. LA492 provides similar
mechanical properties to the LA491 flux but has
better slag release and is the flux we would offer for
new customers and projects wishing to weld P91
and P92 steel.
Examples of applications involving SSB flux.
LA424 Flux
This is a specialist flux for high speed fillet welding,
mainly with CrMo alloys.
SSB Flux
This is a long standing Metrode flux and one that is
still recommended for use with duplex, ER329N, and
superduplex, Zeron 100X, wires. It can also be used
for a wide range of other stainless steel wires
although there is now an alternative flux available
which we would recommend for applications
involving the standard 300 series stainless steel
wires, see Metrode SS300 flux.
SS300 Flux
This is a new flux that has been introduced for use
with the standard 300 series stainless steel wires:
308S92, 316S92 and 309S92. This is the flux we
would now recommend for use with all of the
standard stainless steel wires.
The flux also has other potential applications
including duplex, superduplex and possibly nickel
base wires. These uses will be investigated further
in the future.
NiCr Flux
This is the standard flux we recommend for use with
nickel base wires for joining applications. It is very
high basicity, producing excellent metallurgical
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integrity but this does mean that it does not have
such good slag release as some other fluxes,
particularly when welding with the 62-50 wire. The
limitation in slag release is compensated for by the
high integrity of the deposit and the minimal risk of
hot cracking, even in highly restrained joints.
NiCu Flux
This is a flux that only has limited use because it is
only used with the 65NiCu wire.
L2N Flux
L2N is the only fused flux in Metrode’s range, which
has advantages with respect to the resistance to
moisture pick-up. The flux can be used with low
alloy and stainless steel wires, and also with nickel
base wires for cladding applications.
Cladding with 62-50 wire and L2N flux.
New Decade – new packaging
Metrode will be introducing some exciting new
packaging over the next few months. Our TIG
wires will gradually start to be delivered in new
Reflex Blue, rectangular shaped section, two
piece tubes. The pack weights will not change
from our popular 2.5 and 5.0 kg tubes.
This will be a phased introduction over the
coming months and wires will continue to be
supplied
We also have a new inner carton for our limited
range of low alloy MMA electrodes supplied in
cardboard packs.
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The American Way
Metrode in the guise of John Stoll, recently teamed up with Bill Newell of Euroweld to hold 3 educational symposium’s on a range of subjects. They took place at Beaumont, Corpus Christi and Houston at the end of February.
• The Challenges of Welding Chrome-Molys...Why Technique & Workmanship Matter!
• Altering Welding Consumables to Meet Specialized Needs!
• Dispelling Myths Associated with Current Welding & Consumable Technology!
• Welding P91 - An Update!
A total of 91 of the top QA/QC welding people along the Gulf Coast attended the events and they were all decision makers and WPS qualifiers and writers. All three events were universally well received, this is a typical comment: -
“Just wanted to let you know I thought the class subject and presentation was excellent. The seminar covered actual welding applications we deal with from day to day. I have a couple of young engineers that need to attend this course or maybe attend the next class. Thanks for the invite.”
New People
The customer care team has been joined by
Ritu Srivastava and we would like to
welcome her to the Metrode team.
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Metrode Products Ltd Launches
RCC-M Welding Consumable
Programme
Stainless steel, RCC-M tested and certified
“nuclear grade” MMA and TIG welding
consumables delivered from stock
Founded in 1963, Metrode has always been at
the forefront when it comes to manufacturing
and supplying high quality welding
consumables, particularly in those industries
that require the highest integrity from their
welding consumables.
The nuclear, (French) RCC-M code driven
industry, is one of those industries. In order to
satisfy requirements of those fabricators active
in the nuclear welding industry, Metrode
Products launches a new RCC-M consumable
program.
Not all fabrication work can be scheduled many
months in advance, allowing for production and
testing of both base materials and welding
consumables. This is particularly true for
maintenance and repair work and general
fabrication work that need quick turn-around
time.
That is why Metrode is now launching a new
program to deliver, from stock, fully tested and
certified stainless welding consumables
according to RCC-M Add 2007 Section IV.
Metrode RCC-M Consumable Range
The consumable range will include historically
proven stainless steel products. An overview of
the available products is shown in table 1.
All products will be supplied with the required
product traceability and certification. Upon
request specific RCC-M datasheets can be made
available.
Trade name EN Classification RCC-M
Data Sheet
Ultramet 308L(N) E 19 9 L R 32 S 2920
TIG 308S92(N) W 19 9 L S 2910
Ultramet 316L(N) E 19 12 3 L R 32 S 2925
TIG 316S92(N) W 19 12 3 L S 2915
Ultramet 309L(N) E 23 12 L R 32 S 2930
TIG 309S92(N) W 23 12 L *
Available Upon Request
SAW 308S92(N) S 19 9 L S 2940
SAW 316S92(N) S 19 12 3 L S 2945
SAW 309S92(N) S 23 12 L S 2950
Flux SS300(N) S A AF 2 64 AC
Table 1 Overview of available RCC-M consumables (* No
relevant RCC-M data sheet).
Stick electrodes.
Ultramet stick electrodes have all the benefits of
an advanced rutile flux design. This includes
optimum versatility; downhand welding with
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high cosmetic finish and weld metal integrity;
and all-positional welding with the 2.5/3.2mm
electrodes including fixed pipe work. Recovery is
about 110% with respect to core wire, 65% with
respect to whole electrode.
All Ultramet electrodes have a moisture resistant
coating ensuring porosity-free welds, even under
less favourable (moisture) exposure conditions.
As per Metrode’s standard, all electrodes have
the batch number imprinted on the coating for
optimum traceability.
Solid wires
All 3XXS92(N) wires, for both TIG - and SA
Welding have low carbon and low silicon
content. TIG wires are cleaned to prevent weld
pool contamination.
All TIG wires have the batch number stamped on
both ends of the TIG wire providing optimum
traceability, even when the welder cuts the wire
in half.
Figure 1 Sizewell I Nuclear power plant UK.
SA welding flux
For Submerged Arc Welding applications
Metrode recommends its agglomerated flux
SS300-N. This Aluminate Fluoride type flux with
a basicity index (Boniszewski) of 1.6 provides the
right balance between mechanical properties
and weldability. SS300-N will provide a self-
releasing slag and is suitable for DC and AC.
Under normal transportation and storage
conditions the flux can be used from the tin
without the need for redrying.
Certification
Metrode’s Quality System conforms to the
requirements imposed by RCC-M. Furthermore,
all required testing on the consumables has
been performed in order to satisfy the RCC-M
requirements.
Every batch of Metrode’s RCC-M consumables is
supplied with a 3.1 certificate with both actual
chemical and mechanical properties meeting the
specific requirements stipulated in RCC-M Add
2007 Section IV. In figure 2 a copy of a
certificate is shown.
Figure 2 Certificate of Ultramet 316L(N)
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By taking all necessary steps to fulfill the RCC-M
code requirements Metrode can guarantee that
its consumables meet the full scope of RCC-M.
Packaging
Metrode has introduced specific packaging
labels for its nuclear certified welding
consumable range. Bright orange labels will be
exclusively used for nuclear certified material
which should allow for easy identification and
avoids mixing with standard consumables at
every stage of the supply chain.
Figure 3 Metrode RCC-M labels
MMA electrodes are supplied in Metrode
traditional metal tins with ring-pull opening. The
tins are hermetically sealed and meet the
definition for hermetically sealed containers
given in AWS A5.5. If unopened, and
appropriately stored, this packaging will
maintain the electrodes in the as-packed
condition for an indefinite period of time.
Electrodes can be used directly from the tin
without the need for redrying. Once opened, the
tins can be closed using the plastic lid supplied
and should be stored at >18°C and <60% relative
humidity. Redrying requirements are given on
the data sheets for individual electrodes.
TIG wires are, as mentioned earlier, individually
marked with grade and batch number on both
ends and conveniently packed in a rugged 2.5kg
PE tube. This provides sufficient product
protection for both in-shop and on-site
applications.
Submerged Arc Welding flux is supplied in 25 kg
robust metal drums and can, under normal
conditions, be used direct from an unopened
drum. Submerged Arc wire is supplied on
industry standard 25kg “stein baskets”.
Typical mechanical properties
Product Rp0,2
[MPa]
Rm
[MPa]
A4
[%]
CVN
[J+20°C]
UM308L(N) 465 600 47 65
(+350°C) 305 410 30 --
TIG 308S92(N) 465 605 48 160
(+350°C) 290 400 30 --
UM316L(N) 500 600 38 65
(+350°C) 340 470 33 --
(+360°C) 340 470 30 --
TIG 316S92(N) 465 605 48 110
(+350°C) 280 410 30 --
(+360°C) 280 410 30 --
UM309L(N) 495 595 41 --
TIG 309S92(N) 450 590 43 --
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Figure 4a & b – Sellafield Nuclear Reprocessing Plant - UK
Typical chemical composition
* Ferrite calculated according to DeLong diagram.
Metrode to go – exhibition programme
30 May - 2 June 2010, Barcelona, Spain
ENC 2010 was a unique networking event for
scientists, nuclear industry representatives and
policy makers, who can consider and discuss
ideas and innovations that will drive the
technological developments of the future.
Following on from a series of seven successful
duplex conferences during the past twenty
Product C Mn Si S P Cr Ni Mo Cu Co N FN *
Ultramet 308L(N) <0.025 0.7 0.6 0.01 0.02 19.5 9.5 0.1 <0.1 0.04 0.08 8
TIG 308S92(N) 0.01 1.7 0.4 0.01 0.015 20 10 0.1 0.15 0.04 0.04 8
Ultramet 316L(N) <0.025 0.7 0.6 0.01 0.02 19.5 12.5 2.6 <0.1 0.04 0.1 8
TIG 316S92(N) 0.01 1.7 0.4 0.01 0.015 19 12.5 2.6 0.15 0.04 0.04 10
Ultramet 309L(N) 0.025 0.8 0.6 0.01 0.02 23.5 12.5 0.2 <0.1 0.04 0.1 16
TIG 309S92(N) 0.01 1.7 0.5 0.01 0.015 23.5 13 0.1 0.1 0.04 0.04 12
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years, the next Duplex Stainless Steel
Conference will be held at the same venue in
Beaune, France, where the legendary and
mostfamous Duplex Conference ever, was held
in 1991. Again the content will be solely
dedicated to duplex stainless steels with a
strong emphasis on new developments such as
lean and hyper duplex stainless steels.
Presentations will be sourced on the
comparison of properties between duplex and
other alloys. Visitors to this upcoming
conference will therefore benefit from the up-
to-date exchange of information on long-term
experiences with duplex stainless steels that
have taken place since the previous Beaune
Conference in 1991. The main topic will be cost
saving and life-cycle aspects of nitrogen-
containing duplex stainless steels in a variety of
applications.
Metrode will be presenting an update of the
paper that they presented at the first Beaune
Conference, focused on ‘Corrosion Testing of
Duplex & Superduplex Weld Metal’
June 16-17th
The Atlantic Canada Petroleum Show put the
spotlight the technology, the people, and the
projects of the East Coast region. Over 100
exhibiting companies and 2,000 attendees
came together in the beautiful setting of St.
John’s Newfoundland to source new
technologies, discover new business
opportunities, and explore the latest
innovations.
Sports News
We have been sponsoring the under 8 football
team at Abbey Rangers, based in Chertsey, this
season and having the logo on the shirts seems
to have worked - they won two end of season
tournaments!
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VIP Guests
Article from the Surrey Herald
Keith Palmer shows Philip Hammond our new FCW Plant.
Coalition is trying to protect British
jobs, says Tory MP.
Philip Hammond Conservative MP for
Runnymede and Weybridge, has said it is “more
important than ever” to support local business.
The MP, currently transport secretary in the
Conservative Liberal Democrat coalition
government, was speaking at a meeting at
Metrode Products, in Hanworth Lane, Chertsey,
on Friday. He was visiting the welding
consumerables manufacturing company to
discuss the impact of overseas contracts on
British industry. During his meeting, he met
business managers and had a tour of the
premises.
He said: “I like to visit a local business each
week as I tour my consistuency and I’ve been
hoping to come here since the election.
Supporting local business is important. We are
trying to protect jobs and aid the economy
while we get through this budget deficit.”
The company has been in Chertsey for the past
37 years and is part of US company, Lincoln
Electrical.
Mr Hammond was greeted by general manager
Peter Frost and Runnymede borough valuer Ian
Gifford. Mr Frost said: “I wrote to Mr Hammond
at the turn of the year to discuss some contract
that, if awarded, we were concerned could have
used overseas employment.
“We wanted British workers to be employed
and getting Mr Hammond here is a great
opportunity to tell him about manufacturing in
Britain.
“It is more important for the future of
manufacturing in this country that we not only
hardness theoretical but also practical skills.
For more information on Metrode Products, visit
www.metrode.com.
Metrode Products Limited
Hanworth Lane
Chertsey
Surrey, KT16 9LL UK
www.metrode.com
Email: [email protected]
Email: [email protected]