the australian welding guide 2012

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THE AUSTRALIAN

WELDING GUIDE

welding.com.au

The Ultimate Welding Reference Guide 2012

http://www.welding.com.au

2 welding.com.au 1300 300 884

FOR OVER 50 YEARSWith a proven history of over 50 years in the Australian market, WIA has built a reputation for delivering high quality filler metal products for the industrial user. Known for their quality, consistency and performance, WIA filler metal products are preferred by operators across a wide range of industry sectors.

WIA offers an extensive range of consumables for various welding processes and applications. Choose from mild steel and low hydrogen electrodes to specialised flux cored wires and hardfacing products.

Backed by a team of technical professionals who understand our customers’ needs, we are committed to delivering welding products that offer peak performance in operability, mechanical properties and productivity, and backed by the delivery of technical expertise and support.

WIA is ISO 9001 certified. It’s your guarantee of the highest levels of quality, satisfaction and efficiency when you choose WIA products.


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WELDING INDUSTRIES OF AUSTRALIA AN ITW COMPANY

USING THIS GUIDEPRODUCT SECTIONThe front section of this guide contains comprehensive product information on the range of WIA consumables. Access the latest information on WIA filler metal products, including technical data sheets at welding.com.au.

TECHNICAL REFERENCE SECTIONDesigned as a portable reference tool for welding engineers, design and costing personnel, workshop supervisors, welding specialists and students, the Technical Reference Section incorporates the information welding professionals need to have on hand.

VIEWING THIS GUIDE AS AN INTERACTIVE PDFDepending on the device or computer you are viewing this PDF in, all CONTENTS pages contain ‘clickable’ links to help you navigate easily through the document.

DISCLAIMER - Welding Industries of Australia (WIA) is a supplier of welding products, and does not operate as a provider of consultancy or other technical services or advice related to welding. The information provided in this document is offered as a guide only. Every effort has been made to ensure the information contained in this booklet was correct at the time of printing. WIA does not accept responsibility for errors or information which is found to be misleading. Prior to using WIA products, it is the purchasers’ responsibility to ensure the products selected are suitable for the application.

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INTRODUCTION ELECTRODES General Purpose Electrodes - Mild Steel Hydrogen Controlled Electrodes Iron Powder Electrodes Cellulose Electrodes Stainless Steel Electrodes Cast Iron Electrodes Gouging and Cutting Electrodes WIRES Solid MIG Wires – Mild Steel Solid MIG Wires – Low Alloy Steel Solid MIG Wires – Aluminium Metal Cored Gas Shielded Wires Flux Cored Gas Shielded Wires Flux Cored Self Shielded Wires

HARDFACING PRODUCTS Hardfacing Electrodes Hardfacing Solid MIG Wires Hardfacing Self Shielded Flux Cored Wires Hardfacing Gas Shielded Flux Cored Wires

TECHNICAL INFORMATION

5

1

CONTENTS

33

65

86

5

GENERAL PURPOSE ELECTRODES - MILD STEEL Austarc 12P ................................................................ 6-7Austarc 13S ................................................................ 8-9

HyDROGEN CONTROLLED ELECTRODESAustarc 16TC ...........................................................10-11Austarc 18TC .......................................................... 12-13Austarc 77 ............................................................... 14-15

IRON POWDER ELECTRODESAustarc 24 ............................................................... 16-17

CELLULOSE ELECTRODESAustarc 11 ............................................................... 18-19

STAINLESS STEEL ELECTRODESStaincord 309Mo-16 ................................................ 20-21Staincord 316L-16 ................................................... 22-23Unicord 312 ............................................................ 24-25

CAST IRON ELECTRODESSupercast Ni ........................................................... 26-27 Suercast Ni/Fe ........................................................ 28-29

GOUGING AND CUTTING ELECTRODESAustarc C&G ........................................................... 30-31

ELECTRODESCONTENTS

CONTENTS

6CONTENTS

AUSTARC 12P SUMMARy

• General Purpose Rutile Type Electrode• Versatile/All Positional Capabilities Including Vertical Down• Smooth Performance on Low OCV AC Welding Machines

IDENTIFICATIONCoating - Brown Tip - Red Imprint - WIA 4313A

CLASSIFICATION

• AS/NZS 4855-B - E43 13 A • AWS A5.1: E6013

DESCRIPTION AND APPLICATIONAustarc 12P is a smooth running, rutile type electrode for all positional welding of mild steel. It is characterised by a moderately forceful and extremely stable arc. Superb arc starting and restriking on low voltage AC welding machines.

A stiff fast freezing slag for all positional (especially vertical down) fillet welding capabilities. Typical applications include, the all positional welding of galvanised gates/fences, steel furniture, trailers and wrought iron.

OPERATIONAL DATA

ELECTRODE SIZE (mm)

ELECTRODE LENGTH (mm)

WELDING CURRENT RANGE *(A)

ARC VOLTAGE RANGE **(V)

2.0 300 40-60 192.5 300 60-85 203.2 380 90-130 214.0 380 130-180 225.0 450 180-230 23

*Recommended for DC +/- or AC (minimum 45 OCV) operation. **Voltage is determined by arc current and electrode arc length. Arc voltage shown is typical and is only to be used as a guide.

7CONTENTS

SHIPPING APPROVALSLR 2Ym ABS 2 DNV 2

TyPICAL ALL WELD METAL CHEMICAL ANALySIS

C Mn Si Fe0.07 0.5 0.3 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySIS

Yield Stress 450 MPaTensile Strength 500 MPaElongation 26%CVN Impact Values 70J @ 0°C

In as welded condition.

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG

PART NUMBER

Packet Carton2.0 2.5 12.5 103 12P202.5 2.5 12.5 67 12P253.2 5.0 15 31 12P324.0 5.0 15 20 12P405.0 5.0 15 11 12P50

ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL1G

2G 3G4G 1F

2F4F

3G

8CONTENTS

AUSTARC 13S SUMMARy

• General Purpose/Rutile Type Electrode• Versatile/All Positional (especially vertical up) Capabilities• Ideal for Down Hand Fillet Welding of Mild Steel• Smooth Performance on Low OCV AC Welding Machines

IDENTIFICATIONCoating - Blue/White Stripe Tip - Plain Imprint - WIA 4313A

CLASSIFICATION

• AS/NZS 4855-B - E43 13 A• AWS A5.1: E6013

DESCRIPTION AND APPLICATION

Austarc 13S is the popular “blue and white striped” general purpose electrode for smooth mitre fillet welding applications. 13S has a soft and stable arc and produces flat, uniform fillet welds with ease and a self peeling slag action.

Austarc 13S is formulated primarily for fillet welding in all down hand positions. It is ideal for the general purpose and structural welding of sheet and plate steels (galvanised or otherwise) and tubular components, including trailers, duct work, hoppers and storage tanks, etc.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




2.0 300 40-60 192.5 300 60-85 203.2 380 100-130 214.0 380 140-180 225.0 450 180-230 236.0 450 230-290 24


9CONTENTS

SHIPPING APPROVALSLR 2m ABS 2 DNV 2


C Mn Si Fe0.07 0.55 0.45 Bal




PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG

PART NUMBER

Packet Carton2.0 2.5 12.5 99 13S202.5 2.5 12.5 63 13S253.2 5.0 15 29 13S324.0 5.0 15 10 13S405.0 5.0 15 6 13S506.0 5.0 15 6 13S60

ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL1G

2G 3G4G 1F

2F4F

10CONTENTS

AUSTARC 16TC SUMMARy• Basic/Twin Coated (TC) Manual Arc Electrode• Low Hydrogen, “H10” Status• Versatile/All Positional (Especially Vertical Up) Capabilities• Reliable, Low Temperature Impact Toughness• Easy to Strike and Re-Strike• Smooth Performance on Low OCV AC Welding Machines IDENTIFICATIONCoating - Light Grey Tip - Bronze Imprint - WIA 4916A CLASSIFICATION

• AS/NZS 4855-B - E49 16-A U H10• AWS A5.1: E7116-1 H8 DESCRIPTION AND APPLICATION

Austarc 16TC is a smooth running, basic low hydrogen electrode, developed for all positional (except vertical down) welding, using AC or DC power sources. The electrode gives exceptional arc stability and weldability for its class and produces high quality weld deposits with reliable notch toughness to -40°C. Austarc 16TC is manufactured using a unique twin coating extrusion process, which produces electrodes with two concentric flux coatings. Arc stabilising elements are concentrated in the inner coating of the electrode for significantly improved arc stability on AC welding machines.Other features of 16TC include, a smooth rippled weld profile with excellent edge wetting and a fluid, easily removed glassy slag. Austarc 16TC deposits X-ray quality weld metal with typical diffusible hydrogen levels of 5-8 mls of hydrogen per 100 gms of deposited weld metal, for “as manufactured” product, thus satisfying the “H10” low hydrogen category of AS/NZS 4855 and “H8” of AWS A5.1. OPERATIONAL DATA

ELECTRODE SIZE (mm)



2.5 300 60-903.2 380 90-1354.0 380 140-1905.0 450 190-2406.0 450 250-310

*Please note, 2.5 and 3.2 Austarc 16TC are recommended for DC+ or AC (minimum 45 OCV) operation, whereas 4.0, 5.0 and 6.0mm sizes require a minimum of 55 OCV for stable AC operation.

11CONTENTS

SHIPPING APPROVALSLRS 4Ym H10 ABS 3 H10 DNV 3Y H10 TyPICAL ALL WELD METAL CHEMICAL ANALySIS

C Mn Si P S Fe0.06 1.2 0.4 0.015 0.010 Bal


Yield Stress 460 MPaTensile Strength 560 MPaElongation 28%CVN Impact Values 130J @ -20°C 110J @ -40°C

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG

PART NUMBER

Packet Carton2.5 2.5 12.5 61 16TC253.2 5.0 15 29 16TC324.0 5.0 15 19 16TC405.0 5.0 15 10 16TC506.0 5.0 15 7 16TC60

MATERIALS TO BE WELDED

CODE TyPE

Structural Steel

AS 1163 C250, C350, C450AS 1397 G250, G300, G350, G450AS 1450 C/H200, C/H250, C/H350, C/H450,

AS/NZS 3679.1 250, 300, 350, 400AS/NZS 3678.1 AS/NZS 3679.2

200, 250, 300, 350, 400, 450, A1006, XK1016, WR350

Pressure Equipment

SteelAS 1548 7-430, 7-460, 5-590, 7-490

Fine Grain Steel AS/NZS 1594

HAI, HA3, HA4N, HA200, HA250, HA300, HA1006, HA1010, HA1016,

HA350, HA400Cast Steel AS2074 C2, C3, C7A-1, C1, C4-1, C4-2, C7A-2

Pipe Material API 5LX X42, X46, X52, X60

ELECTRODES - HYDROGEN CONTROLLED ELECTRODES1G

2G 3G4G 1F

2F4F

12CONTENTS

AUSTARC 18TC SUMMARy• Basic Twin-Coated (TC) Iron Powder Electrode• Very Low Hydrogen H5 Status• Suitable for all Positional Welding Except Vertical Down• Excellent Low Temperature Fracture Toughness• Easy to Strike and Re-Strike• Smooth Performance on Low OCV AC Welding Machines

IDENTIFICATIONCoating - Light Grey Tip - Blue Imprint - WIA 4918-1A

CLASSIFICATION

• AS/NZS 4855-B - E49 18-A U H5• AWS A5. 1: E7018-1


Austarc 18TC is a basic iron powder electrode used primarily on C-Mn and low alloy structural steels. The unique twin-coat design for 18 type low hydrogen electrode offers excellent AC arc stability and superb DC+ arc transfer, excellent re-strike, reduced spatter level and extraordinary ease of use for out-of-position welding.

Typical applications include oil and gas, pipe welding, structural steel construction, off-shore where Ni-alloying is prohibited, mining equipment, heavy girders and earth moving plant repair and maintenance.

OPERATIONAL DATA

ELECTRODE SIZE (mm)



2.5 300 60-903.2 380 90-1354.0 380 140-190

*Please note, the recommended welding polarity for Austarc 18TC is DC + or AC (Min. 50 OCV).

SHIPPING APPROVALSLRS/Pending DNV/Pending

13CONTENTS


C Mn Si P S Fe0.06 1.55 0.54 0.010 0.02 Bal


Yield Stress 530 MPaTensile Strength 602 MPaElongation 24%CVN Impact Values 87J @ -50°C

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG

PART NUMBER

Packet Carton2.5 2.5 12.5 45 18TC253.2 5.0 15 26 18TC324.0 5.0 15 17 18TC40

MATERIALS TO BE WELDED

CODE TyPE

Structural Steel

AS 1163 C250, C350, C450AS 1397 G250, G300, G350, G450AS 1450 C/H200, C/H250, C/H350, C450AS 1450 250, 300, 350, 400

C/H200, C/H250,

200, 250, 300, 350, 400, 450, A1006, XK1016, WR350

AS/NZS 3679.1 250, 300, 350, 400

AS/NZS 3678.1 AS/NZS 3679.2

200, 250, 300, 350, 400, 450, A1006, XK1016, WR350

Pressure Equipment

SteelAS 1548 7-430, 7-460, 5-590, 7-490

Fine Grain Steel AS/NZS 1594

HA1, HA3, HA4N, HA200, HA250, HA300, HA1006, HA1010, HA1016,

HA350, HA400

Cast Steel AS2074 C2, C3, C7A-1, C1, C4-1, C4-2, C7A-2

Pipe Material API 5LX X42, X46, X52, X60


2G 3G4G 1F

2F4F

14CONTENTS

SUMMARy

• Basic Coated Iron Powder Electrode• Low Hydrogen Status• Suitable for All Positional Welding Except Vertical Down• Excellent Low Temperature Fracture Toughness

IDENTIFICATIONCoating - Light Grey Tip - Black Imprint - WIA 4918-1A

CLASSIFICATION

• AS/NZS 4855-B - E49 18-1 U H5• AWS A5.1: E7018-1


The Austarc is a smooth running basic type of low hydrogen iron powder electrode used for all positional welding except vertical down. The arc is very quiet with little spatter and the welds are exceptionally smooth with excellent wash in at the toes of the weld, thus giving minimum undercut. This electrode is used where the highest restrained work pieces are fabricated for mining equipment, pressure vessels, heavy girders, earth moving plant, repair and maintenance etc.

For the highest weld quality with low hydrogen levels, Austarc 77 electrodes should be baked at 400˚C for one hour to obtain <5mL/100g weld metal. After baking, the electrodes should be used from a hot box set at 100 -150 ̊C.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




2.5 305 60-105 203.2 380 90-145 224.0 380 140-200 245.0 455 180-300 26


AUSTARC 77

15CONTENTS

SHIPPING APPROVALSLR 4Ym H5 ABS 3Y H5


C S Mn P Si Fe0.05 0.011 1.28 0.022 0.30 Bal




PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG

PART NUMBER

Packet Carton2.5 2.2 11 45 77253.2 5.0 15 26 77324.0 5.0 15 17 77405.0 5.0 15 9 7750


2G 3G4G 1F

2F4F

16CONTENTS

SUMMARy

• High Iron Powder, Rutile Type Electrode• High Deposition Rates and Efficiencies• Suitable for Fast Downhand Fillet and Butt Welding

IDENTIFICATIONCoating - Brown Tip - Yellow Imprint - WIA 4924A

CLASSIFICATION

• AS/NZS 4855-B - E49 24 A• AWS A5.1: E7024


Austarc 24 is a high iron powder, rutile type electrode designed for the fast down hand welding of mild steel using AC or DC power sources. Features include high deposition rates/efficiencies and flat to slightly concave fillet welds with excellent “edge wash” and slag detachability. With its smooth running, positive re strike and high current carrying capacity, Austarc 24 is the ideal fillet welding electrode for down hand positions aimed at higher productivity.

Austarc 24 is suited to long, heavy fillet and butt welding applications using a touch welding or `short arc’ technique. Such applications include the production welding of tanks, structural members/frames and truck and tractor bodies etc.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




3.2 380 120-170 244.0 450 200-240 255.0 450 270-320 26


AUSTARC 24

17CONTENTS

SHIPPING APPROVALSLR 2Ym ABS 2 DNV 2


C Mn Si Fe0.06 0.7 0.4 Bal



In as welded condition

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG

PART NUMBER

Packet Carton3.2 5.0 15 18 24324.0 5.0 15 12 24405.0 5.0 15 6 2450

ELECTRODES - IRON POWDER ELECTRODES1G

1F2F

18CONTENTS

SUMMARy

• High Cellulose Coating• All Positional/High Penetration• Ideal for Site Welding

IDENTIFICATIONCoating - White Tip - Brown Imprint - WIA 4311A

CLASSIFICATION

• AS/NZS 4855-B - E4311A• AWS A5.1: E6011

DESCRIPTION AND APPLICATION Austarc 11 is a high cellulose electrode developed for all positional welding on both AC and DC power supplies.

Features include: Forceful, deep penetrating arc with fast freezing slag. Particularly suited for vertical and incline pipe welding where complete root penetration is required. The thin brittle slag is easily removed.

Austarc 11 is recommended for specific applications including pipeline welding and storage tank construction where either the “Stove Pipe” or “Flick” techniques can be used to obtain full root penetration in critical structural joints.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




2.5 300 60-95 203.2 380 90-125 214.0 380 115-175 225.0 450 160-220 23


AUSTARC 11

19CONTENTS

SHIPPING APPROVALSLR 3M ABS 3


C Mn Si Fe0.13 0.5 0.1 Bal




PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG

PART NUMBER

Packet Carton2.5 2.5 12.5 66 11253.2 5.0 15 33 11324.0 5.0 15 21 11405.0 5.0 15 14 1150

ELECTRODES - CELLULOSE ELECTRODES1G

2G 3G4G 1F

2F4F

3G

20CONTENTS

SUMMARy

• All Positional, Rutile Type Stainless Steel Electrode• Moisture Resistant Flux Coating/”Extra” Low Carbon Deposit• Suitable for the Dissimilar Welding of Stainless Steel to Mild/Low Alloy Steels.

IDENTIFICATIONCoating - Grey Tip - Black Imprint - WIA 309MO-16

CLASSIFICATION

• AS/NZS 4854-B - E309LMo-16• AWS A5.4: E309MoL-16

DESCRIPTION AND APPLICATION Staincord 309Mo-16 is an extra low carbon, rutile type electrode exhibiting superior all positional (except vertical down performance with an improved moisture resistant coating for weld metal of high radiographic integrity. The smooth arc action of Staincord 309Mo-16, together with low spatter and excellent slag control/ detachability, promotes exceptional weld appearance and profile.

Staincord 309Mo-16 is a Molybdenum bearing, highly alloyed 23Cr/12Ni/2.5Mo stainless steel electrode for welding matching 309 and 309Mo base metals. Major applications of Staincord 309 Mo-16 also involve the welding of a wide range of 300 and 400 series stainless steels to mild/low alloy steels. 309M is also suitable for general welding applications with alloyed and non-alloyed dissimilar ferrous metal combinations.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




2.5 300 50-75 223.2 350 75-110 264.0 350 110-150 28


STAINCORD 309Mo-16

21CONTENTS


C Mn Si Cr Ni Mo Fe0.025 0.8 0.7 23.5 13.0 2.4 Bal


Yield Stress 400 MPaTensile Strength 670 MPaElongation 38%


PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG

PART NUMBER

Packet Carton2.5 2.5 12.5 86 SC309MO253.2 2.5 12.5 55 SC309MO32

ELECTRODES - STAINLESS STEEL ELECTRODES1G

2G 3G4G 1F

2F4F

3G

22CONTENTS

SUMMARy

• All Positional, Rutile Type Stainless Steel Electrode• Moisture Resistant “Colour Coated” Flux Coating• Extra Low Carbon Weld Deposit• For the Critical Welding of Matching Type 316 and 316L Steels

IDENTIFICATIONCoating - Pink Tip - Green Imprint - WIA 316L-16

CLASSIFICATION

• AS/NZS 4854-B - ES316L-16• AWS A5.4: E316L-16


New generation Staincord 316L-16 is an extra low carbon, rutile type electrode exhibiting superior all positional (except vertical down) performance with an improved moisture resistant “Pink” flux coating for weld metal of high radiographic integrity. The smooth arc action of Staincord 316L-16, together with low spatter and excellent slag control/detachability, promotes exceptional weld appearance and profile. Other features include high arc stability and easy restriking on low voltage AC welding machines.Staincord 316L-16 deposits Molybdenum bearing, 19Cr/12Ni/2.5Mo filler metal to meet the requirements for welding type 316 and 316L stainless steels in critical applications. Staincord 316L-16 is also recommended for the general purpose welding of common 300 series stainless steels, such as 301, 302, 304 and 304L. It is also suitable for the general welding of ferritic stainless steel alloys, such as 409, 444 and 3Cr12.

STAINCORD 316L-16STAINCORD 316L-16

23CONTENTS

OPERATIONAL DATA

ELECTRODE SIZE (mm)




2.0 300 30-50 202.5 300 50-75 213.2 350 75-110 26



C Mn Si Cr Ni Mo Fe0.025 0.7 0.7 18.5 12.0 2.4 Bal


Yield Stress 380 MPaTensile Strength 600 MPaElongation 40%


PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG

PART NUMBER

Packet Carton2.0 2.5 12.5 86 SC316202.5 2.5 12.5 55 SC316253.2 2.5 12.5 27 SC31632


2G 3G4G 1F

2F4F

24CONTENTS

SUMMARy

• Universal AC/DC Maintenance Electrode for Welding Ferrous Metals• Ideal for Joining Dissimilar Steel Components• Suitable as a Buffer Layer Prior to Hard Surfacing• Stable Performance on Low OCV Welders

IDENTIFICATIONCoating - Grey Tip - Red Imprint - Unicord 312

CLASSIFICATION

• AS/NZS 4854-B - ES312-16• AWS A5.4: E312-16

DESCRIPTION AND APPLICATION Unicord 312 is a basic, rutile type electrode depositing a 29%Cr/9%Ni stainless steel weld metal for the high strength welding of a wide range of alloy steels and dissimilar ferrous metals. The high ferrite, austenitic stainless steel deposit has excellent resistance to hot cracking, even under dilution by high carbon, alloy and tool steels. Unicord 312 is a universal maintenance electrode combining high strength, toughness, wear and corrosion resistance with compatibility to most ferrous metals.

Unicord 312 is suitable for many repair and maintenance applications on steels of unknown composition. It is an ideal electrode for welding medium to high carbon steels, low alloy steels and dissimilar ferrous metal combinations. Unicord 312 is also suitable as a buffer or intermediate layer prior to the application of hard surfacing.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




2.5 300 50-75 223.2 350 75-110 26

*Recommended for DC +/- or AV (minimum 45 OCV) operation. **Voltage is determined by arc current and electrode arc length. Arc voltage shown is typical and is only to be used as a guide.

UNICORD 312

25CONTENTS


C Mn Si Cr Ni Fe0.04 0.9 0.85 30.0 9.0 Bal


Yield Stress 500 MPaTensile Strength 770 MPaElongation 45%Deposit Hardness 28-35 HRc


PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG

PART NUMBER

Packet Carton2.5 2.5 12.5 52 UC312253.2 2.5 12.5 27 UC31232


2G 3G4G 1F

2F4F

26CONTENTS

SUMMARy

• Pure Nickel Core Wire/Basic, Graphite Coating• Soft Machineable Nickel Deposit for the Lower Strength Welding of Cast Irons

IDENTIFICATIONCoating - Black Tip - Plain Imprint - WIA SC Ni

CLASSIFICATION

• AWS A5.15: ENi-Cl

DESCRIPTION AND APPLICATION Supercast Ni is a basic, graphite coated AC/DC electrode for the lower strength welding of cast irons. It is characterised by a soft, smooth arc with low penetration and spatter levels on both AC and DC power sources. Ease of striking is a feature of Supercast Ni and it also has a particularly good wetting action resulting in well bonded welds of regular contour and attractive appearance.

This electrode is made from a pure nickel core wire and produces a ductile, fully machineable weld deposit. Supercast Ni may be used for the repair and reclamation of all standard grades of grey cast iron, malleable iron, austenitic cast iron and some grades of mechanite cast iron.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




3.2 350 50-100 23


SUPERCAST Ni

27CONTENTS


Mn Ni S Fe0.3 97.0 0.006 Bal


Yield Stress 220 MPaTensile Strength 400 MPaDeposit Hardness 150-170 HV (30)

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG

PART NUMBER

Packet Carton3.2 2.5 12.5 37 SNI32

ELECTRODES - CAST IRON ELECTRODES1G

2G 3G4G1F

28CONTENTS

SUMMARy

• Nickel -Iron Core Wire/Basic, Graphite Coating• Machineable Nickel-Iron Deposit for the Higher Strength Welding of Cast Irons, Particularly SG Irons

IDENTIFICATIONCoating - Black Tip - Green Imprint - WIA SC NiFe

CLASSIFICATION

• AWS A5.15: ENiFe-Cl

DESCRIPTION AND APPLICATION Supercast Ni/Fe is a basic, graphite coated AC/DC electrode for the higher strength welding of cast irons. It is characterised by a soft, smooth arc with low penetration and spatter levels on both AC and DC power sources. Ease of striking is a feature of Supercast Ni/Fe.

This electrode is made from a Nickel-Iron core wire and produces a ductile, machineable weld deposit with the extra strength required for welding SG (Spheroidal Graphite) irons.

Supercast Ni/Fe may also be used for the repair and reclamation of all standard grades of grey cast iron, malleable iron, austenitic cast iron and some grades of mechanite cast iron. It is ideally suited to the dissimilar welding of these irons to steels.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




3.2 350 50-100 23


SUPERCAST Ni/Fe

29CONTENTS


Mn Ni S Fe0.85 57.8 0.007 Bal


Yield Stress 300 MPaTensile Strength 500 MPaDeposit Hardness 200-220 HV (30)

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG

PART NUMBER

Packet Carton3.2 2.5 12.5 39 SNIFE32

ELECTRODES - CAST IRON ELECTRODES1G

2G 3G4G1F

30CONTENTS

SUMMARy

• Heavy Coated Manual Electrode for Cutting, Gouging or Piercing Steels

IDENTIFICATIONCoating - Black End Tip - Plain


Austarc C&G is a heavy coated electrode providing a highly mobile means of cutting, gouging and piercing most steels, using standard AC or DC arc welding equipment. Austarc C&G produces a very high arc force and can be used for general cutting and grooving in joint preparation, removing defective welds and reclaiming scrap metal, etc.

Oxy-acetylene and carbon arc-air cutting and gouging are two processes available to industry capable of giving high quality, smooth preparations. Austarc C&G will not replace these processes but rather provide a convenient, easy to use and mobile tool for the arc gouging and cutting of most metals. It is particularly useful to the maintenance welder operating in awkward locations to remove welds, open up joints and trim off bolt or rivet heads, etc. Similarly, the rural welder will find C&G handy in repairing or preparing joints when operating away from (or without) oxy-acetylene equipment.

Cutting - Direct the electrode into the work in the desired cutting direction, working from the outside edge. Use an up and down sawing motion, the “up” arc length being increased to increase heating, the “down” arc length being decreased to contact point to force the molten metal out of the groove. Angle of electrode should be approx 70° to the horizontal.

AUSTARC C&G

31CONTENTS

Gouging - Point the electrode in the direction of gouging at approx 10-20° to the plate surface. Strike the arc and move forward rapidly. If slag and molten metal start to clog the groove bring the electrode up to clear and, without breaking the arc, circle backwards and move forward again. This latter technique may prove more necessary than straight forward motion on lower amps or as the electrode becomes hotter. If amps are excessive, C&G will tend to “cut out” on AC and overheat, causing premature charring of the coating and reduced arc force.

Piercing - For holes, plunge the electrode into the plate at slightly off right angles. With a small circular motion to the holder, force the electrode into the plate until full penetration is achieved. Once the hole has been made it may be trimmed with an up and down sawing motion.

OPERATIONAL DATA

ELECTRODE SIZE (mm)


PACKAGING (KG) WELDING CURRENT RANGE *(A)Packet Carton

3.2 380 4 12 170-2504.0 380 4 12 220-350

ELECTRODES - GOUGING AND CUTTING ELECTRODES

33

SOLID MIG WIRES Austmig ES6 ...................................................................... 34-35

SOLID MIG WIRES - LOW ALLOy STEELAustmig ESD2 ........................................................ 36-37Austmig NiCrMo ..................................................... 38-39

SOLID MIG WIRES - ALUMINIUMAustmig 5183 .......................................................... 40-41Austmig 5356 ......................................................... 42-43

METAL CORED GAS SHIELDED WIRESAustfil 70C-6M ........................................................ 44-45

FLUX CORED GAS SHIELDED WIRESAustfil 71T ............................................................... 46-47Austfil 71T-1M ......................................................... 48-49Hobart XL-525 ........................................................ 50-51TM-71HYD .............................................................. 52-53TM-811N2 ............................................................... 54-55

FLUX CORED SELF SHIELDED WIRESFabshield 4 ............................................................. 56-57 Fabshield 23 ........................................................... 58-59Fabshield 21B ......................................................... 60-61Fabshield XLR-8 ..................................................... 62-63

WIRESCONTENTS

CONTENTS

34CONTENTS

SUMMARy

• Electrostatically Copper Coated Gas Metal Arc (MIG) Wire• All Positional Welding of Mild and Medium Strength Steels• Precision Layer Wound, Very Low Diffusable Hydrogen• Suitable for all Transfer Modes• Designed for use with Argon/CO₂ and CO₂ Shielding Gases

CLASSIFICATION

• AS/NZS 2717.1: ES6-GC-W503AH• AS/NZS 2717.1: ES6-GM-W503AH• AWS A5.18: ER70S-6

DESCRIPTION AND APPLICATION Austmig ES6 is a copper coated, low carbon steel GMAW wire, formulated for optimum performance under Argon/CO₂ mixed gases and welding grade CO₂. Arc transfer characteristics are excellent with Argon based gas mixtures, particularly in spray and pulsed transfer modes. Austmig ES6 is an electrostatically copper coated wire providing excellent wire feeding and electrical conductivity and reducing contact tip wear. The higher manganese and silicon content of Austmig ES6 provides effective weld metal deoxidation for resistance to porosity.Austmig ES6 is suitable for a wide range of welding applications on mild and medium strength steels providing consistently very low “H5” weld metal diffusible hydrogen levels when used with suitable shielding gases.

OPERATIONAL DATA

WIRE SIZE (mm)

WELDING CURRENT RANGE (A)

ARC VOLTAGE RANGE *(V)

0.6 40-100 12-160.8 60-180 14-220.9 70-230 15-261.0 100-290 16-291.2 120-350 18-321.6 160-390 18.34

Welding Current DC + *Voltage is determined by arc current and electrode arc length. Welding currents and voltage shown are operational guides only.

AUSTMIG ES6

35CONTENTS

SHIPPING APPROVALSLR 3S, 3YS


C Mn Si S P Fe0.1 1.45 0.88 0.02 0.022 Bal


Gas Type CO₂ Ar+18% CO₂Yield Stress 460 MPa 480 MPaTensile Stress 560 MPa 580 MPaElongation 28% 26%CVN Impact Values 80J @ -20ºC 70J @ -30ºC

PACKAGING DATA

WIRE SIZE (mm)

PACK SIZE AND TyPE PART NUMBER

0.6 5kg spool 15kg spool

ES606M5KG ES606S


ES608M5KG ES608S


ES609M5KG ES609S

1.0 15kg spool ES610S1.2 15kg spool ES612S1.6 15kg spool ES616S

WIRES - SOLID MIG WIRES - MILD STEEL

1G2G 3G

4G 1F2F

4F

36CONTENTS

SUMMARy

• Copper Coated, High Manganese-Molybdenum Gas Metal Arc (MIG) Welding Wire• For the all Positional Welding of Medium to Higher Strength Steels

CLASSIFICATION

• AS/NZS 2717.1: ESD2-GC-W559AH• AS/NZS 2717.1: ESD2-GM-W559AH• AWS A5.18: ER80S-D2


Austmig ESD2 is a copper coated, low alloy steel wire used for welding medium to higher strength steels, particularly where service temperatures up to 500°C are encountered. ESD2 gives excellent resistance to porosity using CO₂ or Argon based gas mixtures (i.e. Ar/CO₂, Ar/O₂, Ar/CO₂/O₂). When porosity is a potential problem due to dirty or rusty surfaces or higher than normal sulphur contents, Austmig ESD2 will provide a consistently sound weld deposit.Austmig ESD2 is also suitable for out-of-position welding due to its quick freezing weld pool. ESD2 produces high quality welds on plain carbon and C-Mn steels, low alloy steels and higher strength used in pressure vessels and boilers, such as petrochemical and power generation industries, operating at elevated temperatures. Austmig ESD2 may also be used for the fillet welding of higher tensile, quenched and tempered steels, such as Bisalloy 70 and 80 where the lower strength weld metal may be compensated by larger fillet sizes.When used with suitable shielding gases, Austmig ESD2 will consistently produce very low “H5”, weld metal diffusible hydrogen levels, for excellent resistance to HAZ or hydrogen induced cracking.

AUSTMIG ESD2

37CONTENTS

OPERATIONAL DATA

WIRE SIZE (mm)



0.9 70-230 15-261.2 120-350 18-32



C Mn Si Mo Fe0.1 1.95 0.75 0.5 Bal


Gas Type CO₂ Ar+18% CO₂Yield Stress 560 MPa 570 MPaTensile Stress 645 MPa 660 MPaElongation 19% 20%CVN Impact Values 35J @ -20ºC 50J @ -30ºC

In as welded condition.NOTE: The use of less oxidizing Argon based gas mixtures will result in higher manganese and silicon weld metal recovery, leading to higher tensile properties, particularly in heavy multi pass butt welds.

PACKAGING DATA

WIRE SIZE (mm)


0.9 15kg spool ESD209S1.2 15kg spool ESD209S

WIRES - SOLID MIG WIRES - LOW ALLOY STEEL

1G2G 3G

4G 1F2F

4F

38CONTENTS

SUMMARy

• Copper Coated, Low Allloy Gas Metal Arc (MIG) Welding Wire• All Positional Welding of Medium and High Strength Steels• Welded Strength 760 MPa Tensile Class

CLASSIFICATION

• AS/NZS 2717.1: ESMG-GM-W769AH-G• AWS A5.28: ER110S-G


Austmig NiCrMo is a copper coated, low alloy solid wire suitable for the all positional welding of high strength steels using Argon + CO₂ gas mixtures.

Austmig NiCrMo is ideal for the full strength welding of quenched and tempered structural steels, of the 760 MPa tensile class, such as USS-T1, CcMo Pipe, Welten 80, Weldox 700, X80, N-A-XTRA and Bisplate 80.

OPERATIONAL DATA

WIRE SIZE (mm)



0.9 70-230 15-261.2 120-350 18-32


NOTE: Austmig NiCrMo is NOT to be used in weldments which are to be stress relieved.

AUSTMIG NiCrMo

39CONTENTS


C Mn Si Ni Cr Mo V Fe0.07 1.22 0.37 1.42 0.29 0.24 0.07 Bal


Gas Type Ar+18% CO₂Yield Stress 732 MPaTensile Stress 799 MPaElongation 18%CVN Impact Values 78J @ -30ºC


NOTE: The use of less oxidizing argon based gas mixtures (ie Ar/O₂, Ar/CO₂, Ar/CO₂/O₂), will result in higher alloy recovery in the weld metal, leading to higher tensile properties.

PACKAGING DATA

WIRE SIZE (mm)


0.9 15kg spool MNICRMO09S1.2 15kg spool MNICRMO12S

WIRES - SOLID MIG WIRES - LOW ALLOY STEEL

1G2G 3G

4G 1F2F

4F

40CONTENTS

SUMMARy

• Aluminium-Magnesium-Manganese, Metal Inert Gas (MIG) Welding Wire• Precision Layer Wound and Double Shaved for Superb Feedability• For Welding of Alloys of the same Composition

CLASSIFICATION

• AS/NZS ISO 18273 - S AI 5183• AWS A5.10: E5183


Austmig 5183 is a precision layer wound aluminium wire alloyed with Mg, Mn and Cr.

It is recommended for welding Al/Mg material of the 5083 type in the annealed condition, particularly for low temperature applications where good ductility and toughness are required, ie cryogenic plant. It may also be used for welding medium strength Al/Zn/Mg alloys of the 7020 type and joining 5083 alloy to 5456 alloy.

Welding grade Argon or Argon/Helium shielding gas combinations are recommended with flow rates of 10-20 litres/minute.

OPERATIONAL DATA

WIRE SIZE (mm)



1.2 150-250 20-271.6 200-350 23-30


AUSTMIG 5183

41CONTENTS

SHIPPING APPROVALSLR WC/1-1S ABS AWS A5. 10-92/ER5183DNV 5183


Si Fe Cu Mn Mg Cr Zn Ti AI0.4 0.4 0.1 0.5-1.0 4.3-5.2 0.05-0.25 0.25 0.15 Bal


Gas Type ArYield Stress 110 MPaTensile Stress 240 MPaElongation 17%

PACKAGING DATA

WIRE SIZE (mm)


1.2 6kg spool M518312S1.6 6kg spool M518316S

WIRES - SOLID MIG WIRES - ALUMINIUM

1G2G 3G

4G 1F2F

4F

42CONTENTS

SUMMARy

• Aluminium - 5% Magnesium Alloy, Metal Inert Gas (MIG) Welding Wire • Double Shaved and Precision Layer Wound for Superb Feedability• For Welding Cast and Wrought Aluminium Alloys Containing Magnesium

CLASSIFICATION

• AS/NZS ISO 18273 - S AI 5356• AWS A5.10: ER5356


Austmig 5356 is a precision layer wound Aluminium - 5% Magnesium wire suitable for a wide range of gas metal arc welding applications on wrought or cast aluminium alloys containing magnesium as a major alloying element. Some grades of wrought aluminium - magnesium alloys which can be welded with Austmig 5356 are, 5083, 5086, 5454 and 5456.

OPERATIONAL DATA

WIRE SIZE (mm)



0.9 80-190 16-221.0 100-230 18-221.2 150-250 20-271.6 200-330 23-30


AUSTMIG 5356

43CONTENTS

SHIPPING APPROVALSLR WC/I-1,S; ABS AWS A5. 10-92/ER 5356; DNV 5356


Zn Mg Mn Cr Si Fe Ti AI0.1 5.2 0.15 0.1 0.25 0.4 0.15 Bal


Gas Type ArYield Stress 125 MPaTensile Stress 275 MPaElongation 17%

PACKAGING DATA

WIRE SIZE (mm)



M5356092KG M535609S


M5356102KG M535610S


M5356122KG M535612S

1.6 6kg spool M535616S

WIRES - SOLID MIG WIRES - ALUMINIUM

1G2G 3G

4G 1F2F

4F

44CONTENTS

SUMMARy

• Gas Shielded, Metal-Cored Wire• Slag-Free Weld Bead• Higher Deposition Rates• Low Spatter/Smooth Appearance• Better Fusion Profile

CLASSIFICATION

• AS/NZS ISO 17632-B - T 492T15 0MA-UH5• AWS A5.18: E70C-6M


Austfil 70C-6M is a metal-cored wire designed for high speed fillet and butt welding in the downhand position using Argon + 18-25% CO₂ shielding gas mixture. Weld beads are almost completely slag free with only minimal silicon islands, reducing the time and effort spent between runs and on cleanup prior to surface finishing.

Austfil 70C-6M is recommended for single and multi pass welding in both flat and horizontal positions for mild steel, carbon and maganese carbon steels with minimum clean up and where high deposition rates and efficiencies are required in high productivity, semi automatic and fully automatic welding installations. Suitable applications include mining buckets, structural fabrication and tank construction where high speed welding is required.

OPERATIONAL DATA

WIRE SIZE (mm)



1.2 200-350 29-351.6 300-450 27-34

Welding Current DC + *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.

AUSTFIL 70C-6M

45CONTENTS



C Mn Si S P Cu Fe0.038 1.46 0.68 0.009 0.012 0.02 Bal


Gas Type Ar+25%CO₂Yield Stress 628 MPaTensile Stress 587 MPaElongation 29%CVN Impact Values 51J @ -20ºC

PACKAGING DATA

WIRE SIZE (mm)


1.2 15kg spool 70C6M12S1.6 15kg spool 70C6M16S1.2 250kg drum 70C6M12D

WIRES - METAL CORED GAS SHIELDED WIRES

1G2G 1F

2F

46CONTENTS

SUMMARy

• All Purpose Rutile Flux Cored Wire• For Both Single or Multiple Pass Welds• All Positional Wire• Formulated Exclusively For CO₂ Gas

CLASSIFICATION

• AS/NZS ISO 17632-B - T492T1-1CA-UH10• AWS A5.20: E71T-1 H8


Austfil 71T is a rutile flux cored wire designed for excellent performance in all positional fillet and butt-welding applications. Austfil 71T is formulated exclusively for use with cost effective CO₂ shielding gas.

Austfil 71T is recommended for general purpose all positional welding of mild, carbon and carbon-manganese steels where excellent weld profile and penetration is required. Suitable for applications such as storage tanks, structural fabrication, bridge construction, machinery and earthmoving equipment. Suitable for AS/NZS 1554.5 of the structural code; Part 5: Welding of the steel structures subject to high levels of fatigue loading.

OPERATIONAL DATA

WIRE SIZE (mm)



1.2 130-230 25-321.6 200-350 25-32

Welding Current DC + Welding parameters shown above are for DC electrode positive using 100% CO₂ shielding gas at a flow rate of 15-20 litres/minute. *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.

AUSTFIL 71T

47CONTENTS



C Mn Si S P Fe0.03 1.28 0.44 0.01 0.013 Bal


Gas Type CO₂Yield Stress 531 MPaTensile Stress 580 MPaElongation 26%CVN Impact Values 93J @ -20ºC

PACKAGING DATA

WIRE SIZE (mm)


1.2 15kg spool 71T112S1.6 15kg spool 71T116S

WIRES - FLUX CORED GAS SHIELDED WIRES

1G2G 3G

4G 1F2F

4F

48CONTENTS

SUMMARy

• Rutile Type Flux Cored Joining Wire, Micro Alloyed• Formulated Exclusively for use with Ar/CO₂ Shielding Gas Mixtures• Excellent Operator Appeal “Smooth Spray Arc Transfer”• Versatile all Positional Capabilities• Grade 3 Weld Metal Impact Properties

CLASSIFICATION

• AS/NZS ISO 17632-B - T492T1-1MA-UH10• AWS A5.20: E71T-1M


An all positional rutile micro alloyed type flux cored welding wire specifically formulated for optimum performance using Ar/CO₂ shielding gas mixtures.

The exceptionally smooth arc performance produces a superb weld for single or multipass welding with low spatter losses in all positions and applications (except vertical down). Austfil 71T-1M is recommended for the welding of mild, carbon and carbon-manganese medium steels where good impact properties at -20°C are required.

This high deposition wire offers excellent operator appeal for general steel fabrications and constructions such as plate sections, beams, girders, truck chassis/bodies, shipbuilding, earth moving equipment, storage tanks, bridge construction etc.

Recommended shielding gases are: Argon + 18-25%CO₂

AUSTFIL 71T-1M

49CONTENTS

OPERATIONAL DATA

WIRE SIZE (mm)

WELD POSITION



1.2Flat Flat Fillet Vertical - up

250-300 230-280 170-220

29-35 28-30 24-28

1.6Flat Flat Fillet Vertical - up

300-350 200-350 200-250

28-34 24-34 26-28

Recommended electrical stick out is 15-20mm. Welding Current DC + *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.



C Mn Si S P B Fe0.04 1.20 0.42 0.012 0.013 0.001 Bal




PACKAGING DATA

WIRE SIZE (mm)

PACK SIZE AND TyPE

PALLET SIZE (KG) PART NUMBER

1.2 15kg spool 1080 71T1M12S1.6 15kg spool 1080 71T1M16S


1G2G 3G

4G 1F2F

4F

50CONTENTS

SUMMARy

• Low Diffusible Hydrogen• Excellent Toughness at Low Temperatures• Outstanding Weldability• Exceeds 27J CVN @ -40℃

CLASSIFICATION

• AS/NZS ISO 17632-B - T494T1-1MA-UH5• AWS A5.20: E71T-1M, E71T-12MJ H8


A rutile flux cored all position wire designed for welding mild and carbon steels, especially when good impact toughness is required at sub zero temperatures. Ideal for single and multi-pass applications, it delivers outstanding welding performance and produces high quality X-ray clear weld deposit with a bead contour that is flat to slightly convex. It can be used over rust, mill scale and some primers with no pre-cleaning of the steel necessary. Formula XL-525 has outstanding mechanical properties that resemble those of E7018 MMAW (SMAW) electrodes, plus high operator appeal with low fume levels, low spatter and easy slag removal.

Recommended for ship building, storage vessels, off-shore structures, earth moving equipment and pipe welding.

HOBART XL-525

51CONTENTS

OPERATIONAL DATA

WIRE SIZE (mm)



1.2 150-300 24-311.6 200-350 24-34


SHIPPING APPROVALSLR 3S, 3YS; ABS 3SA, 3YSA Impact @ -40̊C 34 ft, lbs DNV Y40MS BV 3YM; CWB E491T-12MJ-H4;


C Mn Si Ni Fe0.04 1.24 0.29 0.37 Bal




PACKAGING DATA

WIRE SIZE (mm)


1.2 15kg spool S283212-0291.6 15kg spool S283219-029


1G2G 3G

4G 1F2F

4F

52CONTENTS

SUMMARy

• Low Diffusible Hydrogen• Exceeds 27J CVN @ -40℃• Outstanding Weldability in all Positions• Actual Certification to AWS A5.01 Lot Class: T3

CLASSIFICATION

• AS/NZS ISO 17632-B - T494T1-1CA-UH5• 1.2mm, AWS E71T-1C, E71T-12CJ H4• 1.6mm, AWS E71T-1C, E71T-12CJ H8


Formulated to provide extremely low hydrogen levels. This outstanding all positional wire produces a high quality X-ray clear weld deposit with high impact values at low temperature. Every batch of the TM-71HYD is actual tested to certify the quoted mechanical property, and the vacuum sealed packaging further ensures the product integrity upon delivery.

Applications include ship building and repair, earth moving equipment, structures, pressure vessel and storage vessels.

OPERATIONAL DATA

WIRE SIZE (mm)



1.2 100-350 22-341.6 200-350 24-34


TM- 71HYD

53CONTENTS

SHIPPING APPROVALSMIL-71T-1-HYD


C Mn Si S P Ni Fe0.05 1.17 0.25 0.014 0.12 0.5 Bal


Gas Type 100% CO₂Yield Stress 533 MPaTensile Stress 585 MPaElongation 26.6%CVN Impact Values 150J @ -18ºC

137J @ -40ºCAged 48 hours @ 104ºC


PACKAGING DATA

WIRE SIZE (mm)


1.2 15kg spool S245112-K531.6 15kg spool S245019-K53


1G2G 3G

4G 1F2F

4F

54CONTENTS

SUMMARy

• Fast-Freezing Slag• Low Spatter• Excellent Arc Characteristics• High Impact Strengths at Low Temperatures

CLASSIFICATION

• AS/NZS ISO 17632-B - T555T1-1C/MA-2Ni-UH5• AWS A5.29: E81T1-Ni2C/MJ H8


Offers excellent arc stability and low spatter using either CO₂ or Ar/CO₂ mixtures with up to 80% Argon. These weldability features, combined with low diffusible hydrogen levels and good impact values makes the wire a good choice for single and multiple pass welding in all positions.

Applications include ship building, offshore drilling rigs, HSLA steels and weathering steels with no colour match requirement..

OPERATIONAL DATA

WIRE SIZE (mm)



1.2 100-350 22.34


TM-811N2

55CONTENTS

SHIPPING APPROVALSABS 3YSA; DNV Y40MS; LR 3Ys


Shielding Gas C Mn Si P S Ni100% CO₂ 0.04 1.02 0.29 0.010 0.007 2.09

75% Ar/25% CO₂ 0.05 1.26 0.44 0.010 0.007 2.07


Gas Type 100% CO₂ 75% Ar/25% CO₂

Yield Stress 535 MPa 579 MPaTensile Stress 600 MPa 662 MPaElongation 27.5% 26%CVN Impact Values 126J @ -40˚C

95J @ -51˚C104J @ -40˚C 71J @ -51˚C


PACKAGING DATA

WIRE SIZE (mm)


1.2 15kg spool S283712-K29


1G2G 3G

4G 1F2F

4F

56CONTENTS

SUMMARy

• Self Shielded or “Gasless” Flux Cored Joining Wires• For Fast Downhand Fillet and Butt Welding Applications• Excellent Bead Appearance/Low Spatter Levels• Crack Resistant Weld Deposits/Tolerant to Poor Joint Fit-up

CLASSIFICATION

• AS/NZS ISO 17632-B - T49ZT4-0NA-H15• AWS A5.20: E70T-4


Fabshield 4 is an outstanding, high deposition rate, (up to 12.7kg/hr using 2.4mm size wire) self-shielded or “gasless” flux cored wire for downhand single or multi-pass welding applications.It is specifically designed to de-sulphurise the weld deposit and thereby resist cracking. Fabshield 4 is particularly suited to the fast fillet welding of mild and medium strength steels.

Typical applications include the welding of structural members and machinery. Due to its self shielding arc, Fabshield 4 is ideal for “on site” field construction and repair applications.

OPERATIONAL DATA

WIRE SIZE (mm)



2.4 250-500 28-343.0 450-680 28-37

Welding Current DC - *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.

FABSHIELD 4

57CONTENTS


C Mn Si P S AI Fe0.27 0.73 0.30 0.11 0.005 1.42 Bal


Yield Stress 432 MPaTensile Stress 652 MPaElongation 25%CVN Impact Values Not Required

PACKAGING DATA

WIRE SIZE (mm)


2.4 22.7kg spool S224529-0143.0 22.7kg spool S224541-014

WIRES - FLUX CORED SELF SHIELDED WIRES

1G1F

2F

58CONTENTS

SUMMARy

• Self Shielded or “Gasless” Flux Cored Joining Wires• All Positional Welding Capabilities• Suitable for Single-Pass Applications only• Ideal for Mild and Galvanized Steels

CLASSIFICATION

• AS/NZS ISO 17632-B - T49ZTG-1SNA• AWS A5.20: E70T-GS


Fabshield 23 is a general-purpose self-shielded tubular wire that is designed for welding thin gauge mild or galvanized steel. Suitable for single-pass applications, especially for fillet lap welds, you will get outstanding welding performance as Fabshield 23 produces a smooth spray arc type of transfer with goods wetting action.

Great for welding outdoors in draughty conditions, this all-positional wire also provides very low splatter levels, resulting in a weld bead that is excellent in appearance. Perfect for on site applications such as welding mild steel/galvanized gates, fences, frames, sheds, prefab building fabrications, ornamental ironwork, general fabrication, etc.

OPERATIONAL DATA

WIRE SIZE (mm)



TyPICAL STICKOUT

(mm)0.8 25-125 14-16 120.9 55-120 17-20 12


FABSHIELD 23

59CONTENTS



C Mn Si S P AI Fe0.18 0.65 0.40 0.01 0.01 1.30 Bal


Tensile Stress 572 MPa

NOTE: Yield Stress and impact values not applicable.

PACKAGING DATA

WIRE SIZE (mm)


0.8 4.5kg spool S222306-0220.9 4.5kg spool S222308-0220.9 15kg spool S222308-029

1G2G 3G

4G 1F2F

4F

60CONTENTS

SUMMARy

• Self Shielded or “Gasless” Flux Cored Joining Wires• All Positional Welding Capabilities• Suitable For Single Pass/Multi-pass Applications • Suitable for Mild/Galvanised Steels

CLASSIFICATION

• AS/NZS ISO 17632-B - T49ZT11-1NA-H15• AWS A5.20: E71T-11


Fabshield 21B is a general purpose self-shielded tubular wire that is designed for single and multi-pass welding of thin gauge to 20mm thick mild or galvanized steels. Great for welding fillet or lap welds, you will find that this all-position wire has high operator appeal, producing a smooth spray-like transfer with low spatter levels, excellent weld appearance and easy to remove slag.

Perfect for on-site applications such as the welding of machine parts, galvanized steels tanks, gates, frames, sheds, prefab construction, light structures, general fabrication etc.

OPERATIONAL DATAWelding parameters shown below are for DC Electrode negative only.

WIRE SIZE (mm)



TyPICAL STICKOUT

(mm)0.9 55-120 17-20 121.2 130-160 15-18 121.6 150-250 18-20 192.0 200-300 16-23 19


FABSHIELD 21B

61CONTENTS



C Mn Si S P AI Fe0.28 0.34 0.15 0.008 0.003 1.04 Bal


Yield Stress 427 MPaTensile Stress 627 MPaElongation 22%CVN Impact Values Not Required

PACKAGING DATA

WIRE SIZE (mm)


0.9 4.5kg spool S222108-0221.2 4.5kg spool S222112-0221.2 15kg spool S222112-0291.6 15kg spool S222119-0292.0 15kg spool S222125-029

1G2G 3G

4G 1F2F

62CONTENTS

SUMMARy

• Welds Out of Position at High Currents• Low Hydrogen Weld Deposit • Excellent Slag Removal• No Shielding Gas Required• High Impact Strength at Low Temperatures• Excellent Mechanical Properties Under a Wide Range of Heat Input

CLASSIFICATION

• AS/NZS ISO 17632-B - T494T8-1NP-H10• AWS A5.20: E71T-8JD H8


Low hydrogen T-8 self-shielded, all positional flux cored wire, producing a stable arc and flat bead profile, especially suited for vertical-up welds at high currents with excellent mechanical properties and a tensile strength of 490 MPa. Capable of depositing X-ray quality welds, making it highly suitable for critical welding applications requiring a high degree of crack resistance due to its low diffusible hydrogen levels, less than 6.7ml per 100g of weld metal deposited. XLR-8 has been designed for single and multi-pass welding applications with improved productivity in out-of-position welding, offering high impact strength of (42J) at sub zero temperatures to -40˚C.Specifically designed for increased productivity and high deposition rates on challenging structural steel erection, heavy equipment repair, mining equipment, bucket repairs, storage tanks, pipe spooling, ship construction and site work applications.

OPERATIONAL DATA

WIRE SIZE (mm)



1.6 180-300 18-251.8 170-330 18-252.0 200-360 18-26

Recommended electrical stick out is 25-35mm. Welding Current DC - *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.

HOBART XLR-8

63CONTENTS

WIRES - FLUX CORED SELF SHIELDED WIRES

SHIPPING APPROVALSABS 3YSA; AWS D1.8 Conformance


C Mn Si P S AI Fe0.19 0.51 0.17 0.009 0.006 1.51 Bal


Yield Stress 470 MPaTensile Stress 580 MPaElongation 25%CVN Impact Values 42J @ -40˚CDiffusible Hydrogen 6.7ml/100g of weld deposited


PACKAGING DATA

WIRE SIZE (mm)


1.6 15kg spool S225719-0531.8 15kg spool S225724-0532.0 15kg spool S225725-0532.0 22.7kg coil S225725-014

1G2G 3G

4G 1F2F

4F

65

HARDFACING ELECTRODES Abrasocord 43 ........................................................ 66-67Abrasocord 350....................................................... 68-69Abrasocord 700....................................................... 70-71Tubecord D - 2355 .................................................. 72-73Tubecord E - 2460 .................................................. 74-75

HARDFACING SOLID MIG WIRES Austmig TD-600 ..................................................... 76-77

HARDFACING SELF SHIELDED FLUX CORED WIRESMckay Tube-Alloy 240-0.......................................... 78-79Mckay Tube-Alloy 258-0.......................................... 80-81Mckay Tube-Alloy A43-0 ......................................... 82-83

HARDFACING GAS SHIELDED FLUX CORED WIRESMckay Vertiwear-600 .............................................. 84-85

HARDFACING PRODUCTSCONTENTS

CONTENTS

66CONTENTS

SUMMARy

• Tough, Wear Resistant Complex Carbide Type Deposit• For Hard Surfacing Components Subjected to Extreme Abrasion and Moderate to Heavy Impact• Similar Deposit Type to Tubecord E-2460

IDENTIFICATIONCoating - Black Tip - Plain Imprint - WIA AC 43

CLASSIFICATION

• AS/NZS 2576: 2465-A4

DESCRIPTION AND APPLICATION Abrasocord 43 is a heavy coated, hard surfacing electrode depositing extremely hard, abrasion resistant Chromium/ Niobium carbides in an austenitic matrix. It is ideal for hard surfacing applications where resistance to extreme abrasion (in particular sliding abrasion) and moderate to heavy impact are required. Due to the nodular shape of the complex carbides, Abrasocord 43 deposits are capable of withstanding heavier impact levels than standard chromium carbide grades. Typical applications include bucket teeth/lips, grizzlies, press screws, crusher hammers and ripper teeth to name but a few.

Abrasocord 43 deposits are non-machineable, grindable, prone to fine relief checking and should be restricted to 3 layers high. While two layers of Abrasocord 43 may be required for maximum wear resistance, this complex carbide alloy has lower dilution sensitivity than straight chromium carbide deposits.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




3.2 380 115-140 194.0 380 140-185 225.0 450 190-255 24


ABRASOCORD 43

67CONTENTS

HARDFACING PRODUCTS - HARDFACING ELECTRODES


C Mn Cr Nb Fe5.0 0.7 22.0 7.0 Bal


Single Layer onto Mild Steel Typical Hardness 60-65 HRcMulti-Layer Typical Hardness 64-69 HRc

Single layer deposit hardness may vary depending on base metal type and degree of dilution

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG

PART NUMBER

Packet Carton3.2 5 15 16 AC43324.0 5 15 11 AC43405.0 5 15 6 AC4350

1G2G

68CONTENTS

SUMMARy

• Tough, Machineable, Wear Resistant Martensitic Steel Deposit• For Hard Surfacing Steels Subjected to Metal-to-Metal Wear Under Compressive Loading

IDENTIFICATIONCoating - Brown Tip - Yellow Imprint - WIA AC 350

CLASSIFICATION

• AS/NZS 2576: 1435-A4

DESCRIPTION AND APPLICATION Abrasocord 350 is a smooth running, AC/DC electrode which deposits a tough wear resistant low carbon martensitic steel alloy. It is suitable for the heavy build-up and surfacing of steel components subjected to metal-to-metal wear and compressive loading such as, track components, gears and shafts, etc.

Abrasocord 350 deposits an air hardening C-Mn-Cr steel alloy which is machineable and can be readily hot forged. It offers high compressive strength and excellent resistance to impact for all types of metal-to-metal wear.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




3.2 380 100-140 194.0 380 150-200 225.0 450 190-240 24


ABRASOCORD 350

69CONTENTS

HARDFACING PRODUCTS - HARDFACING ELECTRODES


C Mn Si Cr Fe0.2 0.4 0.3 2.8 Bal




PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG

PART NUMBER

Packet Carton3.2 5 15 24 HF350324.0 5 15 16 HF350405.0 5 15 9 HF35050

1G2G

70CONTENTS

SUMMARy

• Wear Resistant, High Carbon Martensitic Steel Deposit • For a Wide Range of General Hard Surfacing Applications, Such as Points, Tynes, Lips, Blades and Augers, ect.

IDENTIFICATIONCoating - Grey Tip - Orange Imprint - WIA AC 700

CLASSIFICATION

• AS/NZS 2576: 1855-A4

DESCRIPTION AND APPLICATION Abrasocord 700 is a smooth running, AC/DC electrode which deposits an air hardening martensitic Cr-Mo-V steel alloy. Abrasocord 700 deposits one of the hardest steel alloys available and is free from relief checks. Applications include the surfacing of post hole augers, agricultural points, shares and tynes, grader and cultivator blades and other components subject to fatigue or flexing during service.

Abrasocord 700 deposits an air hardening steel alloy which can be readily hot forged and offers good resistance to all types of abrasion under low to moderate impact conditions.

In the “as welded” condition Abrasocord 700 weld metal cannot be machined without prior heat treatment.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




3.2 380 90-130 194.0 380 140-180 225.0 450 160-240 24


ABRASOCORD 700

71CONTENTS


C Mn Si Cr Mo V Fe0.7 0.3 0.5 8.5 0.3 0.5 Bal




PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG

PART NUMBER

Packet Carton3.2 5 15 27 HF700324.0 5 15 18 HF700405.0 5 15 10 HF70050

HARDFACING PRODUCTS - HARDFACING ELECTRODES1G

2G

72CONTENTS

SUMMARy

• High Chrome Carbide• Improved Abrasion Resistance• Welds can be Shaped by Grinding

IDENTIFICATIONCoating - Black Tip - Light Green

CLASSIFICATION

• AS/NZS 2576: 2355-A1* * Nearest Classification

DESCRIPTION

Tubecord D - 2355 deposits are high in carbon and chromium resulting in improved abrasion resistance. Tubecord D - 2355 is ideal for hard surfacing components subjected to heavy abrasion and moderate impact loading.

No preheat is required for direct application onto grey cast iron, low carbon or manganese steels.

Applications include the hard surfacing of dredge bucket lips, shovel buckets, scraper and dozer sides, cone crushers and mill hammers, etc. Deposits are grindable, subject to relief checking and may be multi-layered up to 3 layers. Features include, controlled fume levels, minimal spatter, easy bead deposition and low penetration.

Tubecord D - 2355 is suitable for AC or DC applications.

OPERATIONAL DATA

ELECTRODE SIZE (mm)




6.3 450 85-135 25

*Voltage is determined by arc current and electrode arc length. Arc voltage shown is typical and is only to be used as a guide.

TUBECORD D - 2355

73CONTENTS


C Mn Cr Fe5.5 1.5 40.0 Bal


Single Layer Typical Hardness 55-60 HRc

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG) PART

NUMBERPacket Carton

6.3 5 15 TUBD60

APPLICATIONS

• Dredge Bucket Lips• Shovel Buckets• Cone Crusher

HARDFACING PRODUCTS - HARDFACING ELECTRODES1G

2G 3G4G

74CONTENTS

SUMMARy

• All Tubecord Electrodes are 450mm Long.• 6.3mm Tubecord E - 2460 is also Suitable for Vertical Up and Overhead Welding Positions.• All Tubecore Electrodes are Coated with a Moisture Resistant, Non Alloying, Black Flux Coating, Resulting in Infinate Storage life!

IDENTIFICATIONCoating - Black Tip - Blue

CLASSIFICATION

• AS/NZS 2576: 2460-A1

DESCRIPTION

Tubecord E - 2460 deposits contain carbon, chromium, niobium and molybdenum alloys for good resistance to both impact and abrasion:

Tubecord E - 2460 produces a similar complex carbide iron deposit to the popular Abrasocord 43 electrode.No preheat is required for direct application onto grey cast iron, low carbon or manganese steels.Applications include the hard surfacing of grizzly bars, bucket teeth, crusher hammers, rail ballast tampers, dredger and ripper teeth, etc. Deposits are grindable, subject to relief checking and should be restricted to 3 layers high.Features include, controlled fume levels, minimal spatter, easy bead deposition and low penetration.Tubecord E - 2460 is suitable for AC or DC applications.

TUBECORD E - 2460

75CONTENTS

OPERATIONAL DATA

ELECTRODE SIZE (mm)



6.3 90-130 258.0 135-185 29

*Voltage is determined by arc current and electrode arc length. Arc voltage shown is typical and is only to be used as a guide. **6.3mm only


C Cr Mo Nb V Mn Si Fe4.0 26.5 0.9 7.9 0.4 0.8 1.5 Bal


Single Layer Typical Hardness 58-61 HRc

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG) PART

NUMBERPacket Carton

6.3 5 15 TUBE608.0 5 15 TUBE80

TyPICAL APPLICATIONS

Grily Bars Bucket Teeth Crusher Hammers

HARDFACING PRODUCTS - HARDFACING ELECTRODES2G3G

4G 1F** **

76CONTENTS

SUMMARy • Copper Coated, Chromium Alloy Gas Metal Arc (MIG) Welding Wire• For Hard Surfacing Components Subjected to Severe Abrasion and Heavy Impact CLASSIFICATION

• AS/NZS 2576: 1855-B6

DESCRIPTION

Austmig TD - 600 is a copper coated, chromium alloy welding wire depositing weld metal with a hardness of 55-60 HRc which has a high resistance against severe abrasion and impact.

The deposit is non-machineable but can be shaped by grinding

Typical applications include: excavator blades, bucket lips, bucket teeth, screw conveyors, crushing mills, shear blades.

OPERATIONAL DATA

WIRE SIZE (mm)



1.2 120-340 18-32


AUSTMIG TD - 600

77CONTENTS


C Si Mn P S Cr Fe0.45 3.00 0.40 0.025 0.020 9.00 Bal


As Welded - Two Layers 55-60 HRcRecommended Shielding Gases:Argon/18 - 25% CO₂, Ar/CO₂ or 100% CO₂

APPLICATIONS • Excavator Blades • Bucket Teeth• Screw Conveyors • Crushing Mills• Sheer Blades

PACKAGING DATA

WIRE SIZE (mm)


1.2 15kg MTD60012S

HARDFACING PRODUCTS - HARDFACING SOLID MIG WIRES1G

2G 3G4G

78CONTENTS

SUMMARy

• Self Shielded Hard Surfacing Flux Cored Wire• General Purpose Alloy with Good Abrasion and Impact Resistance• Chromium Carbide - Alloy Steel• Non Machinable, Difficult to Grind

CLASSIFICATION

• AS/NZS 2576: 2155-B7

DESCRIPTION

McKAY Tube-Alloy 240-O is a self shielded, flux cored hard surfacing wire that deposits a chromium carbide alloy steel. It is an “excellent general purpose alloy due to a combination of good abrasion and impact resistance.

McKAY Tube-Alloy 240-O is designed for overlaying carbon, low alloy or austenitic manganese base metals. The smooth globular type arc transfer gives minimal spatter and the minimum slag cover allows the wire to operate well without de-slagging between weld passes in automatic applications.

Some relief check cracking will occur however it is not detrimental to the wear properties of the deposit and provides some degree of stress relief for the weld metal.

OPERATIONAL DATA

The recommended operating parameters are for DC positive with an electrode stick out of 16-25mm for the 1.2mm size, 25-35mm for 1.6mm. Out-of-position welding is limited to a horizontal shelf technique.

WIRE SIZE (mm)



1.2 120-275 19-271.6 275-400 24-29


McKAY TUBE-ALLOY 240-O

79CONTENTS


C Mn Si Cr Fe3.20 1.80 1.90 15.50 Bal

TyPICAL MECHANICAL PROPERTIES (AS WELDED):

Number of Layers

As-deposited on

1020 Steel Mn Steel

Hardness1 40 Rc 35 Rc2 48 Rc 42 Rc

3-5 52 Rc 50 Rc

Abrasion Resistance: Very GoodImpact Resistance: FairNon-Machinable: Grinding is difficultCannot be Flame CutDeposit will Relief check CracksThickness should be Limited to Five Layers Maximum

APPLICATIONS

• Ammonia Knives • Hammer Mill Hammers• Augers • Impactor Crusher Bars• Bucket Teeth and Lips • Manganese Pump Shells• Bulldozer End Bits & Blades • Mill Guides• Conveyer Screws • Muller Tires• Crusher Jaws and Cones • Pipeline Ball Joints• Crusher Rolls • Pulverizer Hammers• Cultivator Chisels & Sweeps • Scraper Blades• Dragline Buckets • Screw Conveyors• Sheepsfoot Tampers • Sizing Screens• Dredge Pump Impellers and Side Plates

PACKAGING DATA

WIRE SIZE (mm)

PACK SIZE (KG) PART NUMBER

1.2 11.3 S604012-0291.6 11.3 S604019-029

HARDFACING PRODUCTS - HARDFACING SELF SHIELDED FLUX CORED WIRES1G

80CONTENTS

SUMMARy

• Self Shielded or Open Arc Hard Surfacing Flux Cored Wire• Hard Wearing Martensitic Steel Alloy Deposit• Tough, Hard Tool Steel Weld Metal Composition• Good Impact and Abrasion Resistance• Excellent Resistance to Metal-to-Metal Wear• Weld Deposits Grindable Only

CLASSIFICATION

• AS/NZS 2576: 1550-B7* *Nearest Classification

DESCRIPTION

McKAY Tubealloy 258-O is a fabricated type, open arc tubular flux cored wire depositing a Cr-Mo-W Martensitic steel alloy. It is designed for surfacing mild and low alloy steel components subject to moderate abrasive wear and impact under high compressive stresses and/or at temperatures up to 530°C.

Crack free deposits can be obtained by controlled heat input or the use of preheat.

OPERATIONAL DATA

Welding parameters shown below are for DC electrode positive.An electrode stick out length of 12-25mm is recommended for 1.2mm size, 25-35mm for 1.6mm.

WIRE SIZE (mm)



1.2 120-230 24-271.6 225-350 30-34*


McKAY TUBE-ALLOY 258-O

81CONTENTS


C Mn Si Cr Mo W Fe0.45 1.40 0.80 6.00 1.50 1.50 Bal


Number of Layers

As-deposited on

1020 Steel Mn Steel

Hardness1 49 Rc 51 Rc2 53 Rc 54 Rc3 57 Rc 57 Rc

Abrasion Resistance: GoodImpact Resistance: GoodNon-Machinable: Grinding onlyFlame Cutting: DifficultDeposit will Relief Check CracksThickness should be Limited to Five Layers Maximum

APPLICATIONS

• Coupling Boxes • Dragline Chains • Kiln Trunnions • Mill Guides• Spindles • Wobbler Ends PACKAGING DATA

WIRE SIZE (mm)


1.2 11.3 S605812-0291.6 11.3 S605819-029


82CONTENTS

SUMMARy

• Self Shielded or Open Arc Hard Surfacing • Flux Cored Wire• Niobium-Chromium Carbide Iron Weld Deposit• Resistant to Severe High and Low Stress Abrasion• Low to Moderate Impact Loading• Weld deposits are to be Shaped by Grinding Only

CLASSIFICATION

• AS/NZS 2576: 2460-B7

DESCRIPTION

McKAY Tube-Alloy A43-O is a fabricated type, self shielding tubular flux cored wire depositing a high chromium-niobium surfacing alloy which resists severe high and low stress abrasion and low to moderate impact.

The weld deposit will check crack readily and out performs straight C-Cr hard surfacing alloys. It can also be used where high temperature (650°C) wear resistance is required. Spatter level is low, slag cover is minimal and is easily removed.

OPERATIONAL DATA

The recommended operating parameters are for DC positive with an electrode stick out length of 20-35mm.

WIRE SIZE (mm)



1.6 300-350 30-34

Welding Current DC + Other wire sizes and spool weights are available on indent only. *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.

McKAY TUBE-ALLOY A43-O

83CONTENTS


C Mn Si Cr Nb Fe5.50 0.20 1.0 22.00 6.50 Bal


Number of Layers

As-deposited on

1020 Steel Mn Steel

Hardness 1 56-60 Rc 45-50 Rc2-3 60-64 Rc 54-58 Rc

Abrasion Resistance: ExcellentImpact Resistance: PoorNon-Machinable: Grinding onlyFlame Cutting: DifficultDeposit will Relief Check CracksThickness should be Limited to Five Layers Maximum

APPLICATIONS• Augers • Bucket Lips and Teeth• Coal Feeder Screws • Coal Pulverizer Rolls & Tables• Coke Chutes • Coke Pusher Shoes • Conveyer Screws • Fan Blades• Grizzly Bars and Fingers • Pipeline Ball Joints• Muller Tires • Paving Agitator Screws• Pipeline Ball Joints • Pub Mill Paddles• Scraper Blades • Sheepsfoot Tampers• Sizing Screws • Dredge Cutter Heads & Teeth• Dredge Pump Inlet Nozzle and Side Plates PACKAGING DATA

WIRE SIZE (mm)


1.6 11.3 S607719-029


84CONTENTS

SUMMARy

• Suites Out-of Position Applications• Multi-Purpose Martensitic Steel• Moderate Abrasive Wear and Medium to High Impact• Weld Deposits - Machineable

CLASSIFICATION

• AS/NZS 2576: 1855-B5* *Nearest Classification

DESCRIPTION

McKAY Vertiwear 600 is a gas shielded, all position, hard surfacing fluxcored wire designed to operate in a smooth semi-spray arc transfer. The weld metal control is superior to competitive gas shielded hard surfacing wires allowing higher deposition and greater productivity in out-of-position applications. Excellent operator appeal in all positions.

McKAY Vertiwear 600 deposits a multi-purpose martensitic steel alloy and can be used to hard surface mild and low alloy steel components subject to moderate abrasion coupled with medium to high impact. It also exhibits excellent compressive strength and metal-to-metal wear resistance.

The recommended shielding gas for Vertiwear 600 is 75% Argon - 25% CO₂.

OPERATIONAL DATA

The recommended operating parameters are for DC positive with an electrode stick out length of 20-35mm.

WIRE SIZE (mm)



1.2 165-185 24-28


McKAY VERTIWEAR-600

85CONTENTS


C Mn Si Cr Mo Fe0.40 0.75 0.60 6.50 1.00 Bal

TyPICAL MECHANICAL PROPERTIES (AS WELDED)

Number of Layers

As-deposited on

1020 Steel

Hardness1 52 Rc2 56 Rc

3-8 57 RcHardness as-

deposited Time at Temp Hardness after Tempering535C° 620C°

55 10 Hours 54 4620 Hours 49 4080 Hours 47 40

Abrasion Resistance: GoodImpact Resistance: GoodMachinability GoodFlame Cutting: DifficultMagnetic

APPLICATIONS

• Coupling Boxes • Dragline Chain• Dredge Ladder Rolls • Kiln Trunnions• Mill Guides • Sliding Metal Parts• Wobber Ends PACKAGING DATA

WIRE SIZE (mm)


1.2 15 S607112-029

HARDFACING PRODUCTS - HARDFACING GAS SHIELDED FLUX CORED WIRES1G

2G 3G4G

The following pages cover a range of technical information and data tables pertaining to the field of welded fabrication and general engineering.

This section is designed to provide a ready reference guide for welding engineers, design costing personnel, workshop supervisors and welding operators, and to foster higher quality, higher productivity welding.

GLOSSARy .......................................................... 88-105

OXy-ACETyLENE FLAME ADJUSTMENT .........106-107

WELDING SyMBOLS .........................................108-115

ELECTRODE CLASSIFICATIONSManual Metal Arc Welding Electrodes ....................116-123Gas Metal Arc Welding Ferritic Steel Electrodes ...... 124-126Flux Cored Arc Welding Electrodes ....................... 127-129Manual Metal Arc and Gas Metal Arc Welding for Aluminium and Stainless Steel Electrodes .......... 130-131Repair and Hardfacing .......................................... 132-133Submerged Arc Welding Electrodes and Fluxes ... 134-135

WELD DEPOSITION AND COSTING DATAUsers Guide........................................................... 136-147Mass of Weld Metal in Joint ................................... 148-153Quantity of Consumables Required....................... 154-157Deposition Rates ................................................... 158-165Duty Cycles ........................................................... 166-167Electrode Consumption for Typical Butt Joints ...... 168-169

CONTENTS

TECHNICAL INFORMATION

CONTENTS

87

WELDABILITy GUIDE FOR STEELS .................170-193

COMMON WELD TROUBLES ...........................194-199

SI UNITS AND CONVERSION DATA ..................200-203Table 1. Conversion from Inches to Millimetres ..........................204Table 2. Travel and Wire Feed Speeds .......................................205Table 3 °C - °F Temperature Conversions.......................... 206-209Table 4. Comparison of Hardness Scales ...................................210Table 5. Stress and Energy Conversions ....................................211Table 6. Wire and Sheet Sizes ............................................ 212-213

SyMBOLS FOR ELEMENTS AND GEOMETRIC FORMULAE ........................................ 214

CONTENTS

TECHNICAL INFORMATION TECHNICAL INFORMATION

CONTENTS

88CONTENTS

The following is a selection of some of the more common welding terms and abbreviations in current Australian usage. Please refer to Australian Standard AS2812 (Welding, Brazing and Cutting of Metals - Glossary of Terms) for a more comprehensive list.AMPERAGE - The measurement of the amount of electricity flowing past a given point in a conductor per second. Current is another name for amperage.ANGLE OF BEVEL - The angle at which the edge of a joint is prepared for making a weld, refer to FIG 1. (A) - (F) for typical examplesARC BLOW - An uncontrolled deflection of a welding arc caused by an uneven distribution of magnetic field around the arc.ARC LENGTH - The distance from the end of the electrode to the parent material.ARC VOLTAGE - The voltage across the welding arc.ARC WELDING (AW) - Fusion welding in which heat for welding is obtained from an electric arc or arcs.ARC WELDING GUN - A device used in semi-automatic and automatic arc welding to transfer current, guide the consumable electrode and direct shielding gas when used.AS-WELDED - The condition of weld metal, welded joints or weldments after welding prior to any subsequent thermal or mechanical treatment.BACKING - A weld backing maybe incorporated in welded joint design to simplify the root pass. Backing of suitable material can be incorporated in the weldment, or alternativley removable temporary backing material can be used. e.g. ceramic tilesBACK-STEP WELDING - A welding technique wherein the increments of weld metal are deposited in a direction opposite to that of progression.BARE ELECTRODE - A filler metal electrode consisting of a single metal or alloy that has been produced into a wire, strip or bar form which has no flux coating or covering applied to it.

GLOSSARY

89CONTENTS

BASE (PARENT) METAL - The metal to be welded or joined other than the filler metal. BASIC ELECTRODE - A flux coated electrode in which the covering contains a high proportion of basic materials, such as limestone and flurospar etc.BRAZE WELDING (BW) - The joining of metals using similar joint designs as for fusion welding. However, the parent metal is not melted as in fusion welding. A non-ferrous alloy with a melting point above approx. 500°C and below that of the parent metal is normally used as the filler metal and is deposited without the aid of capillary action, as in brazing.BRAZING - A joining process in which, during heating, molten filler metal is made to flow by capillary action between a narrow joint preparation. In general, the melting point of the filler metal is above approx. 450°C, but is always below the melting temperature of the parent metal. A fluxing agent is usually used to promote the flow of filler metal along and around the joint.BRONZE WELDING - Term used to describe Braze Welding using a Copper rich filler metal.BUTTERING - A material preparation process in which one or two layers of weld metal are deposited on the surfaces to be joined. The buttering provides a suitable transition weld deposit for subsequent completion of the joint.BUTT WELD - A weld in which the weld lies substantially within the extension of the planes of the surfaces of one or more of the pads joined, see Fig 1 for typical examples.CDT - Controlled Droplet TransferCELLULOSE ELECTRODE - A flux coated electrode in which the covering contains at least 15 percent cellulose and up to 30 percent titania as rutile or titanium white.CO₂ WELDING - Gas Metal-Arc welding using CO₂ as the shielding gas, see preferred term - Gas Metal Arc Welding.CONSTANT VOLTAGE POWER SOURCE - An arc welding power source whose terminal voltage remains substantially constant between full load and no load conditions.

GLOSSARY

90CONTENTS

CONSUMABLES - Materials directly consumed in the making of a weld, including electrodes, flux heating and shielding gas and filler wire etc.CORED ELECTRODE - A consumable electrode having a core of flux and/or alloying ingredients. COVERED ELECTRODE - A filler metal electrode, used in arc welding, consisting of a metal core wire with a relatively thick covering of flux which provides protection for the molten metal from the atmosphere, improves the properties of the weld metal and stabilises the arc.CRATER - A depression left in the weld where the arc is broken.CONSUMABLE GUIDE WELDING - see Electroslag Welding.DEFECT - One or more discontinuities that cause non compliance of a weld.DEPTH OF FUSION - The distance from the fusion face to that point within the joint at which fusion ceases, see Fig 2.(a) and (b).DEPOSITION EFFICIENCy - (a) For manual metal arc welding electrodes, the ratio of the mass of deposited metal to the mass of the core wire consumed (excluding stubs); expressed as a percentage. (b) For continuous electrodes, the ratio of the mass of deposited metal to the mass of electrode consumed; expressed as a percentage. For 85% deposition efficiency means 85kg of weld metal was produced from 100kg of electrode metal.DEPOSITION RATE - The mass of metal deposited (excluding spatter) in a unit of time. DILUTION - The alteration of composition of the weld metal deposited from a filler metal or electrode due to mixing with the melted parent metal. It is expressed as a percentage of melted parent metal to the weld metal.DIP TRANSFER - see Short Circuiting Arc Transfer.DISCOUNTINUITy - a flaw in the weld which complies or may comply with the acceptance standard

GLOSSARY

91CONTENTS

DROOPING CHARACTERISTIC POWER SOURCE - An arc welding power source whose terminal voltage drops to a value appreciably below the open circuit voltage (O.C.V.) after the arc has been initiated.DUTy CyCLE - (a) Power Source Duty Cycle is the amount of time a welding machine can be used at a given amperage, generally expressed as a percentage of a 5 min. period, eg. 60% at 300amps means the machine can be used at 300 amps for 3 mins in every 5 mins(b) Operator Duty Cycle is the ratio of welding or cutting time to the total work time expressed as a percentage.ELECTRODE - A component of the welding circuit through which current is immediately conducted to the arc, molten slag, or base metal.(a) Non-consumable electrode - an electrode which does not provide metal eg. a Tungsten electrode.(b) Consumable electrode - an electrode which provides filler metal. ELECTRODE NEGATIVE - Arc welding using direct current in which the electrode is connected to the negative pole of the welding power source. Also referred to as, “straight polarity”. ELECTRODE POSITIVE - Arc welding using direct current in which the electrode is connected to the positive pole of the welding power source. Also referred to as, “reverse polarity”. ELECTRODE STICKOUT - In automatic and semi-automatic arc welding, the length of the electrode projecting beyond the region of current pick-up / contact tip during welding.ELECTROSLAG WELDING (ESW) - A continuous wire electrode, vertical fusion welding process in which the molten pool of metal and covering slag are confined to the joint by copper shoes. The wire feeding nozzle progresses automatically up the joint or in the case of the consumable guide variant, is melted as the weld level rises. The heat for fusion is generated by the electrical resistance of the slag bath.

GLOSSARY

92CONTENTS

FILLET WELD - A weld or series of welds of approximately triangular cross-section joining two surfaces approximately at right angles to each other in a lap joint, tee joint or corner joint. Note. The bulk of the weld metal is outside the planes made by the surfaces of the base metals, see Fig 2, (b) and (d) for typical examples.FLAT POSITION - The position in which welding is performed from the upper side of the joint and the weld face is approximately horizontal (Sometimes called downhand welding), see Fig 3, 1F and 1G positions.FLUID SLAG - A slag which flows freely during whilst molten during welding.FLUX - A substantially non-metallic material used during welding, brazing, braze welding or soldering to clean the surfaces of the joint chemically, to prevent atmospheric oxidation and to reduce impurities or float them to the surface in the form of a slag.FRIABLE SLAG - A slag that crumbles easily to aid removal.FUSION FACE - The portion of a surface, or an edge, which is to be fused (melted) in making a fusion weld, see Fig 2(a) and (b).FUSION ZONE - The area of parent metal melted as determined on the cross section of a weld, see Fig 2(a) and (b).FLUX CORED ARC WELDING (FCAW) - Arc welding using a continuous, consumable, flux cored wire (electrode) which provides the filler metal. Gas shielding, alloying addlions and slag coverage may be provided by the flux contained within the electrode. Gas shielding may or may not be required. FUSION WELDING - Welding in which similar parent metals are fused (melted) together with or without the use of a filler metal of similar composition.GAS METAL ARC WELDING (GMAW) - The preferred terminology for the process of arc welding using a continuous, consumable, solid wire (electrode) which provides the filler metal and in which shielding is obtained entirely from an externally supplied gas or gas mixture. The process is similar to and also known as MIG, MAG AND CO₂ welding.

GLOSSARY

93CONTENTS

GAS PORE - A weld cavity caused by entrapped gas.GAS TUNGSTEN ARC WELDING (GTAW) - The preferred terminology for the process of arc welding, with or without added filler metal, using a non-consumable electrode of pure or activated tungsten, shielded by an externally supplied gas or gas mixture. The process is similar to and also known as TIG, Heliarc or Argonarc welding.GAS WELDING - Welding in which the heat for welding is produced by the combustion of a gas mixture. Filler metal may or may not be used. The most popular gas combination is oxygen / acetylene however oxygen / LP gas, air / acetylene or air / LP gas are mixtures which may be used, depending on the joining process adopted.GLOBULAR TRANSFER - Metal transfer which takes place as globules of diameter substantially larger than that of the consumable electrode from which they are transferred.HARD SURFACING - Surfacing with a wear resistant material. The preferred term to hardfacing.HEAT AFFECTED ZONE (HAZ) - The portion of parent metal which has not been fused but has nevertheless been metallurgically affected by the heat of welding, brazing or cutting, Refer to Fig 2(a) and (b) for clarification.HERTZ - Hertz is often referred to as “cycles per second”. In Australia, the frequency or directional change of alternating current is usually 50 hertz.HIGH FREQUENCy - Covers the entire frequency spectrum above 50,000 Hz. Used in GTA welding for arc ignition and stabilization.HORIZONTAL POSITION - The position of welding wherein the line of the weld root is approximately horizontal, see Fig 3, 2F and 2G positions.

GLOSSARY

94CONTENTS

HyDROGEN CONTROLLED ELECTRODE - An electrode depositing weld metal containing not more than a specified quantify of diffusible hydrogen in the deposited weld metal when assessed in accordance with the appropriate standard. The category of such electrodes may be sub-divided into classifications of medium hydrogen, low hydrogen and “very low” hydrogen, each having successively lower allowable levels of diffusible hydrogen.INCLUDED ANGLE - The angle between the planes of the fusion faces of the parts to be welded, see Fig 1 for typical examples.INDUCTANCE - Inductance comes from an inductor (stabilizer). The inductor slows down the changes in current, changing the machine’s rate of response and number of short circuits per second. An inductor helps limit the amount of spatter, and generally improves the wetting out of the weld puddle.INTERMITTENT WELD - A series of welds at specified intervals along a joint, see Fig 7 (c).INTERRUN TEMPERATURE - In a multi run weld, the temperature of the weld and adjacent parent metal immediately prior to the deposition of the next weld run. Also called INTERPASS TEMPERATURE.INVERTER - Power source which increases the frequency of the incoming primary power, thus providing for a smaller size machine and improved electrical characteristics for welding, such as faster response time and more control for pulse welding.IRON POWDER ELECTRODE - A flux coated electrode in which the covering contains a high percentage of iron in the form of powder to improve deposition efficiency typically 110-130%.JOINT PENETRATION - The minimum depth of fusion into a joint, excluding reinforcement.JOINT PREPARATION - Details of the edge preparations and set up of workpieces for welding. Refer to Fig 1, (A)-(F) for examples. Ksi - (kips) kilo (1000) pounds per square inch.

GLOSSARY

95CONTENTS

LAND - The straight portion of a fusion face between the edge of the root face and: (a) the sloping face of a bevel preparation, or (b) the curved part of a J edge preparation, see Fig 1, (F).LANDING - See root faceLAP JOINT - A joint between two overlapping members approximately in the same plane, see Fig 9, (C).LEG LENGTH - The distance between the root and the toe of a fillet weld. Leg length is the dimension used to size a fillet weld to AS1101.3. Leg length is known as the ‘z’ dimension in ISO 2553, see Fig 2(d) and weld symbols section.LOW HyDROGEN ELECTRODE - see Hydrogen Controlled Electrode.MAG WELDING - “Metal Active Gas”, see Gas Metal Arc Welding.MANUAL METAL ARC WELDING (MMAW) - Arc welding with a flux covered electrode manually applied by the welder without automatic or semi-automatic replacement of the electrode. Shielding is provided only by decomposition of the electrode covering. In American terminology, known as, Shielded Metal Arc Welding (SMAW).MECHANISED WELDING - Welding with equipment which performs the welding operation under preset conditions under the constant control of a welding operator.MIG WELDING - “Metal Inert Gas”, see Gas Metal Arc Welding.MITRE FILLET WELD - A fillet weld of equal leg lengths in which the face of the weld is essentially flat.MULTIPLE ARC WELDING - Welding wherein a single process runs with more than one electrode from a single power source eg. twin arc, or a single process operates with more than one electrode from separate power sources and separate nozzles eg. tandem arc. Essentially a single weld pool is maintained throughout.

GLOSSARY

96CONTENTS

NARROW GAP WELDING - A modification of conventional automatic arc Welding of thick sections where square preparations or ‘V’ preparations with small included angles and narrow gaps are used.NON-TRANSFERRED ARC - A plasma arc struck between the tungsten electrode and the torch nozzle.OPEN-CIRCUIT VOLTAGE (OCV) - The voltage between the live output terminals of a welding power source when no current is flowing/no arc.OVERHEAD POSITION - The position in which welding is performed from the underside of the joint, see Fig 3, 4F and 4G positions.OVERLAP - Weld metal at the toe of a weld which covers the parent metal surface but is not fused to it.OXyGEN-ACETyLENE WELDING - Gas welding in which the heat for welding is produced by the combustion of an oxygen-acetylene gas mixture.PARTIAL PENETRATION - A butt weld where, by design, fusion does not extend the full depth of the joint.PASS - see Weld Run.PEENING - The mechanical working of weld metal by means of hammer blows or bombardment with shot or pellets to reduce residual stress or distortion.PENETRATION BEAD - Weld metal protruding through the root of a fusion weld made from one side only.PLASMA ARC WELDING (PAW) - A process in which the electric arc generates a hot ionised gas stream that both shields and transfers heat to the joint.POROSITy - Clustered/grouped gas pores or voids in weld metal.POROUS SLAG - A slag that has a honeycomb structure.POSITIONER - A mechanical device manually or power operated to hold, tilt or rotate the work to the desired position for welding.

GLOSSARY

97CONTENTS

POST WELD HEAT TREATMENT (PWHT) - Any thermal treatment carried out after welding.PREHEAT - The application of heat to the parent metal immediately prior to welding or cutting. PULSED ARC WELDING - Welding in which pulses of current are superimposed on a constant background current. In continuous electrode processes the pulses control metal transfer across the arc. Ideally, one pulse produces one droplet of molten metal across the arc.PULSING - Sequencing and controlling the amount of current, the polarity, and the duration of the welding arc.REINFORCEMENT - Weld metal lying outside the plane joining the weld toes.RESIDUAL WELDING STRESS - Stress remaining in a metal part of structure as a result of welding. RESISTANCE WELDING - A process in which two pieces of metal are joined by placing pressure on electrodes which are on opposite sides of the joint to be welded, maybe a spot or a continuous weld. There is no arc with this process, the resistance of the metal to the current flow is what causes fusion.RMS - Root Mean Square. The “effective” values of measured AC voltage or amperage. RMS equals 0.707 times the maximum, or peak value.ROOT FACE - The portion of a fusion face at the root which is not bevelled or grooved, Refer to Fig 1 for examples.ROOT GAP - The minimum distance at any cross-section between edges, ends or surfaces to be joined, Refer to Fig 1 for examples.ROOT OF WELD - The points as shown in cross-section, at which the back of the weld intersects the base metal surfaces, see Fig 2 (a) and (b) for examples.

GLOSSARY

98CONTENTS

SHORT CIRCUITING ARC TRANSFER - Metal transfer in which fused parts of a consumable electrode are detached in rapid succession during repeated short circuiting contacts with the molten weld pool. Also called short arc or dip transfer.SILVER BRAZING - Brazing in which a silver alloy is used as the filler metal. SILVER SOLDERING - See Silver Brazing.SIZE OF WELD - (a) Equal leg fillet weld - the length of the equal sides of the largest isoceles triangle which can be inscribed within the fillet cross-section, see leg length.(b) Unequal leg fillet weld - the lengths of the sides containing the angle of the largest triangle which can be inscribed within the fillet cross section.(c) Butt weld - the minimum depth which a butt weld extends into a joint, exclusive of reinforcement.SLAG INCLUSION - Slag entrapped in weld metal or between weld metal and base metal. Only present with welding processes that use a flux eg. MMA and SAW.SOFT SOLDERING - see Soldering.SOLDERING - A low strength joining process in which, during heating, a molten Lead-Tin filler alloy is made to flow onto and around the joint preparation. In general, the melting point of the filler metal is less than 450°C, but always below the melting temperature of the parent metal. A fluxing agent is often used to promote the flow of filler metal around the joint.SPATTER - Globules of weld metal which are expelled during welding and which do not form part of the weld.SUBMERGED ARC WELDING (SAW) - Arc welding in which a continuous, consumable, wire electrode (flux cored or solid) is used and the arc is submerged under a granular flux cover, some of which fuses to form a slag. Single or multiple electrodes in the form of solid or tubular wires or strip may be employed, attached to one or more power sources and feeding devices.

GLOSSARY

99CONTENTS

TIG WELDING - “Tungsten Inert Gas”, see Gas Tungsten Arc Welding.SPRAy TRANSFER - Metal transfer which takes pace as a rapid projected stream of droplets of diameter not larger than that of the consumable electrode from which they are transferred.STRESS RELIEF HEAT TREATMENT - Heating to, and if necessary holding at, some temperature generally below the transformation range, usually followed by slow cooling, for the purpose of reducing internal stresses.STRINGER BEAD RUN - A bead or run made without intentional weaving motion.TACK WELD - A weld (generally short) made to hold parts of a weldment in alignment until final welds are deposited.THROAT THICKNESS - (a) Actual throat thickness - the perpendicular distance between two lines (each parallel to a line joining the outer toes) one being a tangent at the weld face and the other being through the further most point of fusion penetration. Measured from the root to the weld face. Known as the ‘a’ dimension in ISO 2553.(b) Design throat thickness - the minimum dimension of throat thickness used for design purposes, refer to Fig 4, (a) and (b) for examples.TINNING - The term as applied to brazing and braze welding defines the deposition of a thin layer of fluxed filler metal onto joint surfaces in order to provide a sound and strong interface between parent metal and weld deposit.T-JOINT - A joint between the end or edge of one part and the face of the other part, The parts making an angle to one another of more Than 5 degrees up to and including 90 degrees in the region of the joint, see Fig 1, (E) and (F) for examples.TOE - The junction between a weld face and the base metal or between weld faces, refer to Fig 2, (C) and (d) for examples.

GLOSSARY

100CONTENTS

TOUCH OR SCRATCH START - An arc starting procedure for TIG (GTAW). The tungsten is touched or scratched on the workpiece; when the tungsten is lifted from the workpiece an arc is establishedTOUCH WELDING - Metal arc welding using a coated electrode, where, as a result of a characteristic of the coating, it can be kept in contact with the base metal during welding to facilitate control of arc length.TRANSFERRED ARC - A plasma arc which is struck between a tungsten electrode and the workpiece.UNDERCUT - A sharp groove at the toe of a weld flaw which is a run between the weld and the parent metal or in previously deposited weld metal caused by wastage of the underlying material, see Common Weld Defects section.VERTICAL POSITION - The position of welding wherein the line of the weld root is approximately vertical, see Fig 3, 3F and 3G positions.VISCOUS SLAG - A slag with characteristics which restrict the flow of molten slag into the weldpool during welding.VOLTAGE - The pressure or force that pushes the electrons through a conductor. Voltage does not flow, but causes amperage or current to flow. Voltage is sometimes termed electromotive force (EMP) or difference in potential.VOLTAGE REDUCTION DEVICE (VRD) - a device used to reduce the OCV of welding machines to lower and safer levelsWEAVING - Transverse movement of the end of an electrode during deposition of weld metal. WELDING PROCEDURE - The detailed methods and practices involved in the making of a weld eg. amps, volts, travel speed, material and consumable type etc.WELD FACE - The exposed surface of a weld on the side from which welding was performed, refer to Fig 2, (C) and (d) for examples.

GLOSSARY

101CONTENTS

WELD JUNCTION - The boundary between the fusion zone and the heat affected zone (HAZ) of a weld, see Fig 2, (a) and (b).WELD METAL - All metal melted during the making of a weld and retained in the weld, see Fig 2, (a) and (b).WELD RUN - The weld metal resulting from one passage of an electrode, torch or blowpipe, also called weld pass.WIRE FEED SPEED - Expressed in in/min or mm/s, and refers to the speed and amount of filler metal fed into a weld. Generally speaking the higher the wire feed speed, the higher the amperage.WORK - The material or object on which welding, brazing, soldering or cutting is carried out. Also called workpiece..

GLOSSARY

102CONTENTS

Included angle

(A) SINGLE-V BUTT JOINT

(C) DOUBLE-V BUTT JOINT

(E) SIBGLE BEVEL-T BUTT JOINT (F) SIBGLE-J T-BUTT JOINT

(B) SINGLE-U BUTT JOINT

Included angle

Angle of bevel

Root radius

Angle of bevel

Root face

Root gap

Root face

Angle of bevel

Included angle

Root face

Root gap

Root gap

(D) DOUBLE-U BUTT JOINT Root gap

Root face

Root radius

Angle of bevel

Included angle

Included angle & angle of bevel

Root face

Root gap

Included angle & angle of bevel

Root face

Root gap

Root radius

Land

GLOSSARY

103CONTENTS

Weld zone

Weld width

Weld width

Weld face

Weld face

Weld face

Toes

Leg (length)

Leg (length)

Toe

Toe

Toes

Toe

Weld zone

Fusion zone

Heat affected zone

Parent metal

Depth of fusionFusion

faceWeld

junction

Weld metal

Weld metal

Heat- affected

Zone

Fusion zone

Root of weld

(A) BUTT WELD

(C) BUTT WELD (D) FILLET WELD

(B) FILLET WELD

Root of weld

GLOSSARY

104CONTENTS

PIPE BUTT WELDS

FILLET WELDS

FLAT POSITION 1F

HORIZONTAL POSITION 2F

VERTICAL POSITION 3F

OVERHEAD POSITION 4F

Axis of Weld Horizontal


Axis of Weld Vertical


FLAT 1G

HORIZONTAL 2G

POSITION 5G

POSITION 6G

Pipe shall be turned or rolled while welding, Axis of Pipe Horizontal

Pipe shall NOT be turned or rolled while welding, Axis of Pipe HorizontalAxis of pipe

VerticalInclined Axis with Pipe Stationary

BUTT WELDS

FLAT POSITION 1G

HORIZONTAL POSITION 2G

VERTICAL POSITION 3G

OVERHEAD POSITION 4G

Plates Horizontal Plates HorizontalPlates Vertical Plates Vertical

45º± 5ºL

GLOSSARY

105CONTENTS

(A)

Design throat thickness

Actual throat

thickness

(B)

Actual throat

thickness

Design throat thickness

D₂

D₁ + 0.85 D₂

D₁

FIGURE 4 ACTUAL AND DESIGN THROAT THICKNESS OF TYPICAL WELDS

FIGURE 4A DEEP PENETRATION WELD AND DESIGN THROAT THICKNESS TO AS 1554.1

GLOSSARY

106CONTENTS

ADD

107CONTENTS

OXY-ACETYLENE FLAME ADJUSTM

ENT

FLAME ADJUSTMENTS FOR OXyGEN — ACETyLENE WELDINGFor oxy-acetylene welding there are essentially four main types of flame adjustments used for welding a wide variety of base metals. A neutral flame is the most common setting used for the majority of fusion welding and braze welding applications. The following diagrams are intended as a guide to the easy identification of these flame types and their use with specific base metals.

OXY-ACETYLENE FLAME ADJUSTMENT

(A) OXIDISING FLAME

Small inner cone

Bright inner cone

(B) NEUTRAL FLAME

Bright acetylene feather

(D) CARBURIZING FLAME

Small pale green feather

(C) REDUCING FLAME

For welding Copper and certain Copper based alloys

For welding Steel, Stainless Steel, Cast Iron, Aluminium and Copper etc.

For welding Aluminium and Low Alloy Steel etc.

Suitable for silver brazing, soldering and many hard surfacing applications.

108CONTENTS

Welding symbols are the shorthand of welding, they provide a concise means of relaying information on engineering drawings. Detailed information such as the type, size, orientation and finishing requirements of the weld joint can be communicated.Welding symbols do not always contain all the information required for welding. Reference is often given on the welding symbol, to a specification, process, procedure or other document which provides the necessary data to complete the welding operation.The use of welding symbols result in the following benefits:1.The complete translation of specific design requirements to the workshop; regarding such parameters as weld sizes, processes to be used, joint preparations etc thus allowing the welding task to be complete as per instruction.2.The elimination of unnecessary and incomprehensible details on drawings-when such details specify weld type, size, length, pitch etc.3.The establishment of a common understanding of design intent and welding prerequisites between designers, workshop welder/inspectors, welding engineers, Q.A./Q.C personnel and code authorities etc.4.Standardisation, within and across the welding, fabrication and construction industries.BASIC SyMBOLS There are different standards for welding symbols. The following pages are set out using the International Standard ISO2553 (Welded, brazed and soldered joints - Symbolic representation on drawings) and the Australian Standard AS1101.3 (Graphical Symbols for General Engineering - Welding and Non-Destructive Examination) which is based on the American Welding Society Standard. AWS A2.4 In AS1101.3, a clear distinction is made between the terms weld symbol and welding symbol. The term, weld symbol describes the type of weld to be deposited — see FIGURE 6A for the basic weld symbols in common use. The welding symbol is a method of representing the weld symbol on drawings and includes all the relevant information and references necessary to complete the welded joint.

WELDING SYMBOLS

109CONTENTS

WELDING SYM

BOLS

ELEMENTS OF A WELDING SyMBOL TO AS1101.3The major elements are:(a) Reference line (shown horizontally) (b) Arrow(c) Basic weld symbols(d) Dimensions and other data (e) Supplementary symbols(f) Finish symbol (g) Tail(h) Specification, process, or other references

Refer to Figure 5 for the standard location of these elements on a welding symbol.

110CONTENTS

WELDING SYMBOLS

FIG

UR

E 4:

LO

CAT

ION

OF

ELEM

ENTS

ON

A W

ELD

ING

SYM

BOL

Fini

sh s

ymbo

l

Prep

arat

ion

angl

e; in

clud

ed a

ngle

of

cou

nter

sink

for p

lug

wel

ds

Leng

th o

f wel

d

Pitc

h (c

entre

-to-c

entre

sp

acin

g) o

f wel

ds

Site

wel

d sy

mbo

l

Arro

w c

onne

ctin

g re

fere

nce

line

to a

rrow

sid

e m

embe

r of j

oint

Wel

d-al

l-aro

und

sym

bol

Ref

eren

ce li

ne

Con

tour

sym

bol

Roo

t gap

; dep

th o

f fillin

g fo

r plu

g an

d sl

ot w

elds

Des

ign

thro

at th

ickn

ess

Dep

th o

f pre

para

tion;

siz

e or

stre

ngth

for c

erta

in w

elds

Spec

ifica

tion,

pro

cess

, pr

oced

ure

or o

ther

refe

renc

e

Tail

(Tai

l om

itted

whe

n re

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nce

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sed)

Basi

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eld

sym

bol

or d

etai

l ref

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ce

Num

ber o

f spo

t, se

am, s

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pl

ug o

r pro

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ion

wel

ds

Elem

ents

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ain

as

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wn

whe

n ta

il an

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arro

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vers

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F

LP

A R

TS

(D)

BOTH SIDES

ARROW SIDE

OTHER SIDE

(N)

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TE: R

epro

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ith p

erm

issi

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om

SA

I Glo

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ence

111

0-c0

75

( ) ( )

( )

111CONTENTS

WELDING SYM

BOLS

Weld All Around Site Weld

Complete Penetration From One

Side

Backing Or Spacer Material

Surfacing Convex Concave

Fillet Weld

Plug Weld

Or Slot Weld

Spot Weld Or Projection

Weld

Seam Weld

Backing Run Or Backing

Weld

Surfacing Edge Weld

Stud Weld

BUTT WELD

Square Scarf V Bevel U J Flare V Flare Bevel

FIGURE 6B SUPPLEMENTARY SYMBOLS

FIGURE 6A BASIC WELD SYMBOLS

112CONTENTS

WELDING SYMBOLS

(D) COMBINED FILLET AND BUTT WELD IN T-JOINT WITH SPECIFIED ROOT GAP.

Symbol

(3)5

23

5

5Desired weld

2

(3)

(C) STAGGERED INTERMITTENT FILLET WELDS.

75-25075-250

75

250C Weld C Weld

Desired weldsC Weld C Weld

125 125

75 75 75

(B) UNEQUAL DOUBLE-FILLET WELDS.

612

SymbolDesired weld12

126

6

(A) SINGLE-FILLET WELD

8

SymbolDesired weld

8

8

113CONTENTS

WELDING SYM

BOLS(A) PARTIAL PENETRATION, SINGLE-V BUTT WELD

(B) FULL PENETRATION

690°6 (10)

Desired Weld (D=10) Symbol

90°

Desired WeldNote

overlapSymbol

Note: The total design throat thickness (D)=22mm

90°

5

5

22

(D=12)5 (12) 90°

90°5 (12)

See Note

(D=12)90°

Desired Weld

Symbol

Note: The total design throat thickness cannot be greater than plate thickness (10mm)

See Note

(4)(7)

2

60°

(4)

60°

10

(7)

2

Symbol

(D) COMBINED FILLET AND BUTT WELDS

970°

70°9

6 (14)6 (14)

Desired Weld9 9

6 6

25

70°70°

14 14

Note overlap

(C) SINGLE BEVEL BUTT WELD WITH ROOT OPENING

114CONTENTS

WELDING SYMBOLS

Symbol

See Note

NOTE: See drawing for dimensions and orientation

1245°

45°

12

Section of desired weld

Symbol

Desired weld 33

(A) SURFACE WELD

(B) PLUG WELD (D) SEAM WELD

115CONTENTS

WELDING SYM

BOLS

(D) SEAM WELD

(C) SPOT WELD

SymbolRSW - Resistance spot weldingDesired weld Section A-A

24 2412 12

6

12RSW6 24

(5)A

A

24 24

+ + + + +

Min acceptable shear strength 35 N/mm₂

Desired weld Section A-A SymbolEBW - Electron- beam welding

A

A

EBW35 N/mm₂

116CONTENTS

A GUIDE TO INTERPRETING THE AUSTRALIAN / NEW ZEALAND STANDARD CLASSIFICATION FOR LOW CARBON STEEL MMAW ELECTRODESThe Australian/New Zealand Standard 4855 for Manual Metal Arc Welding of non-alloy and fine grain steel is identical to ISO 2560 standard, and is to supersede AS/NZS 1553.1. Under the new AS/NZS 4855 standard, covered electrode can be classified based upon either yield strength and 47J minimum impact energy known as method -A, or tensile strength and 27J minimum impact energy known as method -B, which the second method is widely accepted in Australian market. For details of the complete range of classifications, please consult AS/NZS 4855.

AS/NZS 4855-B - E49 16 A U H10

Compulsory clalssification designatorsSpecification numberClassification by tensile strength and 27J CVN requirementCovered electrodeDeposit metal tensile strength. “49” indicates minimum tensile strength of 490 N/mm

₂,

other designator like “43, 55 or 57” is often usedType of flux coatingCondition of heat treatment. The symbols “A” and/or “P” are used to indicate the as-welded and/or heat treated condition/sOptional supplemental designatorsDiffusible hydrogen. “H5, H10,H15” is used to indicate a maximum diffusible hydrogen content of “5,10, and 15 ml/100g of deposited metal, respectively

Optional supplemental designators

47J impact energy at the normal

27J test temperature has also been met.

ELECTRODE CLASSIFICATIONS

117CONTENTS

ELECTRODE CLASSIFICATIONS - MANUAL METAL ARC WELDING ELECTRODES

A GUIDE TO INTERPRETING THE AMERICAN ANSI / AWS SPECIFICATION FOR CARBON STEEL ELECTRODES FOR SHIELDED METAL ARC WELDINGThe ANSI/AWS A5.1 Specification for Shielded Metal Arc Welding details classifications covering general purpose, iron powder and low hydrogen electrodes. The classification system consists of an alphanumeric group followed by a group of optional designators. Please consult ANSI/AWS A5.1 for further details on the range.

1ST GROUPMinimum Weld Metal Strength

Tensile Yield Elongation ksi ksi %

60 48 22

70 58 22

2ND GROUPWelding Position, Welding Current and Coating Type ie EXX12, EXX24 and EXX18For details refer to the Usability Digits of Major Classifications on next page.

3RD GROUPOptional Designator for Improved Impact ToughnessE7016-1=20 ft.lb @ -50°F av.min.E7018-1=20 ft.lb @ -50°F av.min.E7024-1=20 ft.lb @ -0°F av.min.

3RD GROUPOptional Diffusible Hydrogen Designator indicates that the low hydrogen electrode meets the requirements of the diffusible hydrogen test.

H4 <4mL/100g) of deposited weld metalH8 <8mL/100g) of deposited weld metal H16 <16mL/100g) of deposited weld metal

3RD GROUPOptional Coating Absorbed MoistureDesignator indicates that the coating of a low hydrogen electrode is moisture resistant after being exposed to an environment of 80°F and 80% relative humidity for a period of not less than 9 hours. Maximum specified moisturecontents are detailed in Table 10 of thespecifications.

E XX XX XHXRELECTRODE

3RD GROUP Optional designators

118CONTENTS

USABILITy DIGITS OF MAJOR CLASSIFICATIONS INDICATING TyPE OF POSITIONS AND CURRENT TyPE REQUIREMENTS

USABILITy CLASSIFICATION

WELDING POSITIONS

TyPE OF CURRENT AND POLARITy

TyPE OF COVERING AND

SLAG

10 F,V,OH,H D.C. electrode positive High cellulose

11 F,V,OH,H A.C. or D.C. electrode positive High cellulose

12 F,V,OH,HA.C. or D.C

electrode positive or negative

High titania viscous slag



High titania viscous slag



Low iron powder

15 F,V,OH,H D.C. electrode positive

*Hydrogen controlled

16 F,V,OH,H A.C. or D.C. electrode positive

*Hydrogen controlled

18 F,V,OH,H A.C. or D.C. electrode positive

*Hydrogen controlled basic, low iron powder



Limenite

20 F,H, Fillet A.C. or D.C. electrode positive High iron oxide

24 F,H, FilletA.C. or D.C electrode

positive or negativeHigh iron

oxide titania

27 F,H, FilletA.C. or D.C


*Hydrogen controlled powder

iron oxide

28 F,H, Fillet A.C. or D.C. electrode positive

*Hydrogen controlled low iron

powder basic46 F,V-down

OH, HA.C. or D.C.

electrode positive*Hydrogen

controlled basic

48 F,V-down OH, H

A.C. or D.C. electrode positive

*Hydrogen controlled basic, low iron powder

99 As specified

As Specified by manufacturer As Specified by

NOTE: The abbreviations, F, V, V-Down, OH, H, and H-FiIIet indicate the following welding positions: F-Flat, V-Vertical, V-down - Vertical down, OH-Overhead, H-Horizontal, H-fillet-Horizontal fillet. *Unless otherwise indicated the classification digits have wide usage amongst the Australian AS, USA (AWS), Canadian (CSA), Japanese (JIS) and the new draft ISO Standards. European Economic Community Standards (CEN). As national standards are subject to regular revision these situations could alter.


119CONTENTS

USABILITy DIGITS OF MAJOR CLASSIFICATIONS INDICATING TyPE OF POSITIONS AND CURRENT TyPE REQUIREMENTS

A GUIDE TO INTERPRETING THE AUSTRALIAN STANDARD CLASSIFICATION FOR HIGH STRENGTH STEEL MMAW The Australian/New Zealand Standard 4857 for Manual Metal Arc Welding of high-strength steesl is identical to ISO 18275 standard, and is to supersede AS/NZS 1553.2. Under the new AS/NZS 4857 standard, covered electrode can be classified based upon either yield strength and 47J minimum impact energy known as method -A, or tensile strength and 27J minimum impact energy known as method -B, which the second method is widely accepted in Australian market. For details of the complete range of classifications, please consult AS/NZS 4857.

AS/NZS 4857-B - E62 18-G A U H10

Compulsory clalssification designatorsSpecification numberClassification by tensile strength and 27J CVN requirementCovered electrodeDeposit metal tensile strength. “62” indicates minimum tensile strength of 620 N/mm

₂,

other designator like “59, 69, 76, 78 or 83” is often usedType of flux coatingAny other agreed chemical compositionCondition of heat treatment. The symbols “A” and/or “P” are used to indicate the as-welded and/or heat treated condition/sOptional supplemental designatorsDiffusible hydrogen. “H5, H10,H15” is used to indicate a maximum diffusible hydrogen content of “5,10, and 15 ml/100g of deposited metal, respectively

Optional supplemental designators

47J impact energy at the normal

27J test temperature has also been met.


120CONTENTS

A selection of designators for nominal alloy weld metal compositions widely used in ISO, Australian (AS) European and American (AWS) systems of classification for electrodes and weld metal. See the appropriate Standard for the fully specified composition requirements and the location(s) of the designator in the classification.

ALLOy GROUP DESIGNATOR NOMINAL COMPOSITION REQUIREMENTS

Carbon - Molybdenum A1 0.40 - 0.65Mo

Chromium - Molybdenum Steels

B1 B2 or B2L• B3 or B3L B6 (5Cr)#

B7, B7L (7Cr)# B8, B8L (9Cr)#

0.50Cr 0.5Mo 1.25Cr 0.5Mo 2.25Cr 0.5Mo

5Cr 1Mo 7Cr 5Mo 9Cr 1Mo

Nickel SteelsNi1, Ni3L or C3

Ni2, Ni2L or C1, C1L Ni3, Ni3L or C2, C2L

NM

1 Ni 2.5 Ni 3.5 Ni

1 Ni 0.5MoManganese

Molybdenum SteelsD1 D2

1.5 Mn 0.35 Mo 1.8 Mn 0.35 Mo

Mil. Spec. Type Low Alloy High Tensile Series, AS 1553.2 and AWS A5.23

Examples

M (eg. E7618-M) M1, M2, M3, M4

eg. F9A2-ECM1-M12)

A series of Mn-Ni-Cr-Mo specified compositions

for various strength levels Refer to standards

Other Low Alloy Steels of specified composition (SAW

and FCAW standards

EF1-EF6 series F1-F6 series K1-K7 series

SAW Electrodes• SAW Weld metals•

FCAW Weld metals• Refer to AWS Standards

Weathering Steels (Corten - Austen

etc.)W, W1, W2 Ni-Cr-Cu steels

typically 0.5Ni-0.5Cr 0.5Cu

Alloy unspecified G, GSComposition exceeds

minimum requirements in at least one specified element.

• L variants are a low carbon version (usually 0.05 % max) of the standard alloy carbon range # Alternative designators in some AWS standards.


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DESCRIPTION OF MMAW ELECTRODE TyPES AS CLASSIFIED By NATIONAL AND INTERNATIONAL STANDARDSEXX10 AND EXX11 TyPES (AUSTARC 11) Electrodes of these classifications have thin coatings which contain at least 15% cellulose and up to 30% titania as rutile or titanium white. The group is characterised by a forceful, deeply penetrating, spray type arc with fairly high spatter. A voluminous gas shield is produced, as a result of decomposition of the cellulose materials in the arc region, which protects the weld metal from atmospheric contamination. High weld metal quality (including radiographic soundness) is achieved in all welding positions and the electrodes operate satisfactorily from AC or DC (electrode positive) power sources for EXX11 types and from DC (electrode positive) only for EXX10 types.EXX12 TyPE (AUSTARC 12P) Electrodes of this classification have thin coatings which contain a high proportion of titania as rutile, ilmenite or titanium white. The group is characterised by a quiet, medium penetrating arc with low spatter. The slag is viscous, full covering and easily removed when cool. General ease of handling in all welding positions and an ability to bridge gaps in work having poor fit-up are features common to this electrode type. Due to the viscous slag, many of these electrodes are suitable for use in the vertical down position. In Europe, rutile-cellulose is a common designation, while in the AWS classification sodium binders are specified.EXX13 TyPE (AUSTARC 13S) Electrodes of this classification are similar in formulation to the EXX12 group. However, basic materials are added to increase the fluidity of the slag. Similar to EXX12 electrodes, they operate with a quiet medium-penetrating arc with low spatter. The slag is fluid, full covering and easily removed when cool. The fluid slag makes this electrode ideal for fillet welding in the flat or horizontal, vertical-up and overhead welding positions. Potassium binders give improved arc stability and are specified for the AWS classification. (cont. over)


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EXX14 TyPE Electrodes of the EXX14 type have medium thick coatings, containing a high proportion of titania and sufficient iron powder to ensure a deposition efficiency of 105 - 130%. They operate with a smooth, medium penetrating arc with low spatter. The slag is fairly viscous, full covering and easily removed when cool. These electrodes are suitable for both single-run and multiple-run welds in all positions and can be used to bridge gaps in work having poor fit-up. Due to the viscous slag, many of these electrodes are suitable for use in the vertical down position.EXX15 TyPE The original basic low hydrogen type is suitable for use on DC electrode positive only. Similar characteristics and application to EXX16 and EXX18.EXX16 TyPE (AUSTARC 16TC) These electrodes have a chemically basic slag, generally of the limestone-fluoride type similar to the EXX15 group but with the ability to run on AC as well as DCEP Higher arc stability is provided by the use of potassium silicate binders and other potassium bearing materials in the coating. Coating materials are inorganic, selected for minimal combined moisture and coverings are baked at a high temperature to provide low hydrogen in the arc atmosphere. Basic coated electrodes are noted for their tough low oxygen weld metals and suitability for welding a wide range of carbon and low alloy steels. The fluid full covering slag gives slight convex beads and excellent all position welding capabilities.EXX18 TyPE (AUSTARC 18TC AND AUSTARC 77) Similar coating type and operational characteristics to the EXX16, but the somewhat heavier coating contains sufficient iron powder to give increased deposition efficiency to 105-130%. This still permits all position welding on AC or DCEP but the presence of the iron powder also improves metal transfer and operational characteristics. The EXX18 group are widely used in a range of steels and critical applications where weld quality is the main requirement, particularly in all position welding. The group also serves as the major basic group for a wide range of low alloy high tensile electrodes.


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EXX19 TyPE The slag type is based on the titanium oxide-iron oxide mineral, ilmenite, and therefore has similarities to the EXX12 & 13 types but with some distinct differences. Characterised by fluid slag and forceful arc it gives Grade 1 radiographic standards, good ductility and toughness down to -20°C.EXX20 TyPE A high iron oxide-manganese oxide/silicate type slag giving a spray type arc and smooth flat to concave welds. Easily removed honeycomb type brittle slag.EXX24 TyPE (AUSTARC 24) Similar slag type to EXXl2, 13 & 14 but with larger proportion of iron powder and heavier coating, approximating some 50% of electrode weight. High deposition rate, high speed runs and high efficiency in the 130 to 150% class. EXX27 TyPE Electrodes of this type have thick, heavy coatings which contain a high proportion of iron and manganese oxides and/or silicates, and sufficient iron powder to ensure a deposition efficiency greater than 130%. They operate with a vigorous, spray type arc with medium to deep penetration. The slag is fluid, voluminous, full covering and when cool well honeycombed on the underside, friable and easily removed. Electrodes of this type are suitable for high speed welding applications in the flat and horizontal-fillet positions where good penetration and easy deslagging are essential.EXX28 TyPE A heavy coated high iron powder version of the basic coated lime fluorspar EXX18 electrode. The coating usually contains approximately 50% of the weight of the electrode, restricting its use to the flat and horizontal fillet positions.EXX46 AND EXX48 TyPES Electrodes of the EXX46 and EXX48 classifications have respectively the same usability, composition and design characteristics as EXX18, except for excellent vertical-down performance.


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A GUIDE TO INTERPRETING THE AUSTRALIAN STANDARD CLASSIFICATION FOR FERRITIC STEEL GMAW ELECTRODESThe standard AS/NZS 2717.1 for Gas Metal Arc Welding Ferritic Electrodes is the only AS/NZS standard for semi-automatic welding process that has not been superseded by ISO standards. Previous FCAW stand AS 2203.1 has been supersended by AN/NZS ISO 17632, 17634 and 18276. The system of classification consists of three alphanumeric groups separated by the hyphens, which may be summarised as follows. For full details of the complete range of classifications, testing, chemical, mechanical, radiographic and other requirements of the standard, please consult AS/NZS 2717.1.

AS 2717.1 ES6 - GC - W 50 3 A H

2ND GROUPType of external shielding gas First digit is G for gas.C = shielding with welding grade carbon dioxideM = shielding with mixed gases.I = shielding with inert gas.

3RD GROUPWeld metal properties.A indicates as-welded condition, or P after post weld heat treatmentH indicates hydrogen controlled weld metal.

AS WELDED TENSILE PROPERTIES*

Weld Metal Classification

Min. Tensile Strength

Min.Yield Strength

Min. Elongation on 5d

W50XH 500 MPa 360 MPa 22%W559H 550 MPa 470 MPa 19%For complete details refer to AS / NZS 2717.1

FIRST GROUP - ES = Electrodes, Solid, followed by a numerical or alphanumerical code which define the chemical composition of the wire. For example

Wire Class. C Mn Si Other

ES3 ES4 ES5 ES6 ES7

.06-.15

.07-.15

.06-.19

.06-.15

.07-.15

.90-1.40 1.00-1.50 .90-1.40 1.40-1.85 1.50-2.00

.45-.75

.60-.85

.30-.60

.80-1.15

.50-.80

- - .50-90AI- -

ESB2L ESNi2 ESD2 ESM3 ESMG ER70S-G

Low carbon Cr-Mo Alloy 2.5 Ni Alloy Mn-Mo-Alloy Mn-Ni-Cr-Mil Spec Alloy o specified composition

Refer AS / NZ 2717 for full range of classifications and compositions.

The third digit, for carbon steel electrodes, indicates the Impact energy grade number as specified below. For low alloy, ferritic steel electrodes, the third digit is 9 and the minimum average CVN impact values are as stated in AS / NZS 2717.1.Impact Energy Grade #

Min. Avrge Charpy ‘V’ notch impact value

Z Not requiredA 47J at +20°0 47J at 0°2 47J at -20°4 47J at -40°6 47J at -60°


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A GUIDE TO INTERPRETING THE ANSI /AWS GAS SHIELDED ARC WELDING FILLER METAL SPECIFICATIONThe ANSI / AWS A5.18 specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding includes Metal Cored electrodes formerly classified in ANSI / AWS A5.20 and an example is illustrated to acquaint the user with information provided by the specification.While the full range of classifications can be employed with GMAW only solid rods should by used for GTAW (TIG) and PAW processes. For full details of all test requirements, radiographic standards, manufacturing tolerances, packaging etc refer to the latest edition of the standard.

E R 7 0 S - 6 H 4E R 7 0 C - 6 M H 4

LETTER DESIGNATORSE = ElectrodeR = RodS = Solid WireC = Composite Metal Cored WireM = Mixed Shielding GasC = Cabon Dioxide Shielding Gas

OPTIONAL DESIGNATORS

Indicate diffusible weld metal hydrogen contentH4 = <4mL/100g)H8 = <8mL/100g)H16 = <16mL/100g)

AS WELDED TENSILE PROPERTIES*

Weld Metal Classification

Min. Tensile Strength

Min. Yield Strength

Min. Elongation %psi MPa psi MPa

ER 70-X 70,000 480 58,000 400 22

ER 70-XX 70,000 480 58,000 400 22

*Properties as detailed are appliccable for all classifications

DEPOSITION PROCESS

Class C Mn Si Other

ER70S-2 ER70S-3 ER70S-4 ER70S-5 ER70S-6 ER70S-7

0.07 0.06-0.15 0.07-0.15 0.07-0.19 0.06-0.15 0.07-0.15

0.90-1.40 0.90-1.40 1.00-1.50 0.90-1.40 1.40-1.85 1.50-2.00

0.40-0.70 0.45-0.75 0.60-0.85 0.30-0.60 0.80-1.15 0.50-0.80

Ti, Zr, AI 0.50 Cu 0.50 Cu Cu, Al 0.50 Cu 0.50 Cu

ER70S-G Agreed between the supplier & customer

WELD METAL ANALySISE70C-3X 0.12 1.75 0.90 0.50 CuE70C-6X 0.12 1.75 0.90 0.50 CuE70C-G Agreed between the suppler & customer E70C-GS(X) Agreed between the suppler & customerSingle figures are maximum G- general, GS = general, single pass only

DEPOSITION PROCESS

Class Ftlb JER70S-2 ER70S-3 ER70S-4 ER70S-5 ER70S-6 ER70S-7 ER70S-G ER70S-3X ER70S-6X ER70S- G(X) ER70S- GS(X)

20 @ -20°F 20 @ 0°F N/A N/A 20 @ -20°F 20 @ -20°F As Agreed 20 @ 0°F 20 @ -20°F As Agreed N/A

27 @ -29°F 27 @ -18°F N/A N/A 27 @ -29°F 27 @ -29°F As Agreed 27 @ -18°F 27 @ -29°F As Agreed N/A

ELECTRODE CLASSIFICATIONS - GAS METAL ARC WELDING FERRITIC STEEL ELECTRODES

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EXAMPLES:1. AWS A5.18: ER70S-6 Indicates a solid wire electrode and filler rod. Mechanical testing of an all weld metal test plate, deposited under CO₂ shieldng will give min. 72 ksi (500 MPa) tensile strength, 60 ksi (420 MPa) yield strength, min. 22% elongation on 4D and a charpy impact strength of 27J at - 29°C. The weld will meet radiographic requirements. The wire meets a specffied chemical analysis, dimensional requirement and some additional testing where supplied as a filler rod only.2. AWS AS.28: ER80S-B2 Indicates a solid wire electrode and filler rod. Mechanical testing of an all weld metal deposit, welded under Argon+1-5% O₂ gas shielding is carried out after PWHT at 620°C. The requirements are a min. tensile strength of 80 ksi (550 MPa) yield strength at 0.2% offset of 68 ksi (470 MPa) and an elongation 19% min. on 4D. It has to meet radiographic soundness but no impact properties are specified for this alloy. The wire, a nominal 1.25% Cr/0.5% Mo alloy must meet a specific composition analysis, dimensional requirements and some addtional requirements for supply as a filler rod only.3. AWS A5.28: E80C-B2 A cored or composite electrode the dropping of the R indicates it meets the specification for an electrode only. It meets all the weld metal soundness and mechanical requirements specified in example 2 above but the B2 alloy specific composition is confirmed by anaysis of the deposited weld metal.


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A GUIDE TO INTERPRETING THE AS/NSZ ISO SPECIFICATIONS FOR FLUX CORED ARC WELDINGThe new AS/NZS ISO 17632 standard is a series of adopted ISO standards to cover Flux Cored Arc Welding (FCAW) electrodes for Non-alloy and fine grain steels. The following provides a brief introduction into the classification systems, and the standard series cover different electrode range. For full classification details, please consult the latest standards. AS/NZS ISO 18276: high strength Steels AS/NZS ISO 17634: creep resisting steels AS/NZS ISO 17633: Stainless steels.

ELECTRODE CLASSIFICATIONS - FLUX CORED ARC WELDING ELECTRODESAS/NZS ISO 17632-B - T 55 4 T5-1 M A-N2-U H5Optional supplemental designators47J impact energy at the normal 27J test temperature has also been met.

Diffusible hydrogen. “H5,H10,H15” is used to indicate a maximum

diffusible hydrogen content of “5, 10 and 15 ml/100g of deposited metal,

respectively.

Classification by tensile strength and 27J CVN requirementTubular cored electrode Minimum tensile strength meets 550MPa Tested temperature @ -40°C meets the minimum impact properties of 27JUsability designator. T5 indicates Lime-flouride flux, and generally referes to Basic flux systemWelding position. 1 indicates all positional; and 0 - downhand only.Shielding gas M indicates mixed gasesIndicates tested in the as welded conditionchemical composition designator, N2 indicate 2%Nil in deposited weld metal

Compulsory clalssification designators

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A GUIDE TO INTERPRETING THE ANSI / AWS SPECIFICATIONS FOR FLUX CORED ARC WELDINGThe ANSI / AWS A5.20 (Plain Carbon) and A5.29 (Low AlIoy) Electrode specifications have similar classification systems. They are shown in a combined form to acquaint the user with the information provided by the classification. For full details of all test requirements, radiographic standards, manufacturing tolerances, packaging, weld metal compositions etc., please consult the latest edition of the appropriate specification

WELD METAL COMPOSITIONElectrodes to A5.20 have a weld metal composition requirement that ensures they are plain carbon steels and do not employ an alloy suffix. Electrodes to A5.29 have specific compositions and employ the designations as shown in Table 4 of this section (Page 126). These include the A1, B2, B3, Ni1, Ni2, D1, D2, D3, K1 to K7: W types. For full details of the chemical compositions, refer to Table 1 of A5.29

IMPACT STRENGTHThe A5.20 classification EXXT-1, T-5, T-6 & T-8 have min. impact requirements shown in the usability table. In A5.29 the requirement for impact testing on as-welded or PWHT specimens and the test temperature for min. 20ft-lb (27J) is specified in Table 4 against the complete classification eg. E81T1-Ni2 AW-40°F (40°C)E80T5-Ni2 PWHT - 75°F (-60°C)

USABILITy AND PERFORMANCENote: A5.20 Classifications shown here are T-X, A5.29 as TX. For details of usability and performance refer to Page 135.

POSITIONAL CAPABILITIES“0” = Flat and Horizontal “1” = All Positions

TUBULARFlux Cored Electrode

ELECTRODE

WELD METAL STRENGTH DIGITSThe strength digits ‘6’ and ‘7’ in A5.20 and ‘6’, ‘7’, ‘8’, ‘9’, ‘10’, ‘11’ and ‘12’ in A5.29 represent 0.1 of the min. tensile strength in ksi, eg. ‘8’=80ksi (550MPa) ‘11’=110ksi (760MPa)Each strength group has a min. yield strength, 12ksi (10ksi for ‘6’ in A5.29) below the min. tensile strength and a min. elongation requirement.

AWS A5.20 E X X T - XAWS A5.29 E X X T X - X


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USABILITy AND PERFORMANCE CAPABILITIES CLASSIFICATIONT-1, T1 - Almost invariably a Rutile (Titania) based flux imparting smooth running, spray transfer, low spatter using CO₂ shielding, electrode positive. Some designed for out of positioning welding when Argon/CO₂ mixtures may be preferred. Most popular group.E7XT-1 - Has impact requirement of 20ft-lb (27J) at 0°F. (-18°C).T-2 - Essentially similar to T-1 but higher Mn and Si for improved single pass welding over mill scale, rust or on rimmed steel in the flat and horizontal fillet positions.T-3 - Self shielded, high speed single pass welds on sheet metal up to 5mm thick using DCEP.T-4, T4 - Self shielded, very high deposition rate with globular transfer on DCEP. Low penetration, desulphurised welds, resistant to cracking, can be used on poor fit up. Suitable single or multiple run in flat and horizontal positions.T-5, 15 - Lime Fluoride basic flux for high toughness and crack resistance using DCEP and CO₂ shielding. Argon/CO₂ mixtures may be preferred for some applications.Globular transfer, convex beads (similar E7016-18 electrodes) for critical flat and horizontal fillet welds. Impact requirement for EXXXT-5 is 20ft-lb. (27J) at -20°F (-29°C).T-6 - Self shielded, DCEP, spray type transfer for single or multiple pass welding in flat or horizontal positions. Provides good low temperature impact properties 20ft-lb (27J) at -20°F (-29°C) and root penetration, easy slag removal in flat and horizontal positions. Single or multipass welds,T-7 - Self shielded, DCEN, single and multipass pass welds with desulphurising slag giving crack resistant welds. Larger sizes give high deposition rates, small sizes provide all position welding.T-8, T8 - Self shielded, DCEN, all position welding, single and multipass. The slag system produces good impact properties (T8 min. 20ft-lb (27J) at -20°F (-29°C). and a desulphurised weld metal resistant to weld cracking.T-10 - Self shielded, DCEN, single pass welding at high travel speeds in the flat, horizontal, down slopes (to 20°).T-11 - Self shielded, DCEN, with a smooth spray arc, General Purpose electrodes for single and multipass welding in all positions and high travel speed welding.T-G, TX-G - A classification for new multipass electrodes not covered by any of the above.T-GS - A classification for new single pass electrodes not covered by any of the presently defined classifications.

ELECTRODE CLASSIFICATIONS - FLUX CORED ARC WELDING ELECTRODES

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STANDARDS AUSTRALIA AND THE ANSI/AWS SPECIFICATION STANDARDS FOR STAINLESS STEEL AND ALUMINIUM ALLOy ELECTRODESThe new AS/NZS standards offer two classification systems, which are according to nominal composition (-A) and alloy type (-B)respectively. In Australia market, the B system is widely accepted and substantially the same to AWS standards.The following provides a brief introduction into the classification systems employed and the information they provide to the user. These are:ANSI/AWS A5.4 - Stainless Steel MMAW ELECTRODES - AS/NZS 4854 ANSI/AWS A5.9 - Stainless Steel GMAW ELECT. - AS/NZS ISO 14343 ANSI/AWS A5.10 - Al./Al. Alloy GMAW - AS/NZS ISO 18273For full details of the manufacturing tolerances, testing requirements, packaging, chemical composition and other aspects of the standard specifications, please consult the latest edition of the appropriate above standard.1. CORROSION-RESISTING CHROMIUM AND CHROMIUM-NICKEL STEEL ELECTRODES (a) MMAW COVERED ELECTRODES - AS/NZS 4854-B and ANSI/AWS A5.4 The basis of these classifications is the chemical composition and mechanical properties of the deposited metal, the coating type and current.The system of designation is as follows:

COATING TIME-15 DC Electrode Positive Lime Type-16 AC or DCEP Lime or Rutile Type-17 AC or DCEP Acid Rutile Type•-25 DC EP Heavy Coated Lime Type•-26 AC or DCEP Heavy Coated Rutile Type •

An alphanumeric system of alloy designation almost universally employed. eg. 308, 316L, 309Mo, 310 etc.

X X X - XELECTRODE

EALLOy DESIGNATION

The -17, -25, and -26 suffixes are recent additions to the classifications. The -17 is a more siliceous version of the -16. The -25 and -26 coatings are designed for flat and horizontal welding and are generally “synthetic” versions using lower alloyed or plain carbon core wires. (b) GMAW ELECTRODES The Standards Australia AS/NZS ISO 14343 for gas metal arc electrodes bases its classification of the electrode range on the composition of the solid wire. This is followed by the commonly employed alphanumeric designation of the chromium nickel steel, the actual composition of which is specified in the standard.


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No mechanical properties are specified. The ANSI/AWS A5.9 Specification covers solid wires, and metal cored, stranded or composite wires and again bases its classification on the chemical composition of the solid wires or a fused sample of the cored or composite wires. This specification covers electrodes or filler metals for GMAW, GTAW or SAW processes. For this reason, no mechanical testing requirements are specified. The designations in the classifications differ slightly.2. ALUMINIUM AND ITS ALLOyS — GMAW ELECTRODESThe AS/NZS ISO 18273 and ANSI / AWS A5.10 standards specifications for Aluminium and Aluminium alloys GMAW electrodes (and in the case of A5.10, filler rods) both base their classification on the chemical composition of the solid wire. The alloy is designated by an internationally accepted system involving a four digit number, the first indicating the aluminium content or the main alloying element, Of these, the following are employed in welding as electrodes or filler rods, viz.1XXX = Aluminium content 99% min. 2XXX = Copper is main alloying element 4XXX = Silicon is main alloying element. 5XXX = Magnesium is main alloying element.The second digit indicates modifications to the basic alloy or impurity limits while the third and fourth digits identity the aluminium alloy or indicate the aluminium purity.A prefix of E indicates an electrode wire in the Australian Standard and ER indicates Electrode/Filler Rod in the ANSI / AWS System.Example:- E5356 and ER5356 are classifications for a popular 4.5-5.5% Mg aluminium alloy with minor additions of Mn, Cr and Ti and limits on Si,Fe,Cu,Zn and others.Modifying the alloy designation to 5556 indicates mainly a rise in Mn level from approximately 0.1 to 0.5-1.0% and marginally higher “aim” value for Mg and Zn (0.1 max to 0.25 max.), which results in a higher tensile strength deposit.Alloy E5183 and ER5183 has become a popular filler metal used in the fabrication of marine passenger, car ferry and pleasure craft. It is a modification of the 5356 alloy with increases in Si, Mn and Zn and is particularly suitable for welding 5083 alloy in marine applications because of the higher tensile strength weld metal.The composition of the wires in both standards are almost identical with slightly narrow tolerance on Beryllium content from AWS standard and an electrode fully meeting the requirements of AWS A5.10 will be deemed to be qualified to the AS/NZS ISO 18273.

ELECTRODE CLASSIFICATIONS - MANUAL METAL ARC & GAS METAL ARC WELDING

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ELECTRODE CLASSIFICATIONSA GUIDE TO INTERPRETING THE AUSTRALIAN ANDNEW ZEALAND SPECIFICATION FOR REPAIR AND HARDFACING CONSUMABLEThe AS/NZS 2576 Welding Consumable for Build-Up and Wear Resistance is based on the Welding Technology Institute of Australia (WTIA) Technical Note 4. The standard classifies consumables by alloy type, deposit hardness, welding process and consumable type. For complete details of the consumable classifications please refer to the latest edition of AS/NZS 2576.

2ND DIGIT = ALLOy TyPEIn combination with the first digit it indicates the specific type of alloy whithin a group. 23XX = Austenitic chromium-carbide iron

2 3 6 0 - A 4

1ST = ALLOy GROUP1 = Steels2 = Chromium white irons3 = Tungsten carbide composites4 = Cobolt alloys5 = Nickel alloys6 = Copper alloys

3RD & 4TH DIGIT = DEPOSIT HARDNESSIndicates mean undiluted deposit hardness prior to any heat treatment or work in service. Hardness is expressed in Rockwell C (HRC) units. ie. XX60 = 60-65 HRC

DEPOSITION PROCESSThe letter indicates the welding process.A = Manual Metal Arc WeldingB = Submerged Arc Welding and Flux Cored Arc WeldingC = Gas Welding

5TH DIGIT = CONSUMABLE TyPEA1 = Tubular electrode no alloy contribution from the flux coating.A4 = Low carbon steel core wire alloy additive flux coating.B1 = Tubular wire no alloy. contribution from the flux coating.B5 = Gas shielded tubular flux core wire.B7 = Self shielded tubular flux core wire.C1 = Filler Rod.C3 = Powder.

ELECTRODE CLASSIFICATIONS - REPAIR AND HARDFACING

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A GUIDE TO INTERPRETING THE AUSTRALIAN STANDARD CLASSIFICATION FOR SUBMERGED ARC WELDING ELECTRODES AND FLUXESThe Australian Standard for electrodes and fluxes for SAW, AS 1858.1 (C and C-Mn Steels) published by Standards Australia and its classification system has strong similarities with the ANSI / AWS SAW specifications, particularly in relation to electrode and alloy weld metal designations and compositions. The following provides a guide to the designations and layout of the classification systems (shown in combined form) to acquaint the user with the information provided by the classifications. For full details of the complete range of classification testing requirements, chemical, mechanical, radiographic and other requirements of the standard, consult AS 1858.1.EXAMPLE: AS1858.1 EL12-FMM-W404 is a complete designation. It refers to a flux and wire combination that will produce weld metal which in the as-welded condition, will have a tensile strength no lower than 430 MPa and Charpy V-notch impact strength of a minimum of 35J at -40°C when deposited with an EMK12 electrode under the conditions called for in this specification.


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A GUIDE TO INTERPRETING THE AUSTRALIAN STANDARD CLASSIFICATION FOR SUBMERGED ARC WELDING ELECTRODES AND FLUXES

E or EC XXX - F X X - W XX X X X HX

ELECTRODE AND WELD METAL DESIGNATIONS AND COMPOSITIONS

Electrode C Mn Si

EL8 EL12 EM12K

0.10max 0.05-0.15 0.05-0.15

0.25/0.60 0.25/0.60 0.80/1.25

.0.07max 0.07max 0.10/0.35

Note: A small selection only of carbon steel electrodes. For full list and details refer tothe appropriate part of the standard

FLUX APPLICATIONS = Single RunM = Multi RunB = Basic FluxG = General Purpose

FLUX CONTRIBUTION TO WELD ANALySIS

HyDROGEN

A suffix indicatinghydrogen controlled weld metal may be added when max. H2 level is established.(AS 3752 - 1996)H15 <15mL/100gH10 <10mL/100gH5 <5mL/100gof deposits of metal

ELECTRODE (SOLID)

ELECTRODE COMPOSITE (CORED)

WELD METAL HEAT TREATMENTA+ Tested “As Welded”P=Tested “Post Weld heat treated”

WELD METAL STRENGTH DIGITSThe strength digits ‘40’ and ‘50 in part 1 of AS 1858 represent one-tenth of the approximate min. tensile strength in MPa of the tensile range. Each strength level also has a min. Proof Stress (0.2% Offset) and Elongation requirements specified by this standard.

IMPACT ENERGy NUMBER‘0’ = No impact required‘1’-‘5’ = test temperature of +20°C to -60°C in 20° intervals.Energy Requirement W40X = 35JW50X = 40JWXXX = 27J

FLUX

A = Alloys other than Mn & Si and added to L, M or H eg.LA, MA or HA

L = Low Mn & SiM = Medium Mn & SiH = High Mn & Si

ELECTRODE CLASSIFICATIONS - SUBMERGED ARC WELDING ELECTRODES AND FLUXES

136CONTENTS

WELD DEPOSITION AND COSTING DATAWeld costing systems differ throughout the world and between companies in similar operations but with different methods of cost accounting. Some variations in systems are due to variations in methods of selling consumables. For example, MMAW consumables may be sold by the number, length or mass of the electrodes. However, all systems invariably rely on a basic philosophy of determining the quantity (in kg.lb, m etc) of consumable required to produce a given volume of joint. From this, the labour time for joint completion, based on the deposition rate and duty cycle estimates for the welding consumables/processes, welding positions and workshop/site situations, in question, can be determined.The costs of joint preparation and finishing must also be considered, and like the other factors mentioned can be substantially influenced at the design stage. The lowest welding costs are achieved when full use is made of the high productivity welding processes and when joints are designed specifically for these processes.Australia sells all major solid (and some gas) welding consumables by mass (kg), and all requirements can be related back to the mass of added weld metal required to produce a unit length of joint. Most well equipped welding shops have a range of processes, particularly MMAW, GMAW and SAW machines, and the following approach to weld costing is based on a system which can integrate the various methods and allow for substitution as desired.THE WIA APPROACH TO WELD COSTS DETERMINATIONS TO ASSIST yOU IN ESTIMATING WELDING COSTS WE HAVE PUT TOGETHER THE FOLLOWING GUIDE IN FOUR SECTIONS. A COMPREHENSIVE GUIDE TO USING SECTIONS 1-4 The mass of weld metal in a length of joint is a product of its volume (cross-sectional area x length) and its density. Most weld joint cross-sections can be broken up into basic shapes as detailed below and illustrated in Figure 10

137CONTENTS

WELD DEPOSITION AND COSTING DATA - USERS GUIDE

RECTANGULAR CROSS SECTIONS

Major area of the square, vee and U joints and roof gap components.

TABLE 1.0

TRIANGULAR CROSS-SECTIONS

Major areas of vee and bevel joints, fillet sections TABLE 1.1

REINFORCMENT CROSS-SECTIONS

1 Semi-elliptical shapes of predictable or measurable heights and widths reinforcing the weld face.

TABLE 1.2

RADIUS CROSS-SECTIONS

Part circle segments associated with U and J joints

TABLE 1.3

BACK GOUGED CROSS-SECTIONS

The carbon arc electrode selected Or gas nozzle) determines the width, while the rate of travel and angle determines the depth of gouge. Areas of predicable contours are covered.

TABLE 1.4

FILLET WELD SECTIONS

A range of fillet sizes and shapes including convexity and concavity allowances.

TABLE 1.5

138CONTENTS

Figure 10TABLES 1.0-1.5 of SECTION 1 are a convenient means of determining the mass of weld metal per unit length of joint for each of the simple joint cross-sections described. Simply look up the appropriate dimensions of the shape in question, and the weld metal mass, in kilograms per metre (kg/m), is calculated for you. By referring to GUIDE 1, shown in the following pages, a practical example is given illustrating the correct usage of TABLES 1.0-1.5Where ready made tables are not available or greater accuracy is required you can calculate the area. Given the length of the required weld, the volume of weld metal can be calculated and converted to the mass of weld metal, using an appropriate density figure. For example, 1 mm² cross-sectional area of steel weld metal by 1000 mm (1 metre) long has a mass of .00785 kg. Therefore, finding the cross-sectional area, in mm², and multiplying by .00785 will give the mass of weld metal per metre of joint, in kg/m.

Side A

Side b

f A h A

h B

f B

dr

d 2

T1/2 L

WELD DEPOSITION AND COSTING DATA

W= 2r

139CONTENTS

A COMPREHENSIVE GUIDE TO USING SECTIONS 1-4 CONT.“Quantity of consumables” data, tabled in section 2, allows the quantity of consumable(s) required to weld a given joint, to be calculated. Further to this, the “DEPOSITION RATE” and “Duty Cycle” data of sections 3 & 4 enable realistic estimates of actual welding speeds and times to be determined for specific consumables/welding processes, welding positions and workshop/site situations. Detailed practical examples, illustrating the use of information contained in Sections 2-4 are featured respectively in Guides 2-4.By FOLLOWING THE GUIDES THROUGH FROM 1-4 THE USER IS GIVEN A STEP-By-STEP METHOD FOR DETERMINING:1. the mass of weld metal required per metre of joint 2. the quantity of consumable(s) required per metre of joint 3. the continuous (100% duty cycle) welding speed/time for one metre of joint 4. a realistic estimate of the actual welding speed/time to complete one metre of joint.GUIDE 1 - DETERMINE MASS OF WELD PER METRE USING TABLES 1.0 - 1.5 OF SECTION 1 (a) Fillet Welds For fillet welds the user is directed to TABLE 1.5. Select the desired leg length (L) with the likely degree of convexity (h) given the electrode size/type used, the welding position and process etc., and read off the mass of weld metal per metre of joint (kg/m).For acute angle or obtuse angle fillets or fillets of unequal leg length treat as for a butt weld and refer to (b).(b) Butt WeldsFor butt welds, first sketch the joint cross-section under consideration, breaking it down into fundamental shapes such as rectangles, triangles and reinforcement and radius sections as shown in figure 10.Dimension the shapes, from available information, by calculation or by “intelligent guessing”. Using these dimensions, the mass of weld metal per metre of joint can be arrived at for each shape segment using the data from TABLES 1.0-1.4. From here, the total mass of weld metal required per metre of joint can be simply calculated by adding the figures obtained for each shape segment.


140CONTENTS

PRACTICAL EXAMPLE 1 For the U-joint illustrated in FIGURE 10, assume the following dimensions:T (plate thickness) = 60 mm Ø = 10° (therefore, included angle is 20°) r (root radius) = 10 mm d₂ (root face) = 8 mmSide A Rectangular, Triangular and Radius Cross-SectionsWith a root face (d₂) of 8 mm and a root radius (r) of 10 mm, the depth of the rectangular and triangular sections (d) will be, d = T - (d₂ + r) = 60 - 18 = 42 mm. The width of the rectangle (w) is of course equal to 2r = 20 mm.From table 1.0, the mass of weld metal per metre of joint required for a rectangle of area, 20 x 42 mm = 840 mm2, is approximately 6.59 kg/m (A).From table 1.1, two triangles with an included angle of 20° and a depth of 42 mm will need a mass of weld metal per meter of joint of approximately ....................................................2.50 kg/m (B). From table 1.3, a semi-circular section of radius 10 mm will require a mass of weld metal per metre of joint of approximately . ................................................................................1.23 kg/m (D).GUIDE 1 CONT. SIDE A REINFORCEMENT CROSS-SECTION The reinforcement width of Side A (fA ) will be the addition of 2r (20mm) and L (15mm, taken from TABLE 1.1) plus whatever overlap onto the parent metal is considered desirable practice. For this example, assume an average overlap of 3mm on each side of the joint which gives fA = 6 + 20 + 15 = 41 mm. Also let us assume a reinforcement height on Side A (hA ) of 3 mm.From table 1.2, the mass of weld metal required per metre of joint for the reinforcement section of Side A of f = 41 mm and h = 3 mm is approximately ...................................................0.75 kg/m (C1).


141CONTENTS

SIDE B BACK GOUGED CROSS-SECTION Here the user will be guided by such factors as, the welding process used for the root pass, to determine resultant root penetration, the fracture toughness requirements of the root and established workshop practices, etc. to determine the extent of back gouging required. For this example, we will assume a carbon-arc gouge carried out with a 10 mm carbon electrode to produce a groove 14 mm wide and 10 mm deep. From TABLE 1.4, the mass of weld metal required per metre of joint to fill a groove of these dimensions is approximately .........................................................0.86kg/m (E).Side B Reinforcement Cross-Section With a gouge width of 14 mm (allow a little more for uneven gouging) and estimating a 3 mm overlap onto each side of the joint gives a reinforcement width for Side B (f8) of 21 mm.From TABLE 1.2, the mass of weld metal required per metre of joint for a reinforcement section of f = 21 mm and an assumed height of h = 1.5 mm is approximately .................. 0.19 kg/m (C2).Therefore, A + B + D + C1 + E + C2 gives the total mass of weld metal required per metre of joint: 6.59 + 2.50 + 1.23 + 0.75 + 0.86 + 0.19 = 12.12 Kg/mGUIDE 2 - DETERMINE QUANTITy OF CONSUMABLES REQUIRED PER METRE USING TABLES 2.0 - 2.3 OF SECTION 2 Given the mass of weld metal required to “Fill” a metre of joint, the next step is to determine the mass of consumable(s) initially required. The weld metal yield achieved from welding with a consumable electrode or filler wire largely depends on the efficiency of the welding process / consumable in question. This efficiency is influenced by such inherent wastage factors as, weld metal spatter, slag coverage and gas plume production. The “Quantity of consumables” figures listed in tables 2.0-2.3 are for a weld metal yield of 1 kg and take account of these inherent losses. An additional percentage (listed in the ‘EXTRA FOR WASTAGE” column) is usually added to allow for typical shop wastage such as stub ends & wire snips etc.


142CONTENTS

PRACTICAL EXAMPLE 1 CONTINUED For the U-joint discussed in EXAMPLE 1 of GUIDE 1 let us assume that 1.6 mm Austfil 71T with CO₂ shielding gas is used for the single root pass weld on Side A and for welding the entire back gouged section on Side B; and a SAW process using 4.0mm wire is used for the remainder of the joint.AUSTFIL 71T REQUIREMENTS (NOT INCLUDING ALLOWANCE FOR SHOP WASTAGE) Side A. Allow .25 kg of weld metal/metre of joint for the root pass deposit (assuming that a single pass with a 1.6 mm Austfil 71T is comparable in size to an 8 mm fillet weld).Side B. From Guide 1, the mass of weld metal per metre of joint for the back gouged cross-section (including reinforcement) is 1.05 kg/m. (0.86 +0.19)Therefore, the total weld metal required from Austfil 71T is 1.05 + 0.25 = 1.30 kg/m.From table 2.2 type A, 1.20 kg of Austfil 71T will produce 1 kg of weld metal. Therefore, 1.20 x 1.30 = 1.56kg of Austfil 71T will produce 1.30 kg of weld metal per metre of joint.CO₂ Shielding Gas ConsumptionTo estimate CO₂ gas consumption let us assume, the 1.6mm Austfil 71T is deposited at 350 Amps and 29 Volts, which will produce a weld metal deposition rate of approx 5.4 kg/hr (see table 3.2 part B of section 3).GUIDE 2 CONT.For a CO₂ flow rate of 12 L/min approximately 0.13m₃ (or .24kg) of CO₂ gas will be consumed per kg of weld metal deposited (see table 2.2). Therefore, 1.30 x 0.13 = 0.17 m3 (or .32 kg) of CO₂ will be used to deposit 1.30 kg of weld metal per metre of joint.SAW FILLER METAL AND FLUX REQUIREMENTS (NOT INCLUDING ALLOWANCE FOR SHOP WASTAGE) The wire/flux submerged arc combination is required to produce 12.12 - 1.30 = 10.82 kg of weld metal per metre of joint. From table 2.3 approximately 1.02 kg of wire will produce 1 kg of weld metal. Therefore, 1.02 x 10.82 = 11.04 kg of wire will produce 10.82 kg of weld metal per metre of joint. Also from table 2.3 approximately 1.1 kg of flux is required to produce 1 kg of weld metal. Therefore, 1.1 x 10.82 11.90 kg of flux will be consumed to produce 10.82 kg of weld metal per metre of joint.In the summary, the quantity of consumables required to complete one metre of joint are:


143CONTENTS

• 1.6 kg of 1.6 mm Austfil 71T wire • 0.2 m₃ (0.3 kg) of CO₂ shielding gas • 11.0kg of wire • 11.9 kg flux not including allowances for shop wastage. GUIDE 3 - DETERMINE 100% DUTy CyCLE WELDING SPEED TIME USING TABLES 3.0 - 3.6 of SECTION 3 From the “Deposition Rate” data in tables 3.0 - 3.6 of section 3 for the selected consumables and arc processes, the continuous welding speed (in m/hr) and welding time (in hr/m) can be determined. Where deposition conditions are substantially varied for different sections of a joint - for example narrow root passes versus wide weave capping passes, the welding speed should be calculated separately rather than an average taken.PRACTICAL EXAMPLE 1 — CONTINUED For the U-joint discussed in example 1 of guides 1 and 2 let us assume the 1.6 mm Austfil 71T (used for the single root pass weld on Side A and for welding the entire back gouged section on Side B) is deposited at 350 amps and 29 volts under CO₂ shielding gas with an electrode stickout of 25 mm. From table 3.2, part B, the typical deposition rate is 5.4 kg/hr.As calculated in guide 2, the wire requirements is 1.30 kg of weld metal per metre of joint. Therefore the welding speed for Austfil 71T will be 5.4 ÷ 1.30 = 4.15 metres of joint/hour or the welding time will be 0.24 hours/metre of joint.For welding the remainder of the joint with SAW process, assume a welding current of 700 amps and voltage of 34 volts for the 4 mm wire nominated. From table 3.3 the typical deposition rate is approximately 8.3 kg/hr.As determined in guide 2, the wire/flux combination is required to produce 10.82 kg of weld metal per metre of joint. Therefore, the welding speed will be:8.3 ÷ 10.82 = 0.77 metres of joint/hour or the welding time will be 1.30 hours/metre of joint. 10.82From the calculated welding time for continuous welding of the Austfil 71T /CO₂ and SAW process combinations, the total welding time is .24 + 1.30 = 1.54 hours/metre of joint.In summary, given a duty cycle of 100%, (that is continuous, uninterrupted, welding of the consumables detailed in this example) one metre of joint will be completed in 1.54 hours.


144CONTENTS

GUIDE 4— DETERMINE REALISTIC ESTIMATE OF WELDING SPEED/TIME USING THE DUTy CyCLE DATA OF SECTION 4The continuous welding speeds and welding times, (That is for a Duty Cycle of 100%) calculated in practical example 1 of guide 3 serve as a starting point for determining realistic welding speeds and welding times for joint completion.As stated in section 4, Duty Cycle is a measure of the “arc on” time as a percentage of the total time elapsed. The total elapsed time must take into account all additional “non-arc” operations, such as materials handling, weld deslagging, electrode changes overs etc and personal allowances, as well as the total “arc-on” time.In order to arrive at realistic welding speeds and times which will approach the actual figures achieved, it is important to use duty cycle estimates which are realistic for the consumable/arc process combinations and workshop/site in question.The choice of a satisfactory duty cycle may be determined by referring to past records for workshop or site projects undertaken using similar welding consumables and arc processes under similar working conditions. Since detailed information of this nature is often unavailable, a suitable duty cycle figure may be arrived at by using “published data” and/or by “educated guessing”.section 4 entitled “Duty Cycles” details a range of achievable duty cycles for the main arc welding processes used. The duty cycles given under each heading are generally accepted as ‘maintainable’ by most reasonably equipped workshops or welding sites.To continue practical example 1 from guide 3, let us assume from the information in parts (b) and (c) of SECTION 4;• a duty cycle of 30% for the FCAW process • a duty cycle of 40% for the SAW processTherefore, a realistic estimate of the welding speed for Austfil 71T/CO₂ is 4.15 x .30 = 1.25 metres of joint/hour, and the welding time is 0.80 hours/metre of joint; and a realistic estimate of the welding speed for SAW process is 0.77 x .40 = 0.31 metres of joint/hour, and the welding time is 3.25 hours/metre of joint.


145CONTENTS

FROM THE CALCULATED WELDING TIMES FOR THE FCAW AND SAW COMBINATIONS THE TOTAL WELDING TIME TO COMPLETE ONE METRE OF JOINT IS 0.80 + 3.25 = 4.05 HRS.This welding time will be a good approximation of the actual time to complete one metre of join given that the duty cycle estimates used are realistic for the welding task involved.PRACTICAL EXAMPLE 2 If, for the joint described in example 1, the initial two passes on Side A and all of Side B is welded with MMAW electrodes, Austarc 77 and Austarc 24 -instead of Austarc 71T; and the remainder of the joint is welded with SAW process, the following variations could take place. Side A. The initial two passes with 4 mm Austarc 18TC will deposit 2 x .14 = .28 kg of weld metal per metre of joint (assuming, a single pass with 4 mm Austarc 18TC is comparable to a 5 mm fillet, see section 1, Table1.5). The remainder of Side A is to be welded with SAW process.Side. The first pass welded with 4 mm Austarc 18TC will deposit .14 kg of weld metal per metre of joint. The remainder of Side B is to be complete with 5 mm Austarc 24.GUIDE 4 CONT. 4 MM AUSTARC 18TC REQUIREMENT The total mass of weld metal required from 4 mm Austarc 18TC is .28 + .14 = .42 kg per metre of joint. At a typical current setting of 170 amps, the deposition rate (at 100% duty cycle) is 170 x .01 = 1.70 kg/hr (see section 3 table 3.0) Therefore, the continuous welding time to deposit .45 kg of weld metal with 4 mm Austarc 18TC is..42 = 0.25 hours/metre of joint 170Assuming a duty cycle of 25% (see section 4), a realistic estimate of the actual welding time is.25 = 1,00 hours/metre of joint .25


146CONTENTS

5 MM AUSTARC 24 REQUIREMENT The remainder of Side B requires 1.05 - 0.14 = 0.91 kg of weld metal per metre of joint, deposited with 5 mm Austarc 24.At a typical current setting of 300 amps, the deposition rate (at 100% duty cycle) is 300 x 0.135 =4.05 kg/hr (see section 3, table 3.0) Therefore, the continuous welding time to deposit 0.92 kg of weld metal with 5 mm Austarc 24 is 0.91 = 0.22 hours/metre of joint 4.05Assuming a duty cycle of 30% (see section 4), a realistic estimate of the actual welding time is .22 = 0.73 hours/metre of joint .30SAW CONSUMABLE The remainder of Side A requires 11.07 - .28 = 10.79 kg of weld metal per metre of joint.A typical current and voltage setting of 700 amps and 34 volts, for the 5 mm SAW wire nominated will produce a typical deposition rate (at 100% duty cycle) of 8.3 kg/hr (see section 3, table 3.3)Therefore, the continuous welding time to deposit 10.72 kg of weld metal with 5 mm wire is10.79 = 1.30 hours/metre of joint 8.3Assuming a duty cycle of 40% (see SECTION 4), a realistic estimate of the actual time is1.30 = 3.25 hours/metre of joint .40For Example 2, The Total Welding Time To Complete One Metre Of Joint May Be Summarised As Follows: 4mm Austarc 18TC (at 25% duty cycle) - 1.00 hrs/metre of joint 5mm Austarc 24 (at 30% duty cycle) - 0.73 hrs/metre of joint 5mm wire/flux combination (at 40% duty cycle) - 3.25 hrs/metre of joint Estimate of actual welding time to complete joint - 4.98 hrs/metre of joint


147CONTENTS


RECTANGULAR WELD CROSS-SECTIONS TABLESI

MPL

y, M

ULT

IPLy

“D

X W

” FO

R C

RO

SS-S

ECTI

ON

AL

AR

EA (M

M₂ ) A

ND

REA

D D

IREC

TLy

FRO

M T

HE

TAB

LE. W

HER

E A

SEC

TIO

NA

L O

R T

OTA

L JO

INT

AR

EA IS

ALR

EAD

y K

NO

WN

IN

SQ

UA

RE

INC

HES

, MU

LTIP

Ly B

y 64

5.2

FOR

MM

₂ AN

D U

SE T

HIS

TA

BLE

.Th

is ta

ble

prov

ides

the

mas

s of

ste

el w

eld

met

al p

er m

etre

of j

oint

(kg/

in) f

or

know

n cr

oss-

sect

iona

l are

as.S

impl

y, m

ultip

ly “d

x w

” for

cro

ss-s

ectio

nal a

rea

(m

m₂ ) a

nd re

ad d

irect

ly fro

m th

e ta

ble.

Whe

re a

sec

tiona

l or t

otal

join

t are

a is

al

read

y kn

own

in s

quar

e in

ches

, mul

tiply

by 6

45.2

for m

m₂ a

nd u

se th

is ta

ble.

AR

EA

(mm

₂ )0

1020

3040

5060

7080

90

0-

0.08

0.16

0.24

0.31

0.39

0.47

0.55

0.63

0.71

100

0.79

0.86

0.94

1.02

1.10

1.18

1.26

1.33

1.41

1.49

200

1.57

1.65

1.73

1.81

1.88

1.96

2.04

2.12

2.20

2.28

300

2.36

4.43

2.51

2.59

2.67

2.75

2.83

2.90

2.98

3.06

400

3.14

3.22

3.30

3.38

3.45

3.53

3.61

3.69

3.77

3.85

500

3.93

4.00

4.08

4.16

4.24

4.32

4.40

4.47

4.55

4.63

600

4.71

4.79

4.87

4.95

5.02

5.10

5.18

5.26

5.34

5.42

700

5.50

5.57

5.65

5.73

5.81

5.89

5.97

6.04

6.12

6.20

800

6.28

6.36

6.44

6.52

6.59

6.67

6.75

6.83

6.91

6.99

900

7.07

7.14

7.22

7.30

7.38

7.46

7.54

7.61

7.69

7.77

1000

7.85

7.93

8.01

8.09

8.16

8.24

8.32

8.40

8.48

8.56

Whe

re in

crem

ents

of l

ess

than

10

mm

₂ are

con

side

red

nece

ssar

y, ad

d to

the

abov

e, o

n th

e ba

sis

of .0

08 k

g/in

for e

very

1 m

m₂ .

w

d

w

w

d ddw

148CONTENTS

MASS OF STEEL WELD METAL PER METRE OF JOINT (kg/m)

Depth d

(mm)

Width L

(mm)kg/m

Width L

(mm)kg/m

Width L

(mm)kg/m

Width L

(mm)kg/m

6 3.5 008 6.0 0.14 2.1 005 3.2 0.088 4.6 0.14 8.0 0.25 2.8 0.09 4.3 0.1410 5.8 0.23 10.0 0.39 3.5 0.14 5.4 0.2112 6.9 0.32 12.0 0.57 4.2 0.20 6.4 0.3014 8.1 0.45 14.0 0.77 4.9 0.27 7.5 0.4116 9.2 0.58 16.0 1.00 5.6 0.35 8.6 0.5420 11.5 0.90 20.0 1.57 7.1 0056 10.7 0.8422 12.7 1.10 22.0 1.90 7.8 0.67 11.8 1.0224 13.9 1.31 24.0 2.26 8.5 0.80 12.9 1.2226 15.0 1.53 26.0 2.65 9.5 0.94 13.9 1.4228 16.2 1.78 28.0 3.08 9.9 1.09 15.0 1.6530 17.3 2.04 30.0 3.53 10.6 1.25 16.1 1.9035 20.2 2.77 35.0 4.81 12.3 1.69 18.8 2.5840 23.1 3.63 40.0 6.28 14.1 2.21 21.4 3.3645 26.0 4.59 45.0 7.95 15.9 2.81 24.1 4.2650 28.9 5.67 50.0 9.81 17.6 3.45 26.8 5.2655 31.8 6.86 55.0 11.87 9.4 4.19 29.5 6.3760 34.6 8.15 60.0 14.13 21.2 5.99 32.2 7.5870 40.4 11.10 70.0 19.23 24.7 6.79 37.5 10.3075 43.3 12.75 75.0 22.08 26.4 7.77 40.2 11.8380 46.2 14.51 80.0 25.12 28.2 8.85 42.9 13.47

TABLE 1.1 TRIANGULAR WELD CROSS-SECTIONS

MASS OF WELD METAL IN JOINT

30˚ 45˚ 20˚

L L L

d

d d

30˚

L

d

SECTION SHAPES AND ANGLES

149CONTENTS


Depth d

(mm)

Width L

(mm)kg/m

Width L

(mm)kg/m

Width L

(mm)kg/m

Width L

(mm)kg/m

6 3.5 008 6.0 0.14 2.1 005 3.2 0.088 4.6 0.14 8.0 0.25 2.8 0.09 4.3 0.1410 5.8 0.23 10.0 0.39 3.5 0.14 5.4 0.2112 6.9 0.32 12.0 0.57 4.2 0.20 6.4 0.3014 8.1 0.45 14.0 0.77 4.9 0.27 7.5 0.4116 9.2 0.58 16.0 1.00 5.6 0.35 8.6 0.5420 11.5 0.90 20.0 1.57 7.1 0056 10.7 0.8422 12.7 1.10 22.0 1.90 7.8 0.67 11.8 1.0224 13.9 1.31 24.0 2.26 8.5 0.80 12.9 1.2226 15.0 1.53 26.0 2.65 9.5 0.94 13.9 1.4228 16.2 1.78 28.0 3.08 9.9 1.09 15.0 1.6530 17.3 2.04 30.0 3.53 10.6 1.25 16.1 1.9035 20.2 2.77 35.0 4.81 12.3 1.69 18.8 2.5840 23.1 3.63 40.0 6.28 14.1 2.21 21.4 3.3645 26.0 4.59 45.0 7.95 15.9 2.81 24.1 4.2650 28.9 5.67 50.0 9.81 17.6 3.45 26.8 5.2655 31.8 6.86 55.0 11.87 9.4 4.19 29.5 6.3760 34.6 8.15 60.0 14.13 21.2 5.99 32.2 7.5870 40.4 11.10 70.0 19.23 24.7 6.79 37.5 10.3075 43.3 12.75 75.0 22.08 26.4 7.77 40.2 11.8380 46.2 14.51 80.0 25.12 28.2 8.85 42.9 13.47


Depth d

(mm)

Width L

(mm)kg/m

Width L

(mm)kg/m

Width L

(mm)kg/m

Width L

(mm)kg/m

6 5.6 0.13 6.9 0.16 8.4 0.20 12.0 0.287.5 7.5 0.24 9.2 0.29 11.2 0.35 16.0 0.5010 9.3 0.37 11.5 0.45 14.0 0.55 20.0 0.7912 11.2 0.53 13.9 0.65 16.8 0.79 24.0 1.1314 13.1 0.72 16.2 0.89 19.6 1.08 28.0 1.5416 14.9 0.94 18.5 1.16 22.4 1.41 32.0 2.0120 18.7 1.47 23.1 1.81 28.0 2.20 40.0 3.1422 20.5 1.77 25.4 2.19 30.8 2.66 44.0 3.8024 22.4 2.11 27.7 2.61 33.6 3.17 48.0 5.4226 24.2 2.47 30.0 3.06 36.4 3.71 52.0 5.3128 26.1 2.87 32.3 3.55 39.2 4.31 56.0 6.1530 28.0 3.30 34.6 4.07 42.0 4.95 60.0 7.0735 32.6 4.48 40.4 5.55 49.0 6.73 70.0 9.6240 37.3 5.86 46.2 7.25 56.0 8.79 80.0 12.5645 42.0 7.42 52.0 9.18 63.0 11.13 90.0 15.9050 46.6 9.15 57.7 11.32 70.0 13.74 100.0 19.6355 51.3 11.07 63.5 13.71 77.0 16.62 110.0 23.7560 56.0 13.19 69.3 16.32 84.0 19.78 120.0 28.2670 65.3 17.94 80.8 22.20 98.0 26.93 140.0 38.4775 69.9 20.58 86.6 25.49 105.0 30.91 150.0 44.1680 74.6 23.42 92.4 29.01 112.0 35.7 160.0 50.24

TABLE 1.1 TRIANGULAR WELD CROSS-SECTIONS CONT.

SECTION SHAPES AND ANGLES70˚

L

d

90˚

L

d

60˚

L

50˚

L

d

WELD DEPOSITION & COSTING DATA - MASS OF WELD METAL IN JOINT

150CONTENTS

Depth, d

(mm)

MASS OF STEEL WELD METAL PER METRE OF JOINT (kg/m) REINFORCEMENT HEIGHT, h.

h=1.0mm h=1.5mm h=3.0mm h=4.5mm h=6.0mm

6 0.04 0.068 0.05 0.07

10 0.06 0.09 0.18 0.2812 0.07 0.11 0.22 0.3314 0.09 0.13 0.26 0.3916 0.10 0.15 0.30 0.4420 0.12 0.18 0.37 0.55 0.7422 0.14 0.20 0.41 0.61 0.8124 0.15 0.22 0.44 0.67 0.8926 0.16 0.24 0.48 0.72 0.9628 0.17 0.26 0.52 0.78 1.0430 0.18 0.28 0.55 0.83 1.1135 0.22 0.32 0.65 0.97 1.2940 0.25 0.37 0.74 1.11 1.4845 0.28 0.42 0.83 1.25 1.6650 0.31 0.46 0.92 1.39 1.85

Note. For face widths in excess of 50 mm, estimate average height of reinforcement and calculate as for a rectangle, referring to table 1.0

TABLE 1.2 WELD REINFORCEMENT CROSS-SECTIONS


Fh

151CONTENTS

Depth, d

(mm)

MASS OF STEEL WELD METAL PER METRE OF JOINT (kg/m) REINFORCEMENT HEIGHT, h.

h=1.0mm h=1.5mm h=3.0mm h=4.5mm h=6.0mm

6 0.04 0.068 0.05 0.07

10 0.06 0.09 0.18 0.2812 0.07 0.11 0.22 0.3314 0.09 0.13 0.26 0.3916 0.10 0.15 0.30 0.4420 0.12 0.18 0.37 0.55 0.7422 0.14 0.20 0.41 0.61 0.8124 0.15 0.22 0.44 0.67 0.8926 0.16 0.24 0.48 0.72 0.9628 0.17 0.26 0.52 0.78 1.0430 0.18 0.28 0.55 0.83 1.1135 0.22 0.32 0.65 0.97 1.2940 0.25 0.37 0.74 1.11 1.4845 0.28 0.42 0.83 1.25 1.6650 0.31 0.46 0.92 1.39 1.85

Radius r

(mm)

MASS OF WELD METAL PER METRE OF JOINT (kg/m)

“U” “J”3 0.11 0.064 0.20 0.105 0.31 0.156 0.44 0.227 0.60 0.308 0.79 0.399 1.00 0.50

10 1.23 0.6211 1.49 0.7512 1.18 0.8913 2.08 1.0414 2.42 1.2115 2.77 1.39

Depth r

(mm)Width (mm)

Area (mm²)

MASS OF WELD

METLEL PER METRE OF

JOINT (kg/m)1.5 6 7.07 0.062.5 8 15.71 0.123.5 7 19.24 0.154 12 37.70 0.305 10 37.27 0.317 12 65.97 0.528 19 119.38 0.94

10 14 109.96 0.9610 22 172.79 1.3612 20 188.50 1.4815 30 353.43 2.77

Note. Note: Appropriate reinforcement additions, selected from table 1.2, will generally be required to be added to the above figures.

TABLE 1.3 RADIUS WELD CROSS-SECTIONS



1/2 width

dept

hL

J r

Ur

152CONTENTS

WELD SIZE

Cross- sectional Area (mm²)

MASS OF WELD METAL PER METRE (kg/m)

Leg Length, LThroat Thickness

T (mm)

Flat and Convex Welds Convex Welds

(mm) (inch) h=0 (There.) h=1.0mm h=1.5mm h=2.5mm

Throat Thickness

T (mm)

Typical Concave

Weld3.2 1/8 2.3 5.1 .04 .07 .08 - 2.3 0.053.5 2.5 6.1 .05 .08 .10 - 2.5 0.064.0 5/32 2.8 8.0 . 06 .09 .11 - 2.8 0.074.8 3/16 3.4 11.5 .09 .13 .15 - 3.4 0.105.0 3.5 12.5 .10 .14 .17 - 3.5 0.115.6 7/32 4.0 15.7 .12 .17 .19 - 4.0 0.136.0 4.2 18.0 .14 .19 .22 - 4.2 0.156.4 1/4 4.5 20.5 .16 .22 .24 - 4.5 0.177.0 4.9 24.5 .19 .25 .28 - 4.9 0.218.0 ~5/16 5.7 32.0 .25 .32 .35 - 5.7 0.279.5 3/8 6.7 45.1 .36 .44 .48 .57 7.7 0.39

10.0 7.1 65.0 .39 .48 .52 .61 7.1 0.4212.7 7.1 50.0 .63 .74 .80 .91 9.0 0.6815.9 5/8 11.2 126.4 .99 1.13 1.20 1.34 11.2 1.0619.0 ~3/4 13.4 180.5 1.42 1.59 1.67 1.84 13.4 1.5222.2 7/8 15.7 246.4 1.93 2.13 2.23 2.42 15.7 20.624.4 1.0 18.0 322.6 2.53 2.75 2.86 3.08 18.0 2.70

TABLE 1.5 FILLET WELDS The table shows the mass of steel weld metal per metre of joint (kg/m) for fillet welds of varying degrees of convexity and a typical concave profile. The figures are based on actual leg length being maintained. Note that the leg lengths shown are not applicable to the concave welds which are designated in this table by throat thickness.

153CONTENTS

WELD SIZE

Cross- sectional Area (mm²)

MASS OF WELD METAL PER METRE (kg/m)

Leg Length, LThroat Thickness

T (mm)

Flat and Convex Welds Convex Welds

(mm) (inch) h=0 (There.) h=1.0mm h=1.5mm h=2.5mm

Throat Thickness

T (mm)

Typical Concave

Weld3.2 1/8 2.3 5.1 .04 .07 .08 - 2.3 0.053.5 2.5 6.1 .05 .08 .10 - 2.5 0.064.0 5/32 2.8 8.0 . 06 .09 .11 - 2.8 0.074.8 3/16 3.4 11.5 .09 .13 .15 - 3.4 0.105.0 3.5 12.5 .10 .14 .17 - 3.5 0.115.6 7/32 4.0 15.7 .12 .17 .19 - 4.0 0.136.0 4.2 18.0 .14 .19 .22 - 4.2 0.156.4 1/4 4.5 20.5 .16 .22 .24 - 4.5 0.177.0 4.9 24.5 .19 .25 .28 - 4.9 0.218.0 ~5/16 5.7 32.0 .25 .32 .35 - 5.7 0.279.5 3/8 6.7 45.1 .36 .44 .48 .57 7.7 0.39

10.0 7.1 65.0 .39 .48 .52 .61 7.1 0.4212.7 7.1 50.0 .63 .74 .80 .91 9.0 0.6815.9 5/8 11.2 126.4 .99 1.13 1.20 1.34 11.2 1.0619.0 ~3/4 13.4 180.5 1.42 1.59 1.67 1.84 13.4 1.5222.2 7/8 15.7 246.4 1.93 2.13 2.23 2.42 15.7 20.624.4 1.0 18.0 322.6 2.53 2.75 2.86 3.08 18.0 2.70

h

L

LT


154CONTENTS

CONSUMABLES TyPEELECTRODE

LENGTH (mm)

QUANTITy OF CONSUMABLES EXTRA

FOR WASTAGE50mm

Stub Length

75mm Stub

LengthHigh Efficiency (150%),

Iron Type Electrodes EXX24, 27 & 28 to

AS/NZS 4855

450 1.60 1.66 10%

380 1.63 1.75 10%

Conventional, Low Iron Powder or Hydrogen

Controlled Electrodes EXX12, 13, 14, 16 &18 Types to AS/NZS 4855

450 1.63 1.73 10%

380 1.66 1.73 10%

Cellulose Type Electrodes

(EXX10 & 11 Types to AS/NZS 4855)

380 1.73 1.87 10%

CONSUMABLES TyPE, CONDITIONS ECT.

QUANTITy OF

CONSUMABLE

EXTRA FOR

WASTAGEMild and Low Alloy Steel Welding Wire 1.02 2%Flux Consumption - For any given wire

size under the following conditionsLow Voltage, Normal Amperage 0.8 kg 15%Low Amperage, Normal Voltage 1.6 kg 15%

Normal Voltage, Normal Amperage 1.1 kg 15%High Voltage, Normal Amerpage 1.6 kg 15%Hight Amperage, Normal Voltage 0.8 kg 15%

Note. For Aluminium weld metal divide the steel weld metal mass per metre by 2.9

The “QUANTITy OF CONSUMABLE” figures listed in TABLES 2.0 - 2.3 are for a weld metal production of 1kg and to take into account inherent wastage losses such as weld metal spatter, slag coverage, and gas plume production. An additional percentage (listed in the “EXTRA FOR WASTAGE” column) is usually added to allow for typical shop wastage such as stub ends and wire snips etc.To obtain the quantity of consumable required to produce 1kg of weld metal read directly from tables 2.0 - 2.3 for the appropriate consumable, shielding gas, arc transfer mode etc.

QUANTITY OF CONSUMABLES REQUIRED

TABLE 2.0 MANUAL METAL-ARC WELDING (MMAW)

TABLE 2.3 SUBMERGED-ARC WELDING (SAW)

155CONTENTS

CONSUMABLES TyPE, SHIELDING GAS, ARC TRANSFER MODE ECT.

QUANTITy OF

CONSUMABLE

EXTRA FOR

WASTAGETyPE A MILD ALLOy STEEL WELDING WIRES (AUSTMIG ES6, ESD2 ECT)

USED WITH (i) CO₂ SHIELDING GAS

• Short Arc Transfer (95%)1.05 kg 2%

• Globular Transfer (90%) 1.11 kg 2 %• Globular ‘Free Flight’ Transfer (93%) 1.08 kg 2%

(ii) Ar + 15 - 25% CO₂ SHIELDING GAS • Short Arc Transfer (97%) 1.03 kg 2%

• Globular Transfer (94%) 1.06 kg 2%“Streaming Spray Transfer (96%) 1.04 kg 2%

(iii) Pulsed Arc Transfer (:Syncro-Pulse CDT”) and Programmed Shielding Gas

(98%)1.02 kg

TyPE B STAINLESS STEEL WELDING WIRES (eg. AUSTMIG 308LSI, 316SI ect):USED WITH Ar or Ar/He Based Shielding

Gases and all Arc Transfer Modes, including Pulsed Arc Transfer (98%)

1.02 kg

TyPICAL CONDITIONS

DEPOSITION RATE OF:

CONSUMPTION PER KG OF WELD METAL

EXTRA FOR

WASTAGE

Short Arc Transfer or Pulsed Arc Transfer with a Typical Gas

Flow rate of 15L/min

1.0 kg/hr; .90m₃ (1.68kg of CO₂+) 10%

2.8 kg/hr .32m₃ (.60kg of CO₂+) 10%

Globular, “FreeFlight” or “Streaming”

Spray Transfer with a typical Gas Flow

Rate of 20L/min

3.0 kg/hr .40m₃ (.75kg of CO₂+) 10%

7.0 kg/hr .17m₃ (32kg of CO₂+) 10%

TABLE 2.1 GAS METAL-ARC WELDING (GMAW) AND PULSED ARC WELDING

SHIELDING GAS CONSUMPTION FOR MILD, LOW ALLOy AND STAINLESS STEEL WIRES

WELD DEPOSITION & COSTING DATA - QUANTITY OF CONSUMABLES REQUIRED

(%) Typical Electrode Efficiency for wire type, shielding gas and transfer mode Indicated. + Where appropriate, the mass of CO₂ shielding gas required.NB. 1m₃ of CO₂ at 15.6°C and 1 atmosphere has a mass of 1.87 kg. 1m₃ = 1000 Litres.

156CONTENTS

CONSUMABLES TyPE, SHIELDING GAS, ARC TRANSFER MODE ECT.

QUANTITy OF CONSUMABLE

EXTRA FOR

WASTAGETyPE D ALUMINIUM WELDING WIRES (eg. AUSTMIG 5356, 4043, 5183 etc.)

Spray Arc Transfer (95%) 1.05 kg 1% Pulsed Arc Transfer (Syncro-Pulse CDT) (98%) 1.02 kg 1%

TyPICAL CONDITIONS DEPOSITION RATE OF:


EXTRA FOR

WASTAGESpray Arc Transfer with a

Inert Gas Flow Rate 1.0kg/hr 1.68m3 10%

of 28L/min 2.0kg/hr 0.84m3 10%Pulsed Arc Transfer with a

Inert Gas Flow Rate 0.5kg/hr 2.16m3 10%

of 18L/min 2.0kg/hr 0.54m3 10%

(%) Typical Electrode Efficiency for arc transfer mode Indicated.

TABLE 2.1 GAS METAL-ARC WELDING (GMAW) AND PULSED ARC WELDING

SHIELDING GAS CONSUMPTION FOR FOR ALUMINIUM WIRES:

QUANTITY OF CONSUMABLES REQUIRED

157CONTENTS

CONSUMABLES TyPE, TyPICAL DEPOSITION EFFICIENCy ECT.


EXTRA FOR

WASTAGETyPE A GAS SHIELDED, DOWNHAND

AND POSITIONAL, DCEP WIRES OF 83% EFFICIENCy:

(E70T-1, E71T-5 TYPES TO AWS A5.20)1.20 kg 2%

TyPE B SELF SHIELDED, DOWNHAND DCEP WIRES OF 83% EFFICIENCy:


TyPE C GAS SHIELDED, DOWNHAND METAL CORED WIRES

OF 95% EFFICIENCy:1.05 kg 2%

TyPE D SELF SHIELDED, POSITIONAL DCEN WIRES OF 75% EFFICIENCy:


Assuming a gas flow rate of 12 L/minfor a weld deposition rate of:

CONSUMPTION PER KG OF WELD METAL

EXTRA FOR

WASTAGE2 kg/hr; .36m₃ (.67kg of CO₂*) 10%4 kg/hr; .32m₃ (.18kg of CO₂*) 10%6 kg/hr; .40m₃ (.12kg of CO₂*) 10%8 kg/hr; .17m₃ (.09kg of CO₂*) 10%

* Where appropriate, the mass of CO₂ shielding gas required. NB. 1 m3 of CO₂ at 15.6°C and 1 atmosphere has a mass of 1.87 kg. 1 m3 = 1000 Litres.

TABLE 2.2 FLUX CORED ARC WELDING (FCAW)

TABLE 2.2 FLUX CORED ARC WELDING (FCAW)

WELD DEPOSITION & COSTING DATA - QUANTITY OF CONSUMABLES REQUIRED

158CONTENTS

DEPOSITION RATES

ELECTRODE TyPE,

CLALSSIFICATION TO AS/NZS 4855

WIA ELECT-RODES

TyPICAL (F)₁

FACTOR kg/amp/

hr

DEPOSITION F X A = kg/hr TyPICAL CURRENT, A( )

5mm 4mm 3.2mmE4110/11 11 .009 1.7(190) 1.4(150) 1.0(110)

E4112/13 12P, 13S .008 1.8(220) 1.4(170) 1.0(130)

E4814 - .01 2.4(240) 1.9(190) 1.4(135)E4824 24 .0135 4.1(300) 2.7(200) 2.0(150)E4127 .0135 4.1(300) 2.8(210) 2.0(150)E4816 16TC .009 2.0(220) 1.5(170) 1.2(130)

E4818 / E4846 18TC, 77 .01 2.0(200) 1.6(160) 1.2(115)

The factors (F) are typical for those low carbon steel electrodes, as classified to AS/NZS 4855 in popular use throughout Australia. Multiplying the FACTOR (F) by the CURRENT (A) selected for the electrode size (within its normal current range) will provide typical deposition rates (kg/hr) at 100% duty cycle.

TABLES 3.0-3.5 provide a comprehensive range of typical deposition rates for the continuous operation of various arc welding consumables and arc processes. The tables are designed as an easy-to-read guide to show typical deposition rates achievable tor the electrode/wire types, sizes, welding parameters and shielding gases shown. The tables also give useful information on suitable welding parameters such as welding current, voltage and modes of operation. It should be emphasised that the deposition rates tabulated are for continuous operation (100% duty cycle) of the consumable/arc process in question. Refer to SECTION 4 for further information on typical duty cycle estimates for the welding task involved. The typical deposition rates given for each current setting may vary with changes in arc voltage, electrode stickout and shielding gas composition - refer to the information given below each Table.For accurate deposition rate calculations for continuous wires, measure wire feed speed (in m/min) during welding and use the appropriate “Mass/Length” figures from table 3.6 and “Quantity of Consumables” data from tables 2.1-2.3.TABLE 3.0 TyPICAL DEPOSITION RATES USING MMAW

159CONTENTS

TABLE 3.1A TyPICAL DEPOSITION RATES USING GMAW WITH LOW CARBON AND LOW ALLOy STEEL WIRES (EG AUSTMIG ES6, ESD2 OR SIMILAR WIRES)

WELD DEPOSITION & COSTING DATA - DEPOSITION RATES

WIRE SIZE (mm)

WELDING CURRENT

(AMPS)

ARC VOLTAGE (VOLTS)

WIRE FEED SPEED (M/

MIN)DEPOSITION RATE (kg/hr)

0.8 60+ 16+ 3.3 0.70.8 80+ 17+ 4.4 1.00.8 100+ 18.5+ 5.9 1.30.8 120+ 20+ 7.0 1.60.8 140+ 20+ 9.9 2.20.8 160+ 22+ 12.4 2.80.8 180 30 14.3 3.20.9 70+ 15+ 3.7 1.10.9 100+ 19+ 6.0 1.70.9 120+ 19+ 6.9 2.00.9 150+ 20+ 8.7 2.50.9 180+ 21+ 11.5 3.30.9 180 29 12.0 3.40.9 200 31 14.0 4.01.0 90+ 19+ 3.3 1.21.0 100+ 19+ 3.6 1.31.0 150+ 20+ 5.6 2.01.0 100+ 20+ 7.0 2.51.0 220 28 14.6 5.21.0 250 32 15.7 5.61.0 280 34 16.8 6.01.2 120+ 18+ 2.7 1.41.2 150+ 18+ 3.5 1.81.2 170+ 19+ 3.9 2.01.2 220 30 6.2 3.21.2 250 32 9.1 4.71.2 310 34 11.3 5.81.2 340 36 12.9 6.61.6 140+ 19+ 1.7 1.61.6 200+ 19+ 1.7 1.61.6 250+ 21+ 3.1 2.81.6 300 30 4.9 4.51.6 350 34 6.2 6.71.6 400 34 7.5 6.8

+ Short arc transfer conditions. Note: Deposition rate data determined using: • DC+ (reverse polarity) with a conventional constant power source. • Ar - 16/18% CO2 shielding gas • An electrode stickout length at 8-10 mm for short arc transfer conditions and 15 mm for spray arc transfer conditions.• Deposition efficiency at 96% for both short arc transfer & spray arc transtor conditions

160CONTENTS

TABLES 3.1B TyPICAL DEPOSITION RATES USING PULSED ARC WELDING WITH LOW CARBON AND LOW ALLOy STEEL WIRES (EG AUSTMIG ES6)

DEPOSITION RATES

WIRE SIZE (mm)

WELDING CURRENT

(AMPS)

ARC VOLTAGE (VOLTS)

WIRE FEED SPEED (M/MIN)

DEPOSITION RATE (kg/hr)

0.8 35 17.0 2.0 0.50.8 70 20.0 5.3 1.20.8 105 23.0 8.6 2.90.8 140 25.0 11.9 2.70.8 175 28.0 15.2 3.50.9 40 18.0 2.5 0.70.9 45 17.0 1.9 0.70.9 90 21.0 6.1 1.80.9 135 24.0 9.3 2.70.9 180 27.0 12.5 3.70.9 230 30.0 16.0 4.71.0 110 21.0 5.3 1.91.0 170 24.0 8.4 3.11.0 230 28.0 11.5 4.21.0 290 31.0 14.6 5.31.2 40 19.0 1.5 0.81.2 100 21.5 3.5 1.81.2 160 24.0 5.5 2.91.2 220 26.5 7.4 3.91.2 280 29.0 94 4.91.2 350 32.0 11.7 6.11.6 70 20.0 1.3 1.21.6 165 24.0 2.8 2.61.6 260 28.0 4.4 4.11.6 355 31.0 5.9 5.51.6 450 35.0 7.5 7.0

WIRE SIZE (mm)

DEPOSITION RATE •(kg/hr) - WELDING CURRENT (AMPS)300 400 500 600 700 800 900

2.0 3.1 4.8 - - - - -2.4 2.9 4.1 5.5 7.5 - - -3.2 2.6 3.9 5.3 6.8 8.7 10.1 -4.0 - 3.6 5.1 6.7 8.3 10.0 11.94.8 - - - 5.0 7.4 8.9 10.4

• Deposition rate data achieved using DC+ (reverse polarity) with, normal voltage settings for the wire sizes listed. An electrode stickout of 25mm is used with all wire sizes & current settings. Note: Deposition rates may be increased by 30-50% using DC- (Straight Polarity) & approximately 15-25% using AC. The use of an electrode stickout longer than 25mm with the same welding current increases deposition rate significantly.

Note: Deposition rate data obtained using: • Ar + 16-18% CO2 shielding gas • A deposition efficiency of 98% for pulsed arc transferTABLE 3.3 TyPICAL DEPOSITION RATES USING SUBMERGED-ARC WELDING (SAW) WITH LOW CARBON AND LOW ALLOy STEEL WIRES

161CONTENTS

TABLE 3.2A TyPICAL DEPOSITION RATES USING FCAW


WIRE SIZE (mm)

WELDING CURRENT

(AMPS)

ARC VOLTAGE •••(VOLTS)

WIRE FEED SPEED (M/MIN)


PART A. T1 TyPE OF CORED WIRE1.2 130 23 3.4 1.41.2 150 24 5.3 2.21.2 200 26 7.4 3.31.2 250 28 9.8 4.51.6 200 26 3.7 2.41.6 250 28 5.1 3.41.6 300 30 6.7 4.41.6 350 32 8.2 5.41.6 400 34 10.8 7.11.6 425 36 11.5 7.62.4 300 27 2.4 3.42.4 350 28 3.0 4.32.4 400 32 3.7 5.22.4 450 32 4.3 6.12.4 500 34 5.0 7.12.4 525 35 5.5 7.8

PART B. T5 TyPE OF CORED WIRE1.2 130 22 3.4 1.41.2 150 23 5.3 2.21.2 200 24 7.4 3.31.2 250 26 9.8 4.51.6 200 25 3.7 2.41.6 250 27 5.1 3.41.6 300 28 6.7 4.41.6 350 29 8.2 5.41.6 375 30 9.4 6.12.4 300 25 2.4 3.42.4 350 26 3.0 4.32.4 400 28 3.7 5.22.4 450 29 4.3 6.12.4 475 30 4.7 6.6

Note. Deposition rate data determined using:• DC+ (reverse polarity) with a conventional Constant Potential power source• Welding grade CO₂ shielding gas• An electrode stickout length of, 15mm for 1.2mm, 25mm for 1.6mm & 2.4mm wire sizes• A deposition efficiency of 84% for globular transfer•••Voltage figures are typical machine meter readings-actual arc voltage will be 1-3 volts lower than meter reading due to voltage drop across welding leads. Reduce arc voltage by 2-3 volts when using mixed gas.

• Deposition rate data achieved using DC+ (reverse polarity) with, normal voltage settings for the wire sizes listed. An electrode stickout of 25mm is used with all wire sizes & current settings. Note: Deposition rates may be increased by 30-50% using DC- (Straight Polarity) & approximately 15-25% using AC. The use of an electrode stickout longer than 25mm with the same welding current increases deposition rate significantly.

162CONTENTS

TABLES 3.4A TyPICAL DEPOSITION RATES USING GMAW WITH “300” SERIES STAINLESS STEEL SOLID WIRES

TABLE 3.4B TyPICAL DEPOSITION RATES USING PULSED ARC WELDING WITH “300” SERIES STAINLESS STEEL SOLID WIRES

DEPOSITION RATES

WIRE SIZE (mm)

WELDING CURRENT

(AMPS)

ARC VOLTAGE (VOLTS)

WIRE FEED SPEED (m/min)


0.9 80+ 17+ 4.2 .30.9 100+ 18+ 5.1 1.50.9 150 20 8.4 2.50.9 200 23 12.5 3.71.2 125+ 18+ 3.1 1.61.2 200 20 5.9 3.11.2 250 27 8.1 4.31.2 300 29 10.9 5.8

WIRE SIZE (mm)

WELDING CURRENT

(AMPS)

ARC VOLTAGE • (VOLTS)



0.8 30 17.0 2.4 0.60.8 60 19.0 5.8 1.40.8 90 21.0 9.2 220.8 120 230 12.6 3.00.8 150 25.0 16.0 3.90.9 35 17.0 2.5 0.80.9 75 20.0 5.6 1.70.9 120 235 9.1 2.70.9 165 26.5 12.5 3.80.9 210 30.0 16.0 4.81.0 35 16.0 1.5 0.61.0 80 18.0 4.2 1.61.0 130 21.0 7.1 2.61.0 180 24.0 10.1 3.71.0 225 26.0 12.7 4.71.2 50 17.0 1.5 0.81.2 100 19.5 2.8 1.51.2 150 22.0 4.1 2.21.2 200 24.5 5.3 2.81.2 250 27.0 6.6 3.51.2 300 295 7.9 4.21.2 350 32.0 9.1 4.8

Note: Deposition rate data obtained using: • A deposition efficiency of 98% for pulsed arc transfer • Ar + He + 1.5% CO₂

+ Short arc transfer conditions Note: Deposition rate data determined using: • DC+ (reverse polarity) with a conventional constant potential power source • Ar+ 1-2% O2 shielding gas • An electrode stickout length of, 8-10mm for short arc transfer conditions and 15mm for spray arc transfer conditions• A deposition efficiency of 98% for both short arc transfer and spray arc transfer conditions

163CONTENTS

TABLES 3.5A TyPICAL DEPOSITION RATES USING GMAW WITH AUSTMIG ALUMINIUM ALLOy WIRES (EG. AUSTMIG 5183)

TABLE 3.5B TyPICAL DEPOSITION RATES USING PULSED ARC WELDING WITH AUSTMIG ALUMINIUM ALLOy WIRES (EG. AUSTMIG 5183)


WIRE SIZE (mm)

WELDING CURRENT

(AMPS)

ARC VOLTAGE (VOLTS)



0.9 100 17 9.2 0.90.9 125 18 10.9 1.10.9 175 21 15.0 1.50.9 200 22 18.0 1.71.2 150 22 7.8 1.41.2 175 23 9.0 1.61.2 225 05 13.8 2.41.2 250 25 13.8 2.4

WIRE SIZE (mm)

WELDING CURRENT

(AMPS)

ARC VOLTAGE • (VOLTS)



0.9 25 14.0 2.8 0.30.9 50 16.0 5.6 0.60.9 70 17.0 7.9 0.80.9 90 18.0 10.1 1.00.9 115 20.0 13.0 1.31.0 35 15.0 3.6 0.51.0 70 17.0 6.5 0.81.0 110 19.0 10.0 1.31.0 140 21.0 12.6 1.61.0 180 23.0 16.0 2.11.2 35 15.0 2.8 0.51.2 85 18.0 6.1 1.11.2 135 21.0 9.4 1.71.2 185 24.0 12.7 2.31.2 235 27.0 16.0 2.91.6 80 15.0 2.5 0.81.6 140 17.5 4.6 1.51.6 200 20.0 6.7 2.11.6 265 22.5 8.8 2.81.6 325 25.0 10.9 3.5

Note: Deposition rate data determined using: • Welding grade Ar shielding gas • A deposition efficiency of 98% for pulsed arc transfer

Note: Deposition rate data determined using:• DC+ (reverse polarity) with a conventional constant potential power source. • Welding grade Ar shielding gas • An electrode stickout length of 20mm • A deposition efficiency of 95%

164CONTENTS

165CONTENTS


TABLES 3.6 MASS / LENGTH TABLES

PART A. LOW CARBON AND LOW ALLOy STEEL GMAW WIRES

PART B. FCAW WIRES

PART C. LOW CARBON AND LOW ALLOy STEEL SAW WIRES

PART D. STAINLESS STEEL WELDING WIRES

PART E. ALUMINIUM WELDING WIRES

DEPOSITION RATES

WIRE SIZE (mm) 0.6 0.8 0.9 1.0 1.2 1.6

GRAM OF WIRE PER METRE 2.2 3.9 5.0 6.2 8.9 15.8

METRES OF WIRE PER KG 450.5 253.7 200.4 161.3 112.7 63.4

WIRE SIZE (mm) 1.2 1.6 2.0 2.4 3.2

GRAM OF WIRE PER METRE 7.6 13.0 20.0 28.0 50.1

METRES OF WIRE PER KG 131.6 76.9 50.0 34.7 20.0

WIRE SIZE (mm) 2.0 2.4 3.2 4.0 4.8


METRES OF WIRE PER KG 40.6 28.2 15.9 10.1 7.0

WIRE SIZE (mm) 0.8 0.9 1.0 1.2 1.6


METRES OF WIRE PER KG 245 197.7 158 111.2 62.6

WIRE SIZE (mm) 0.8 0.9 1.0 1.2 1.6


METRES OF WIRE PER KG 712 528.2 455 327.5 184.2

166CONTENTS

The deposition rates tabled in SECTION 3, are for a duty cycle of 100% - that is continuous (uninterrupted) welding of the consumable/arc process in question.DUTy CyCLE IS, By DEFINITION, A MEASURE OF THE “ARC ON” TIME EXPRESSED AS A PERCENTAGE OF THE TOTAL ELAPSED TIME, IE

DUTY CYCLES

Duty Cycle = (%)arc time x 100total elapsed time

Dut

y C

ycle

%

100

80

60

40

20

0

Surfacing Operations

Automatic Welding

SAW

GM

AW

FCAWRW

MM

AW

GW Manual Welding

Machine or Mechanised Welding

Figure 4.0

This parameter indicates the proportion of the operating time during which weld metal is actually being deposited. The duty cycle can vary considerably according to a number of factors including:• the welding process • the type of consumable • operating conditions • the application involved • the degree of mechanisation • general workshop efficiency • a variety of human factors or personal allowances such as putting gloves and helmet on, putting aside and picking up electrode holder etc.Figure 4.0 summarizes the potential range of duty cycles for various arc welding processes and modes of operation.

167CONTENTS

(a) Manual Metal-Arc Welding (MMAW) The maximum obtainable duty cycle for MMAW is of the order of 65% but most applications will not permit a duty cycle greater than 50% to be achieved over a day’s production. The duty cycle for MMAW operations varies widely with the type of application and operating conditions. Electrode changes, slag removal, intermittent welding and changing positions etc all play a part in reducing the actual “arc on” time. With added delays, such as personal allowances and materials handling, most welding workshops are capable of maintaining duty cycles of 15-30%(b) Gas Metal-Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW) —Semi-automatic Arc Processes For semi-automatic surfacing operations a duty cycle approaching 80% is possible. However, most GMAW and FCAW operates between 30-60%; with mechanised semi-automatic welding yielding duty cycles of 45-60% and conventional (or manual) semi-automatic processes producing duty cycles of typically 30-40%.(c) Submerged-Arc Welding (SAW) For fully automatic hard surfacing operations, a 95% duty cycle is possible with the submerged-arc process; however most submerged-arc welding operates between 40-60% duty cycle due to essential setting up, deslagging, loading / positioning and other handling operations.

WELD DEPOSITION & COSTING DATA - DUTY CYCLES

168CONTENTS

OPEN SQUARE GROOVE BUTT JOINT - WELDED BOTH SIDES Reinforcement height, r = 2 mm.

JOINT DIMENSIONS (MM)

Mass of steel weld metal per metre.

(D) (kg/m)

Mass of MMAW** electrodes required per metre (M) (kg/m)T R W

3 0 7 0.17 0.283 1 7 0.20 0.336 1.5 10 0.32 0.536 3 10 0.39 0.64

ELECTRODE CONSUMPTION FOR TYPICAL BUTT JOINTS

W

R

rT

ELECTRODE CONSUMPTION FOR SOME COMMON BUTT JOINTS The following Tables provide useful data on the mass of weld metal and MMAW electrodes required to complete some common butt joints. Electrode consumption is calculated using the following simple equation:

where M = Mass of electrodes required per metre of joint. D = Mass of weld metal deposited per metre of joint. P** = Proportion of electrode lost, due to spatter, slag loss, stub end etc.

M = D1-P

169CONTENTS

WELD DEPOSITION & COSTING DATA - ELECTRODE CONSUMPTION FOR BUTT JOINTS



(D) (kg/m)

Mass of MMAW** electrodes required per metre (M) (kg/m)T R L W

6 3.5 1.5 10.0 0.26 0.438 3.5 1.5 13.0 0.57 0.95

10 3.5 1.5 15.0 0.79 1.3112 3.0 3.0 15.0 0.83 1.3916 3.0 3.0 19.0 1.38 2.2920 3.0 3.0 23.0 2.06 3.43

SINGLE V BUT JOINT Reinforcement height, r = 2mm

W

60°

RL

T

r

W60°

R

L T

r



(D) (kg/m)

Mass of MMAW** electrodes required per metre (M) (kg/m)T R L W

12 3.0 3.0 10.0 0.71 1.1816 3.0 3.0 12.0 1.06 1.7520 3.0 3.0 15.0 1.50 2.4825 3.0 3.0 18.0 2.13 3.5350 3.0 3.0 32.0 6.97 11.58

Single V But Joint Reinforcement height, r = 2mm

• For 380mm long EXX12, 13, 14, 16 & 18 type MMAW electrodes to AS/NZS 4855, P is typically 0.4. This figure assumes a stub end length of 50mm. (See table 2.0 for further details.)

170CONTENTS

WELDABILITY GUIDE FOR STEELSThe majority of steels in general use are considered “Weldable” using most arc welding processes. The degree to which they are rated as weldable is indicated by an imprecise term, “Weldability” which is (as yet) not fully assessable by a laboratory test or series of tests. We have included two different weldability guides to assist you in determining preheat of materials. The first guide is the same as that used in Australian Standards and WTIA technical notes the second guide is a method adopted by WIA and known as the “WIA Welability Guide”Furthermore, what is considered to be a satisfactory joint for one set of service conditions, possibly, steel sections embedded in concrete under static loading, may not be acceptable for another set of service conditions, such as in the tension member of a flexing structure or under corrosive conditions. For this reason, no economically acceptable hard and fast rules can be provided in a Guide such as this and the recommendations should always be tempered in their translation into practice with a knowledge of the intended application and other factors relevant to the situation.Arc welding is a process of intense localised heating and rapid cooling, providing a sudden heating-quenching heat treatment effect on both the weld metal and the adjacent parent metal (HAZ). As a general rule the tendency of a steel to strengthen and harden, following this heat treatment, increases as the carbon and alloy content increases. Its composition is therefore an important factor in assessing weldability.CARBON EQUIVALENT Carbon is the most effective of the commonly used alloying elements in achieving increased strength and hardness (increased hardenability) and is present in all steels. Over many years, researchers have established numerous rating systems to compare the hardening potential of other common elements such as manganese and chromium against that of carbon. This has led to the concept of calculating “Carbon Equivalent” (CE) from the chemical composition of the steel as a means of assessing its weldability. The following is the IIW formula used for determining Carbon Equivalent from the percentage of elements present:

CE = C + + +Mn Cr + Mo + V Ni + Cu6 5 15

171CONTENTS

WELDABILITY GUIDE FOR STEELS

The Weldability Reference Numbers used in this guide, relate to the following carbon equivalents:

NOTE: Reference numbers above 12 are not related to CE. In instances where the ladle analysis is given for a steel, the maximum specification limits have been used to calculate CE. For steels containing multiple alloy additions, the use of maximum specification limits to calculate CE give conservative results; because the possibility of all alloying elements simultaneously achieving their maximum limit is remote. In these circumstances, it is recommended that the CE be calculated using 80-85% of the ladle analysis maximum specification limits.

OTHER FACTORS INFLUENCING WELDABILITy Composition, although important, is not the only criterion used to assess the weldability, of a given steel, in a given joint situation. Other influences can be broadly related either to their effect on the “heat treatment” or the “stress level” of the joint.

CE REFERENCE NUMBER CE REFERENCE

NUMBERbelow 0.30 1 0.55 to below 0.60 7

0.30 to below 0.35 2 0.60 to below 0.65 80.35 to below 0.40 3 0.65 to below 0.70 90.40 to below 0.45 4 0.70 to below 0.75 100.45 to below 0.50 5 0.75 to below 0.80 110.50 to below 0.55 6 0.80 and above 12

172CONTENTS

WELDABILITY GUIDE FOR STEELSOTHER FACTORS INFLUENCING WELDABILITy Factors which can have an effect on the “heat treatment and hence (with composition) the microstructure include; the mass of the section, its initial temperature, the heat input per unit length and the interpass temperature in multipass welds. Factors which relate generally to the “stress level” include; the degree of restraint imposed on the joint by its own mass and from external sources, base metal strength (rigidity, hardness) and geometry, uneven heating and cooling conditions and geometrical considerations such as joint preparation and alignment, notches due to weld contour, weld nugget shape and the presence of non-metallic inclusions, etc. The tendency towards weld and base metal cracking is further influenced by the inherent toughness and strength of the weld metal, the effect of base metal dilution on these properties and the presence of hydroge in the arc atmosphere.NOTES ON USING THE GUIDE The following pages list recommendations for welding some of the more commonly available steels in Australia. Based primarily on the steel composition, they assume moderate conditions of restraint and joint complexity. Where low hydrogen or hydrogen controlled conditions are nominated, electrodes should be dried accordingly to meet the required level. For MMAW, the use of 4mm electrodes (minimum size) has been assumed, although the user is expected to use the largest size practicable. The use of higher and lower heat inputs by other electrode sizes or processes can respectively lower and raise the recommended preheat temperature.Silicon levels are not listed for steels unless their content, within a particular group, exceeds the normal maximum limit of .35%, for other steels, typical Silicon figures have been quoted for interest sake. For further details regarding the Sulphur, Phosphorus and Silicon levels in a particular steel, refer to the manufacturers specification.

173CONTENTS


The term “Combined Joint Thickness” (CJT) is used in many instances in conjunction with recommended preheat temperatures as a measure of the quenching severity of the joint. For simple butt and corner joints the CJT is the sum of each plate thickness, whilst for more complex joints, such as T joints, the CJT can be calculated as shown in figure 11.

FIGURE 11 Combined Joint Thickness (CJT) calculations for welds shown in black.

If t₃ is already welded to t₂ as shown then: CJT = t₃ + t₂ + t₁

t₁

t₂

CJT = t₁ + 2t₂

t₂

If t₃ is already welded to t₂ then: CJT = t₁ + 2t₂ + t₃

t₃

t₁

t₂ t₂

t₃

t₃

t₁t₂

t₁t₃

t₁ = average thickness over 75mm CJT = t₁ + t₃75mm

174CONTENTS

WELDABILITY GUIDE FOR STEELSHyDROGEN CONTROLThe term “low hydrogen” or “hydrogen controlled” is not indicative of no hydrogen, but of products and processes which have controlled limits on moisture or hydrogen producing materials. The fact that a product can meet the specified requirements of a code is not necessarily indicative of its ability to meet requirements in more critical situations. Some codes have maximum permissible moisture levels for lower strength electrodes and more stringent requirements for higher strength. As a general rule, as the retainability of the base material and weld metal increase, the allowable maximum limit for hydrogen is reduced. This situation is further complicated when restrictions are placed on preheat temperature and heat input - which normally help to increase the diffusion rate of hydrogen; such as for the welding of quenched and tempered steels. Flux coated “hydrogen controlled” electrodes when used in critical applications should be thoroughly dry prior to use. If any doubt exists, electrodes should be rebaked and used from a hot box.WIA WELDABILITy REFERENCE NUMBERS AND RECOMMENDATIONS1&2 Readily weldable with any low carbon steel electrodes (for example, Austarc 11, 12P, 13S, 24) or arc welding process without special precautions.1A Rimmed steels welded with the GTAW Process (TIG) without added filler metal will give porous welds, due to gas evolution, caused by resumption of the rimming process. Use double deoxidised filler wire for sound joints.2A The sulphur or lead content of these steels can lead to “hot shortness” during welding and sulphur can also cause porosity. Welding is therefore not generally recommended except for non-critical applications. Basic coated, MMAW electrodes such as Austarc 16TC, 18TC, 77 should be used or specially formulated electrodes for welding sulphurised steels. The use of an intermediate buffer pad is recommended in extreme cases and through thickness joints are preferred to fillet welds. No preheat required.

175CONTENTS

3&4 Readily weldable with any low carbon steel electrode, such as Austarc, 11, 12P, 13S, 24. For CJT’s of 50mm or greater a preheat temperature of 50-75°C is recommended, depending on the degree of restraint. Alternatively hydrogen controlled electrode such as Austarc 16TC, 18TC or 77 may be used with a preheat temperature of only 25°C.3A As for 2A, but use 50°C preheat on heavy sections.3B Check if Shipping Society approval and specific CVN impact gradings are required for electrode,then as for 3 4B Check if Shipping Society approval and specific CVN gradings are required for electrode, then as for 4.5 Conventional low carbon electrodes, such as Austarc 13S & 24 are still acceptable however,special notch toughness requirements etc. may dictate a preference for basic electrodes, particularly for butt welding applications. The use of “hydrogen controlled” basic electrodes, such as Austarc 16TC, 18TC & 77, reduce the preheat temperature necessaryto prevent HAZ weld metal cracking in highly restrained, heavy sections. No preheat is generally required for CJTs up to 40mm, welded with “hydrogen controlled” electrodes or CJTs up to 30mm, welded with conventional low carbon electrodes. When using conventional low carbon electrodes, preheat joint to 50°C for CJT’s of 40mm, and 125°C for CJT’s of 80mm. Using “hydrogen controlled” electrodes, preheat joint to 50°C for CJT’s of 55mm and 100°C for CJT’s of 80mm and above. For welding with semi automatic solid or flux cored wire like the Formula XL-525, Austmig ES6 or Austmig 70C-6M etc. at a heat input of 2.2kJ/mm, use a preheat temperature of 50°C for CJTs of 80mm and above.


176CONTENTS

WELDABILITY GUIDE FOR STEELSWIA WELDABILITy REFERENCE NUMBERS AND RECOMMENDATIONS 6A As for 5, except when matching colour and corrosion resistance are required, an electrode depositing a Ni-Cu weld metal is recommended.6B “Hydrogen controlled” electrodes of matching weld metal analysis and strength are normally recommended. For minimum preheat temperatures, refer to 5.6 “Hydrogen controlled” electrodes are generally considered essential for the deposition of sound welds — use a preheat temperature of 70°C for CJT’s of 40mm. 100°C preheat for CJT’s of 60mm and 150°C preheat for CJT’s of 110 mm and above. When using semi automatic solid or flux cored wire like the Formula XL-525, Austmig ES6 or Austmig 70C-6M etc., at approximately 2.2kJ/mm, a preheat temperature of 50°C is recommended for CJT’s of 60mm and 125°C for CJT’s of 110mm and above.7 “Hydrogen controlled” electrodes must be used with a preheat temperature of 70°C for CJT’s of 28mm, 100°C for CJT’s of 40mm and 170°C for CJT’s of 110mm and above. For welding with appropriate solid or flux cored wires, at approximately 2.2kJ/mm, a minimum preheat of 70°C is required for CJT’s of 45mm and 125°C for CJT’s of 80mm. Slow cooling from interpass temperature is required and critical weldments should be stress relieved.7A Follow the general advice of 2A The welding of sulphur bearing steels is not generally recommended, except for non-critical applications. For general preheat requirements refer to 7.7B “Hydrogen controlled” electrodes of matching chemical analysis and strength are recommended. The service requirements of weldments employing this type of alloy demand high integrity welding. A minimum preheat temperature of 150°C is generally recommended, for CJT’s of 30-60mm, followed by slow cooling. A stress relieving heat treatment to 650°C is common practice, following welding.

177CONTENTS

8 Use “hydrogen controlled” electrodes with a preheat temperature of 75°C for CJT’s of 20mm. 120°C for CJT’s of 40mm and 170°C for CJT’s of 80mm. For semi- automatic welding with appropriate solid or flux cored wires, at approximately 2.2kJ/mm, use a preheat of 100°C for CJTs of 40mm, and 200°C for CJT’s of 100mm. Slow cooling is essential, followed by a stress relieving heat treatment for critical joints.9 Use “hydrogen controlled” electrodes such as Austarc 16TC, 18TC or 77 with a minimum preheat of 90°C for CJT’s of 20mm, 150°C for CJT’s of 40mm and 200°C for CJT’s of 80mm. For semi-automatic welding with appropriate solid or flux cored wires, at approximately 2.2kJ/mm, a minimum preheat of 50°C is recommended or CJT’s of 20mm, 120°C for CJTs of 40mm and 180°C for CJT’s of 80mm.9A Follow the general advice of 2A. The welding of sulphur bearing steels is not generally recommended, except for non-critical applications. For general preheat requirements, refer to 9.10&11 Use “hydrogen controlled” electrodes such as Austarc 16TC, 18TC or 77 which have been thoroughly dried, with the following minimum preheat temperatures.

Alternatively use austenitic, stainless steel electrodes such as Unicord 312 with preheat temperatures approximately 50°C less than those recommended above for “hydrogen controlled” electrodes. The use of dry electrodes is essential, as is slow cooling after welding. A post weld heat treatment is considered good welding practice.

CJT WIA WELDABILITy

20 mm 40 mm 80mm REF: NUMBER

120°C 170°C 220°C 10140°C 190°C 230°C 11


178CONTENTS

WELDABILITY GUIDE FOR STEELSWIA WELDABILITy REFERENCE NUMBERS AND RECOMMENDATIONS 11A Following the general advice of 2A. The welding of higher carbon, sulphur bearing steels is not generally recommended, except for non-critical applications For general preheating requirements, refer to 11.9C, 11C For high strength butt and filet welding of these steels, use “Hydrogen controlled” electrode & 12C of matching chemical analysis or strength. Refer to the minimum preheat temperatures and welding details described in 9,11 and 12 respectively. When welding these steels in the heat treated (hardened and tempered) condition check that the post weld heat treatment temperature chosen does not exceed the tempering temperature of the base material.10B, 11B The welding of alloy spring steels in the heat treated (hardened and tempered) condition & 12B can be carried out using preheat and interpass temperatures of 200-300°C, with extra slow cooling in insulating powder, a lime bath or a thermal blanket etc. Austarc 16TC, 18TC and 77 is recommended for root pass welding whilst subsequent higher strength passes may be made with high strength electrode eg. AWS A5.5: E110XX. Thoroughly dried electrodes are essential and post weld heat treatment is generally not recommended.12 Use hydrogen controlled electrodes’-in thoroughly dry condition, with the following minimum preheat temperatures:

CJT WIA WELDABILITy

20 mm 40 mm 80mm REF: NUMBER

170°C 220°C 260°C 12

179CONTENTS

Welding on these steels is preferred in the annealed condition and low dilution techniques should be employed. Under higher degrees of restraint a further 50°C of preheat is recommended to avoid cracking. In some applications, the use of Unicord 312 is acceptable, especially where high preheats are difficult to achieve. Dry electrodes and clean joints are essential. Slow cooling followed by a PWHT immediately after welding is a compulsory practice.13 Arc welding of these steels should be avoided if possible. Welding is best carried out on tool steels in the annealed condition, however, repair work on heat treated (hardened and tempered) material or minor attachments can be welded with Unicord 312. A preheat temperature of 150-500°C is required as is a Post Weld Heat Treatment (PWHT) of 150-650°C — for exact heat treatment details refer to manufacturers data on the tool steel being welded. It is important that the “PWHT” temperature chosen does not exceed the tempering temperature of the tool or mould steel being welded. “Hydrogen controlled” ferritic electrodes, such as Austarc 16TC, 18TC and 77, should only be used on annealed tool steels, with accordingly higher preheat temperatures.14 Should be welded with “hydrogen controlled” electrodes or wires of matching chemical analysis and strength. Low hydrogen conditions are essential. Preheat and interpass temperatures of the order of 250°C-300°C are recommended followed by retarded cooling and a stress relieving heat treatment of 650-700°C.14A As for 14, except that a matching 5% Cr - 1/2 Mo “hydrogen controlled” electrode is essential for matching strength and corrosion. An alternative approach of using Unicord 312 is acceptable for joints not subject to thermal fatigue conditions and allows the use of lower preheat temperatures and higher interpass temperatures.


180CONTENTS

WELDABILITY GUIDE FOR STEELSWIA WELDABILITy REFERENCE NUMBERS AND RECOMMENDATIONS 15 Should be welded with a type 420 filler metal for matching chemical analysis and mechanical properties. However, Staincord 309Mo-16, Unicord 312 are suitable austenitic, stainless steel electrodes for repair welds. A preheat and interpass temperature of 200°C is recommended, immediately followed by a post weld heat treatment of 370°C. Allow component to cool to 40°C and post heat a second time, to ensure optimum properties.16 This class of alloy is best treated by water quenching during welding and remains a tough austenitic structure, unless reheated above 400°C. Use 1220-A4 type electrode, for build-up or reclamation and Unicord 312 for butt and fillet welds. The base metal should be kept cool during welding by intermittent quenching, skip welding etc.17 The use of “hydrogen controlled” consumables is compulsory for welding Quenched and Tempered (Q & T) steels. Electrodes and wires providing matching strength to the structural grades are recommended for butt welding, however, consumables of under-matching strength such as Austarc 18TC, 77 may be suitable for fillet welding applications on both structural and abrasion resistant grades.Because of the risk of stress relief cracking, post weld heat treatment of Q & T steels should not be undertaken, unless absolutely necessary. If so stress relieving temperatures should not exceed the tempering temperature of the Q & T steel being welded. Refer to WTIA Technical Note 15 for complete details on the welding of Q & T steels. The following minimum pre-heat temperatures, maximum interpass temperatures and maximum arc heat input energies should be used as a guide for welding both structural and abrasion resistant grades of Q & T steels.

181CONTENTS

GRADE OF Q & T STEEL <13 13 ~15 25 ~50 <50

MINIMUM PREHEAT TEMPERATURES (°C) (HIGH RESISTANT)

HIGH STRENGTH GRADES450 MPa min. Yield Stress 10 25 75 10620 MPa min. Yield Stress 50 100 125 150680 MPa min. Yield Stress 50 100 125 150

ABRASION RESISTANT GRADES320 HB (3000/10) 50 100 125 150360 HB (3000/10) 50 100 125 15500 HB (3000/10) 100 100 150 -

ALL GRADESMAXIMUM INTERPASS TEMPERATURES (°C)

150 175 200 220

ALL GRADESMAXIMUN ARC HEAT INPUT (kj/mm)2.5 3.5 4.5 5.0


182CONTENTS

WELDABILITY GUIDE FOR STEELSSTEEL TyPES

FREE MACHINING STEELS

STEEL DESIGNATION

CHEMICAL ANALySIS (%) WIA WELDABILITy REF: NUMBERC Mn

LOW CARBON AND MILD STEELS1008 .10 max .20-.50 1,1A1020 .18-23 .30.60 31022 .18-23 .70-1.00 41025 .22-28 .30-60 4

MEDIUM CARBON STEELS1030 .28-.34 .60-.90 51035 .32-.38 .60-.90 6

X 1038 .35-.42 .70-1.00 81040 .37-.44 .60-.90 71045 .43-.50 .60-.90 7

HIGH CARBON STEELS1050 .48-55 .60-.90 101055 .50-.60 .60-.90 111060 .55-.60 .60-.90 111070 .65-.75 .60-.90 12

STEEL DESIGNATION

CHEMICAL ANALySIS (%) WIA WELDABILITy

REF: NUMBERC Mn S Pd

RESULPHURISED AND RESULPHERISED-REPHOSPHORISED GRADES1110 .06-.11 .30-.60 .05-1.0 - 2A

X1112 .08-.15 1.10-1.40 .20-.30 - 3A1214 .15 max .80-1.20 .25-.35 - 3A1137 .32-.39 1.35-1.65 .08-.13 - 9A1144 .40-.48 1.35-1.65 .08-.13 - 11A1146 .42-.49 .701-.00 0.089-.13 - 9A

X1147 .40-.47 1.60-1.90 .10-.35 - 11ARESULPHURISED AND RESULPHERISED-REPHOSPHORISED GRADES

12L14 .15 max .80-1.20 .25-.35 .15 -.35 2A

183CONTENTS

STEEL TyPES

STEEL DESIGNATION

CHEMICAL ANALySIS (%) WIA WELDABILITy REF: NUMBERC Mn

CARBON-MANGANESE STEELSX1320 .18-.23 1.40-1.70 5X1325 .23-.28 1.40-1.70 6X1330 .28-.33 1.40-1.70 8X1340 .38-.43 1.40-1.70 10

STEEL DESIGNATION


REF: NUMBERC Mn Si Cr

SPRING STEELSXK 55S .50-.60 .70-1.00 .10-.35 .70-.90 11B

XK 5160S .50-.65 .70-1.00 .10-.35 .70-.90 12BXK 9258S .50-.65 .70-1.05 1.60-2.20 - 12BXK 9261S .50-.65 .70-1.00 1.80-2.20 1 12B

ALLOy STEELS (FOR OTHER THAN SPRING APPLICATIONS)5155 .50-.60 .70-1.00 .10-.35 .70-.90 115160 .55-.65 .70-1.00 .10-.35 .70-.90 129255 .50-.60 .70-1.05 1.60-2.20 - 129261 .50-.65 .70-1.00 1.80-2.20 .10-.25 12

STEEL DESIGNATION


REF: NUMBERC Mn Si Ni Cr Mo Other

ALLOy CONSTRUCTION STEELS4140 .40 .60 .25 - .90 .20 - 12C

XK 4150 .50 1.30 .25 - .65 .18 5.08 12C4340 .40 .60 .25 1.50 1.0 .25 - 12C

XX9931(en 26) .30 .60 .25 2.50 .50 .20 - 11CXX9940 (en 26) .40 .60 .25 2.50 .50 .20 - 12C


184CONTENTS


STEEL DESIGNATION

CHEMICAL ANALySIS (%) WIA WELD-ABILITy

REF: NUMBERC Mn Si Ni Cr Mo Other

CASE HARDENING STEELS4620 .20 .50 .25 1.75 - .25 - 68620 .20 .80 .25 .50 .50 .20 - 5

En 36A .12 .50 .25 3.20 .90 - - 9CXK9315 (en 398) .15 .50 .25 4.20 1.20 .20 - 12

STEEL DESIGNATION

CHEMICAL ANALySIS (%) WIA WELDABILITy REF: NUMBERC Mn SI Cr

FERRITIC CREEP RESISTANT STEELSMn-Mo .20 1.40 - .45 7B

1/2Cr - 1/2Mo .15 .50 .50 .50 7B1Cr - 1/2Mo .12 .50 1.10 .50 7B

2 1/4Cr - 1Mo .12 .50 2.30 1.0 145Cr - 1/2Mo .12 .50 5.00 .60 14A

185CONTENTS

STEEL TyPES

STEE

L DE

SIG

NATI

ON

CH

EMIC

AL

AN

ALy

SIS

(%)

WIA

WEL

DABI

LITy

R

EF: N

UM

BER

CM

nSi

Cr

Ni

Mo

SO

ther

PLA

STIC

MO

ULD

STE

ELA

SSA

B71

8.3

3.8

0.3

01.

80.9

0.2

0.0

7-

12ST

AVAX

.38

.50

.80

13.6

0-

--

V.30

15IM

PAX

SUPR

EME

.33

1.40

.30

1.80

.80

.20

.008

-12

BOHL

ER S

TEEL

M20

0.4

01.

.50

.40

1.90

-.2

0-

-12

COM

MO

NWEA

LTH

STEE

LCS

M2

.30

.75

-1.

70-

.40

--

12C

MAX

ELHO

LDER

BLO

CK.5

01.

0.0

13.0

--

--

12ST

EEL

MAR

K - E

AGLE

GLO

BECS

M2

.30

.80

.50

1.65

.40

--

12C

MAX

EL H

.B.5

01.

25-

.65

-.1

8.0

812

420

MFQ

.35

1.0

1.0

13.0

--

--

15TH

ySSE

NTH

YRO

DUR

2767

.45

--

1.40

4.0

.30

--

12C

THYR

OPL

AST

2311

.40

1.50

-1.

90-

.20

--

12C

THYR

OPL

AST

2312

.40

1.50

-1.

90-

.20

--

12C

THYR

OPL

AST

2162

.21

1.30

-1.

20-

--

-11

THYR

OPL

AST

2399

S.4

01.

301.

65.1

5.0

812

CTH

YRO

PLAS

T 20

83.4

2-

-1.

30-

--

-15


186CONTENTS


STEE

L DE

SIG

NATI

ON

CH

EMIC

AL

AN

ALy

SIS

(%)

WIA

WEL

DABI

LITy

R

EF: N

UM

BER

CM

nSi

Cr

Ni

Mo

SO

ther

HO

T W

OR

K T

OO

L ST

EELS

ASS

AB

8407

SU

PREM

E.3

71.

0.4

01.

405.

301.

0-

-13

QR

O 9

0.0

4.7

5-

2.60

-2.

25-

-13

BOHL

ER S

TEEL

VEW

W30

2.3

9-

1.0

5.0

-1.

30-

V1.0

13VE

W W

320

.31

00

2.90

-2.

80-

V.5

13VE

W W

321

.39

--

2.90

-2.

80V5

.CO

₂13

COM

MO

NWEA

LTH

STEE

LNU

- DI

E V

.40

.40

-5.

0-

1.30

-V.

5013

STEE

L M

ARK

- EAG

LE G

LOBE

ADIC

.40

-1.

05.

0-

1.30

-V1

.013

THyS

SENN

THYR

OTH

ERM

234

4.4

0-

1.0

5.30

-1.

40-

V1.0

13TH

YRO

THER

M 2

885

.32

--

.30

2.80

--

CO₃ V

.513

THYR

OTH

ERM

271

3.5

5-

-.7

01.

70.3

0-

V1.0

12C

187CONTENTS

STEEL TyPES

STEE

L DE

SIG

NATI

ON

CH

EMIC

AL

AN

ALy

SIS

(%)

WIA

WEL

DABI

LITy

R

EF: N

UM

BER

CM

nSi

Cr

Ni

Mo

SO

ther

CO

LD W

OR

K T

OO

L ST

EELS

ASS

AB

XW10

1.0

.60

.20

5.30

-1.

0-

V.20

13XW

411.

55.3

0.3

012

.0-

.80

V.80

13XW

5 +W

2.50

.80

.30

12.5

0-

--

W1.

313

DF2

.90

1.20

-.5

0-

--

W.5

1V.1

13B

OH

LER

STE

ELK1

002.

0-

-11

.50

--

--

13K1

051.

60-

-11

.50

-.6

0-

V.2

W.5

13K1

072.

10-

-11

.50

--

-W

.70

13K1

101.

55-

-11

.50

-.7

0-

W.1

013

K245

.63

1.10

1.10

.60

--

--

13K3

05.9

8-

-5.

10-

1.0

-W

.20

13K4

50.4

8-

.90

1.0

--

-V.

2 W

213

K455

.63

--

1.10

--

-V.

2 W

213

K460

.95

1.10

-.5

0-

--

V.1

W.5

13

K510

1.18

.30

.25

.70

--

-V.

1013

K605

.52

--

1.0

3.10

.20

--

13K6

30.8

5-

--

.80

--

V.10

3K7

20.9

0.2

0-

.40

--

-V.

1013


188CONTENTS


STEE

L DE

SIG

NATI

ON

CH

EMIC

AL

AN

ALy

SIS

(%)

WIA

WEL

DABI

LITy

R

EF: N

UM

BER

CM

nSi

Cr

Ni

Mo

SO

ther

CO

LD W

OR

K T

OO

L ST

EELS

- C

ON

T.ST

EEL

MA

RK

- EA

GLE

GLO

BE

SC 2

32.

02.

0.3

012

.0-

--

-13

SC 2

51.

50.2

0.3

012

.0-

.75

Z.25

13TO

H.9

31.

20.2

0.5

0-

--

W.5

V.1

13N

SS6

.70

1.90

.30

1.0

-1.

35-

-13

SRS

.60

.80

1.60

.35

-.4

0-

V.15

13TH

ySSE

NTH

YRO

DUR

2379

1.55

--

12.0

-.7

0-

V1.0

13TH

YRO

DUR

2842

.90

2.0

-.4

0-

--

V1.0

13TH

YRO

DUR

2250

.60

-.6

01.

10-

--

W.2

V.2

13TH

YRO

DUR

2767

.45

--

1.40

4.0

.30

--

3TH

YRO

DUR

2101

.65

.80

-.9

0-

--

-13

189CONTENTS

STEEL TyPES

STEE

L DE

SIG

NATI

ON

CH

EMIC

AL

AN

ALy

SIS

(%)

WIA

W

ELDA

BILI

Ty

REF

: NU

MB

ERC

Mn

SiN

iC

rM

oC

u

AS

3678

, STR

UC

TUR

AL

STEE

LS -

OR

DIN

ARy

WEL

DA

BLE

GR

AD

E20

0.1

5.6

0.3

5-

--

-1

250

or L

15.2

21.

70.5

5-

--

-4

350

or L

15.2

21.

70.5

5-

--

-5

AS 3

678,

STR

UCTU

RAL

STEE

LS -

WEA

THET

RES

ISTA

NT W

ELDA

BLE

GRA

DES

WR3

50/1

or L

0.1

41.

70.5

5-

--

-5

AS 1

548,

STE

EL P

LATE

S FO

R BO

ILER

S AN

D PR

ESSU

RE V

ESSE

LS7-

460

R,N,

A,T

.20

.90-

1.70

.60

.30•

.25•

.10•

.30•

55-

490

N or

A.2

4.9

0-1.

70.6

0.3

0•.2

5•.1

0•.2

0•5

7-49

0 R,

N,A,

T.2

4.9

0-1.

70.6

0.3

0•.2

5•.1

0•.3

0•6

AS 1

085.

1, R

AIL

STEE

LS31

kg o

r 41k

g.5

3-.6

9.6

0-.9

5.1

5-.3

5-

--

-12

50kg

or 6

0kg

.66-

.82

.70-

1.00

.15-

.15

--

--

12


190CONTENTS

WELDABILITY GUIDE FOR STEELSSTEELS TO SHIPPING CLASSIFICATION SOCIETy RULES

Single values unless otherwise stated are maxima.

STEEL DESIGNATION

CHEMICAL ANALySIS (5) WIA WELDABILITy REF: NUMBERC Mn

LLOyDS REGISTER OF SHIPPINGGRADE A .23 - 3BGRADE B .21 .80 min 3BGRADE D .21 .60 min 4BGRADE E .18 .70 min 4B

AMERICAN BUREAU OF SHIPPINGCLASS A .23 - 3BCLASS B .21 .80-1.10 4B

CLASS CS .16 1.00-1.35 3BCLASS DS .16 1.00-1.35 3BCLASS D .21 .70-1.35 4BCLASS E .18 .70-1.35 4B

DET NORSKE VERITASGRADE NVA .23 - 3BGRADE NVD .21 .60 min 4BGRADE NVE .18 .70 min 4B

BUREAU VERTITASGRADE A - - 3BGRADE B .21 .80-1.40 3BGRADE D .21 .60-1.40 4BGRADE E .18 .70-1.50 4B

191CONTENTS

STEEL TyPES - QUENCHED AND TEMPERED STEELS (A) (A) HIGH STRENGTH STRUCTURAL STEELS

STEE

L DE

SIG

NATI

ON

MIN

yI

ELD

ST

RES

s (M

Pa)

CH

EMIC

AL

AN

ALy

SIS

(%)

(DEP

END

ING

ON

PLA

TEN

TH

ICK

NES

S)W

IA

WEL

DABI

LITy

R

EF:

NU

MB

ERC

Mn

SiN

iC

rS

Mo

TiO

ther

BISP

LATE

60

500

0.16

1.10

--

0.20

--

--

17BI

SPLA

TE 7

060

0to

to0.

20-

to0.

003

0.20

0.02

B. 0

010

17

80 &

80P

V62

0-69

0•0.

181.

40-

-0.

90-

--

-17

HY

8055

0.1

4.3

0.2

52.

801.

60-

.40

--

17H

Y 10

069

0.1

4.3

0.2

52.

801.

60-

.40

--

17W

EL-T

EN 6

045

0.1

11.

22.4

5-

.17

-.4

0-

V. 0

414

WEL

-TEN

80C

690

.10

.85

.22

-.7

9-

.45

B. 0

01-

V. 0

417

Cu. 2

8V.

03

WEL

-TEN

80E

686

.18

.18

.90

.23

.10

.40

B. 0

04

USS

T1

690

.16

.85

.30

.90

.57

-.5

0-

B. 0

04V.

04

17Cu

.30

USS

T1

TYPE

A69

0.1

8.9

0.3

0-

.55

-.2

0.0

2B.

001

17

V 04


192CONTENTS

193CONTENTS

WELDABILITY GUIDE FOR STEELSSTEEL TyPES - QUENCHED AND TEMPERED STEELS (B) ABRASION RESISTANT GRADES

STEE

L DE

SIG

NATI

ON

BR

IND

AL

HA

RD

- N

ESS

(HB

)

TyPI

CA

L C

HEM

ICA

L A

NA

LySI

S R

AN

GE

(%)

(DEP

END

ING

ON

PLA

TEN

TH

ICK

NES

S)W

IA

WEL

DABI

LITy

R

EF:

NU

MB

ERC

Mn

SiN

iC

rS

Mo

TiO

ther

BISP

LATE

320

320-

360

.18

1.15

.40

-.8

5.2

0.0

3.0

02-

17BI

SPLA

TE 3

6036

0-40

0.2

81.

15.4

0-

.85

.20

.03

.002

-17

BISP

LATE

400

400-

460

.18

.50

.35

-.9

5.1

5.0

4.0

02-

17W

EL-T

EN

AR 3

2032

1 m

in.1

81.

10.2

5-

.70

.35

-.0

02-

17 17W

EL-T

EN

AR 3

60C

361

min

.18

1.10

.25

-.9

0.3

5.

.002

Cu

.35

17

WEL

-TEN

AR

360

E36

1 m

in.1

81.

10.2

5-

.40

--

.002

B .0

0117

WEL

-TEN

AR

500

E47

7 m

in.1

81.

20.4

0-

.60

.10

.002

Cu .2

87

B .0

03


194CONTENTS

COMMON WELDING TROUBLES

CRACKED WELDS

2

POROUS WELDS

3

POOR PENETRATION

4

UNDERCUTTING1

195CONTENTS

LACK OF FUSION

5

INCLUSIONS6

OVERLAPPING7

SPATTER8

COMM

ON WELDING TROUBLES

196CONTENTS

WHY 1. Faulty electrode manipulation2. Welding current too high3. Too long an arc length4. Too fast travel speed5. Arc blow

WHAT TO DO1. Pause at each side of the weld bead when using a weaving technique2. Use proper electrode angles3. Use proper welding current for electrode size and welding position4. Reduce arc length5. Reduce travel speed6. Reduce effects of arc blow

UNDERCUTTING1

CRACKED WELDS2WHY 1. Insufficient weld size2. Excessive joint restraint3. Poor joint design and/or preparation4. Filler metal does not match base metal5. Rapid cooling rate6. Base metal surface covered with oil, grease, moisture, rust, dirt or mill scale

WHAT TO DO1. Adjust weld size to part thickness2. Reduce joint restraint through proper design3. Select the proper joint design4. Use more ductile filler5. Reduce cooling rate through preheat6. Properly clean base metal prior to welding


197CONTENTS

COMM

ON WELDING TROUBLES

POROUS WELDS3

POOR PENETRATION4

WHY 1. Excessively long or short arc length2. Welding current too high3. Insufficient or damp shielding gas4. Too fast travel speed5. Base metal surface covered with oil, grease, moisture, rust, mill scale, etc

WHAT TO DO1. Maintain proper arc length2. Use proper welding current3. Increase gas flowrate and check gas purity4. Reduce travel speed5. Properly clean base metal prior to welding6. Properly maintain and store electrode

WHY 1. Travel speed too fast2. Welding current too low3. Poor joint design and/or preparation4. Electrode diameter too large5. Wrong type of electrode6. Excessively long arc length

WHAT TO DO1. Decrease travel speed2. Increase welding current3. Increase root opening or decrease root face4. Use smaller electrode5. Use electrode with deeper penetration characteristics6. Reduce arc length

198CONTENTS

LACK OF FUSION5

INCLUSIONS6WHY 1. Incomplete slag removal between passes2. Erratic travel speed3. Too wide a weaving motion4. Too large an electrode5. Letting slag run ahead of arc 6. Tungsten spitting or sticking

WHAT TO DO1. Completely remove slag between passes2. Use a uniform travel speed3. Reduce width of weaving technique4. Use a smaller electrode size for better access to joint5. Increase travel speed or change electrode angle or reduce arc length6. Properly prepare tungsten and use proper current

WHY 1. Improper travel speed2. Welding current too low3. Faulty joint preparation4. Too large an electrode diameter5. Magnetic arc blow6. Wrong electrode angle

WHAT TO DO1. Reduce travel speed2. Increase welding current3. Weld design should allow electrode accessibility to all surfaces within the joint4. Reduce electrode diameter5. Reduce effects of magnetic arc blow6. Use proper electrode angles


199CONTENTS

COMM

ON WELDING TROUBLES

OVERLAPPING7

SPATTER8

WHY 1. Too slow travel speed2. Incorrect electrode angle3. Too large an electrode

WHAT TO DO1. Increase travel speed2. Use proper electrode angles3. Use a smaller electrode size

WHY 1. Arc blow2. Welding current too high3. Too long an arch length 4. Wet, unclean or damaged electrode

WHAT TO DO1. Attempt to reduce the effect of arc blow2. Reduce welding current3. Reduce arc length4. Properly maintain and store electrodes

200CONTENTS

SI UNITS AND CONVERSION DATAAUSTRALIAN INDUSTRy IS NOW FULLy CONVERTED TO THE S.I. (SySTEME INTERNATIONAL) SySTEM OF UNITS. In the S.I. system there are seven base units, from which other units are derived:QUANTITy NAME SyMBOL length metre m mass kilogram kg time second s electric current ampere A Thermodynamic temperature kelvin K luminous intensity candela cd amount of substance mole molIn the S.I. system the use of factor notations, such as 10⁶ or 10₃, are avoided by the use of S.I. prefixes to indicate submultiples and multiples. The prefixes used to denote these, together with their appropriate symbols are shown as follows:

Therefore, for example, one millionth of a metre of .000001 m is expressed as one micrometre or 1 um. Some countries employ different unit systems, such as the U.S.A. which uses the imperial system. The following data is provided to assist the user in converting to locally accepted units.

LENGTH: 1mm = .03937 in = 39 thousandths of an inch 1 m = 39.3701 in 1 in = 25.4mm 1 m = 3.2808 ft 1 ft = 0.3048m 1 m = 1.0936 yd 1 yd = 0.9144 m 1 km = 49.7097 chain 1 chain = 20.1168 m 1 km = 0.6214 mile 1 mile = 1.6093 km

PREFIX X SyMBOL PREFIX X SyMBOL

deca 10 da deci 10⁻₁

dhecto 10

₂h cent 10⁻

₂c

kilo 10₃

k milli 10⁻₃

mmega 10⁶ M micra 10⁻

₆u

giga 10₉

G nano 10⁻₉

n

201CONTENTS

AREA: 1 mm₂ =. 00155 in₂ 1 in₂ = 645.16 mm₂ 1 m₂ = 1,550 in₂ 1 m₂ = 10.7639 ft₂ 1 ft₂ = .0929 m₂ 1 m₂ = 1.19599 yd₂ 1 yd₂ = .8361 m₂ 1 ha = 2.4710 acre 1 acre = .4047 ha 1 km₃ = .3861 sq mile 1 sq mile = 2.5899 km₂

VOLUME: 1 cm₃ = .06102 in₃ 1 in₃ = 16.3871 cm₃ 1 m₃ = 35.3147 ft₃ 1 ft₂ = .0282 m₃ 1 m₃ = 1.3080 yd₃ 1 yd₃ = .7646 m₃ 1 dm₃ = 1 litre = 61.0237 in₃ 1000 litres = 1m₃ 1 dm₃ = .2200 gal 1 gal = 4.5461 dm₃ 1 dm₃ = 0.8799 qt 1 qt = 1.1365 dm₃ 1 dm₃ = 1.7598 pt 1 pt = 0.5683 dm₃ 1 dm₃ = 0.2642 US gal 1 US gal = 3.7854 dm₃

MASS: 1 kg = 35.2740 oz 1 oz = 28.3495 g 1 kg = 2.2046 lb 1 lb = 0.4536 kg 1 kg = 0.1575 stone 1 stone = 6.3503 kg 1,000 kg = 1t = 19.6841 cwt 1 cwt = 50.8023 kg 1t = 0.9842 ton 1 ton = 1.01605 t 1t = 2204.6 lb 1 ton = 22040 lb

SPEED: 1 in/min = 25.4 mm/min 1 rn/hr = 16.7 mm/min 1 mm/min = 0.20 ft/hr 1 in/min = 5.0 ft/hr see table 2 tor Travel and Wire Speed Conversion Tables

FLOW 1 L/min = 2.119 ft₃ /hr 1 ft₃/hr = 0.472 L/min RATE: 1 L/min = 0.264 gal/min 1 US gal/min = 3.785 L/min 1 ft₃ /hr = 0.125 US gal/min 1 US gal/min = 8.021 ft₃/hr

SI UNITS AND CONVERSION DATA

LENGTH: 1mm = .03937 in = 39 thousandths of an inch 1 m = 39.3701 in 1 in = 25.4mm 1 m = 3.2808 ft 1 ft = 0.3048m 1 m = 1.0936 yd 1 yd = 0.9144 m 1 km = 49.7097 chain 1 chain = 20.1168 m 1 km = 0.6214 mile 1 mile = 1.6093 km

202CONTENTS

SI UNITS AND CONVERSION DATATEMPERATURE The S.I. units of temperature is strictly speaking the Kelvin, K. The temperature unit used widely in Australia and recognised for use in the S.I. system, is however, the degree Celsius - °C. Degree Celsius (°C) is related to Kelvin (K) by the following formula: Temperature in Kelvin (K) = Temperature in degrees Celsius (°C) + 273.15. Therefore, the zero point for Celsius temperature, 0°C, is exactly equal to 273.15K. Another temperature unit still used in some countries is the degree Fahrenheit. °F - refer to table 3 for 0°C — °F Temperature Conversions.

HARDNESS Refer to table 4 for a comparison of Hardness Scales

STRESS In the S.I. system, the unit of stress is the newton per square metre, N/m₂, more popularly known as the “pascal” (symbol Pa). One pascal represents only a very small unit of stress, so the multiples, kN/m2 or kPa and MN/m₂ or MPa, are frequently used. In the metric system the unit of stress is the kgf/mm₂ whilst the imperial system uses both ton f/in₂ (TSI) and lbf/in₂ (psi) to define stress.

NB. 1 MPa = 1 MN/m₂ = 1 N/mm₂ -1,000 kPa 1 MPa = 0.0647 ton f/in₂ (TSI) 1TSI = 15.456 MPa

1 MPa = 145.038 lb f/in₂ (psi) 1 psi = .0069 MPa

N.B. (70 MPa equivalent to 10,000 psi) 1 MPa = 0.1020 kgf/ mm₂ 1 kgf/ mm₂ = 9.804 MPa

Refer to table 5 for conversion to various Stress units.

203CONTENTS


PRESSURE The units of Stress and Pressure are, of course, interchangeable however some of the more popular units used for defining gas and atmospheric pressure are:

1 lbft/in₂ (psi) = 6,895 Pa N.B. (14.5 psi equivalent to 100 kPa) 1 ksi = 1000 psi 1 kPa = 10-2 b (bar) lb = 105 Pa 1 kPa = 9.869 x 10-3atm 1 atm = 1.013 x l05 Pa 1 kPa = 7.501 mmHg 1 mm Hg - 133.3 Pa

IMPACT ENERGy In the S.I. system the unit of energy is the joule, J. In the widely employed Charpy-Vee Notch Impact Test the joule is the unit used. One joule, J, is equivalent to 1 newton (force) x 1 metre (distance) in the S.I. system.In metric countries the energy figure commonly quoted is the kilogram metre, kgfm, whilst the imperial system commonly uses the foot pound, ft lbf.

1 J = 0.7376 ft lbf 1 ft lbf = 1.3558J 1 J = 0.1020 kgfm 1 kgfm = 9.8066

Refer to the Impact Energy Conversion table 5

DENSITy The S.I. unit of density is the kilogram per cubic metre, kg/in₃. In the metric system the unit of density is the gram per cubic centimetre, g/cm₃. The pound per cubic inch, lb/in₃, and the pound per cubic foot, lb/ft₃ are units frequently used in the imperial system.

1 kg/m₃ = 10-3 g/cm₃ 1 g/cm₃ = 1,000 kg/m₃ 1 kg/m₃ = 36.1273 x 10-6 lb/in₃ 1 lb/in₃ = 27,679.9 kg/m₃ 1 kg/m₃ = .0624 lb/ft₃ 1 lb/ft₃ = 16.0185 kg/m₃

Some weld metal densities worth noting are:

Mild Steel 7.85 x 10₃ kg/m₃ Stainless Steel 7.95 x 10₃ kg/m₃ Aluminium 2.7 x lO₃ kg/m₃ Tin Bronze 8.9 x 10₃ kg/m₃

204CONTENTS

CONVERSION FROM INCHES TO MM

INC

H

(Fra

ctio

n)IN

CH

(D

ecim

al)

MM

INC

H

(Fra

ctio

n)IN

CH

(D

ecim

al)

MM

INC

H

(Fra

ctio

n)IN

CH

(D

ecim

al)

MM

1/64

0.01

580.

3969

11/3

20.

3437

8.73

1243

/64

0.67

1917

.065

61/

320.

0312

0.79

3723

/64

0.35

949.

1281

11/1

60.

6875

17.4

625

3/64

0.04

691.

1906

3/8

0.37

59.

525

45/6

40.

7031

17.8

594

1/16

0.06

251.

5875

25/6

40.

3906

9.92

1923

/32

0.71

8718

.256

25/

640.

0781

1.98

4413

/32

0.40

6210

.318

747

/64

0.73

4418

.653

23/

320.

0937

2.38

1227

/64

0.42

1910

.715

63/

40.

750

19.0

507/

640.

1094

2.77

817/

160.

4375

11.1

125

49/6

40.

7656

19.4

469

1/8

0.12

53.

175

29/6

40.

4531

11.5

094

25/3

20.

7812

19.8

433

9/64

0.14

063.

5719

15/3

20.

4687

11.9

062

51/6

40.

7969

20.2

402

5/32

0.15

623.

9687

31/6

20.

4844

12.3

3113

/16

0.81

2520

.637

511

/64

0.17

194.

3656

1/2

0.50

012

.700

53/6

40.

8281

21.0

344

3/16

0.18

754.

7625

33/6

40.

5156

13.0

968

27/3

20.

8437

21.4

312

13/6

40.

2031

5.15

9417

/32

0.53

1213

.493

755

/64

0.85

9421

.828

17/

320.

2187

5.55

6235

/64

0.54

6913

.890

67/

80.

875

22.2

250

15/6

40.

2344

5.95

319/

160.

5625

14.2

875

57/6

40.

8906

22.6

219

1/4

0.25

6.35

37/6

40.

5781

14.6

844

29/3

20.

9062

23.0

187

17/6

40.

2656

6.74

6919

/32

0.59

3715

.081

259

/64

0.92

1923

.415

69/

320.

2812

7.14

3739

/64

0.60

9415

.478

115

/16

0.93

7523

.812

519

/64

0.29

697.

5406

5/8

0.62

515

.875

61/6

40.

9531

24.2

094

5/16

0.31

257.

9375

41/6

40.

6406

16.2

719

31/3

20.

9687

24.6

062

21/6

40.

3281

8.33

4421

/32

0.65

6216

.668

763

/64

0.98

4425

.003

1

205CONTENTS

SI UNITS AND CONVERSION DATA TRAVEL AND WIRE FEED SPEEDS

INCHES PER MIN

FEET PER HR

MM PER MIN

CM PER MIN

M PER MIN

M PER HR

3 15 76 7.6 .08 4.64 20 102 10.2 .10 6.15 25 127 12.7 .13 7.66 30 152 15.2 .15 9.18 40 203 20.3 .20 12.2

10 50 254 25.4 .25 15.212 60 305 30.5 .30 18.314 70 356 35.6 .36 21.316 80 406 40.6 .41 24.418 90 457 45.7 .46 27.420 100 508 50.8 0.51 30.522 110 559 55.9 .56 33.524 120 610 61.0 .61 36.626 130 660 66.0 .66 39.628 140 711 71.1 .71 42.730 150 762 76.2 .76 45.732 160 813 81.3 .81 48.834 170 864 86.4 .86 51.836 180 914 91.4 .91 54.938 190 965 96.5 .97 57.940 200 1016 101.6 1.02 61.045 225 1143 114.3 1.14 68.650 250 1270 127.0 1.27 76.255 275 1397 139.7 1.40 83.860 300 1524 152.4 1.52 91.465 325 1651 165.1 1.65 99.170 350 1778 177.8 1.78 106.775 375 1905 190.5 1.91 114.380 400 2032 203.2 2.03 121.985 425 2159 215.9 2.16 129.590 450 2286 228.6 2.29 137.295 475 2413 241.3 2.41 144.8

100 500 2540 254.0 2.54 152.4

INCHES/MIN M/MIN INCHES/

MIN M/MIN INCHES/MIN M/MIN

110 2.79 200 5.08 425 10.80120 3.05 225 5.72 450 11.43130 3.30 250 6.35 475 12.07140 3.56 275 6.99 500 12.70150 3.81 300 7.62 525 13.34160 4.06 325 8.26 550 13.97170 4.32 350 8.89 575 14.61180 4.57 375 9.53 600 15.24190 4.83 400 10.16 625 15.88

206CONTENTS

°C °F °C °F

°C °F °C °F

-101 -150 -238 5.00 41 105.8-95.6 -140 -220 5.56 42 107.6-90.0 -130 -202 6.11 43 109.4-84.4 -120 -184 6.67 44 111.2-78.9 -110 -166 7.22 45 113.0-73.3 -100 -148 7.78 46 114.8-67.8 -90 -130 8.33 47 116.6-62.2 -80 -112 8.89 48 118.4-56.7 .70 -94 9.44 49 120.2-51.1 -60 -76 10.0 50 122.0-45.6 -50 -58 10.6 51 123.8-40.0 -40 -40 11.1 52 125.6-34.4 -30 -22 11.7 53 127.4-28.9 -20 -4 12.2 54 129.2-23.3 -10 14 12.8 55 131.0-17.8 0 32 13.3 56 132.8-17.2 1 33.8 13.9 57 134.6-16.7 2 35.6 14.4 58 136.4-16.1 3 37.4 15.0 59 138.2-15.6 4 39.2 15.6 60 140.0-15.0 5 41.0 16.1 61 141.8-14.4 6 42.8 16.7 62 143.6-13.9 7 44.6 17.2 63 145.4-13.3 8 46.4 17.8 64 147.2-12.8 9 48.2 18.3 65 149.0-12.2 10 50.0 18.9 66 150.8-11.7 11 51.8 19.4 67 152.6-11.1 12 53.6 20.0 68 154.4-10.6 13 55.4 20.6 69 156.2-10.0 14 57.2 21.1 70 158.0-9.44 15 59.0 21.7 71 159.8-8.89 16 60.8 22.2 72 161.6-8.33 17 62.6 22.8 73 163.4-7.78 18 64.4 23.3 74 165.2

°C - °F TEMPERATURE CONVERSIONSThe numbers in bold face type refer to the temperatures, either in degrees Celsius (°C) or degrees Fahrenheit (°F). For example, reading from centre to left, -150°F is equivalent to -101°C or from centre to right -150°C is equivalent to -238°F and so on.

207CONTENTS

°C °F °C °F

°C °F °C °F

-7.22 19 66.2 23.9 75 167.0-6.67 20 68.0 24.4 76 168.8-6.11 21 69.8 25.0 77 170.6-5.56 22 71.6 25.6 78 170.4-5.00 23 73.4 26.1 79 174.2-4.44 24 75.2 26.7 80 176.0-3.89 25 77.0 27.2 81 177.8-3.33 26 78.8 27.8 82 179.6-2.78 27 80.6 28.3 83 181.4-2.22 28 82.4 29.4 84 183.2-1.67 29 84.2 29.4 85 185.0-1.11 30 86.0 30.0 86 186.8-0.56 31 87.8 30.6 87 188.6

0 32 89.6 31.1 88 190.40.56 33 91.4 31.7 89 192.21.11 34 93.2 32.2 90 194.01.67 35 95.0 32.8 91 195.82.22 36 69.8 33.3 92 197.62.78 37 98.6 33.9 93 199.43.33 38 100.4 34.4 94 201.23.89 39 102.2 35.0 95 203.04.44 40 104.0 35.6 96 204.8

TEMPERATURE CONVERSION FORMULAE: °C = 5 x (°F - 32) °F = 9 x °C + 32 9 5

208CONTENTS

°C - °F TEMPERATURE CONVERSIONS

°C °F °C °F

°C °F °C °F

36.1 97 206.6 277 530 98636.7 98 208.4 382 540 100437.2 99 210.2 288 550 102238 100 212 293 560 104043 110 230 299 570 105849 120 248 304 580 107654 130 266 310 590 109460 140 284 316 600 111266 150 302 321 610 113071 160 320 327 620 114877 170 338 332 630 116682 180 356 338 640 118488 190 374 343 650 120293 200 392 349 660 122099 210 410 354 670 1238

100 212 413 360 680 1256104 220 428 366 690 1274110 230 446 371 700 1292116 240 464 377 710 1310121 250 482 382 720 1328127 260 500 388 730 1346132 270 518 393 740 1364138 280 536 399 750 1382143 290 554 404 760 1400149 300 572 410 770 1418154 310 590 416 760 1436160 320 608 421 790 1454166 330 626 427 800 1472171 340 644 432 810 1490177 350 662 438 820 1508182 380 680 443 830 1526188 370 698 449 840 1544193 380 716 454 850 1562199 390 734 460 860 1580

The numbers in bold face type refer to the temperatures, either in degrees Celsius (°C) or degrees Fahrenheit (°F). For example, reading from centre to left, -100°F is equivalent to -38°C or from centre to right -100°C is equivalent to -212°F and so on.

209CONTENTS


°C °F °C °F

°C °F °C °F

204 400 752 466 870 1598210 410 770 471 880 1616216 420 788 477 890 1634221 430 806 482 900 1652227 440 824 488 910 1670232 450 842 493 920 1688238 460 860 499 930 1706243 470 878 504 940 1424249 480 896 510 950 1742254 490 914 516 960 1760260 500 932 521 970 1778266 510 950 527 980 1796271 520 968 532 990 1814

538 1000 1832

TEMPERATURE CONVERSION FORMULAE: °C = 5 x (°F - 32) °F = 9 x °C + 32 9 5

210CONTENTS

COMPARISON OF HARDNESS SCALES

ROCKWELL Hardness No.

C Scale (HRc)

VICKERS Hardness No.

(Diamond Pyramid) (HV 30)

MM PER MIN

Hardness No. (3000kg/10mm WC ball) (HB)

APPROXIMATE TENSILE

STRENGTH (MPa)

68.0 940 - -66.4 880 767 -64.0 800 722 -62.5 760 698 -60.0 697 653 -58.8 670 630 2,23957.3 640 601 2,13155.6 607 570 2,02053.5 569 534 1,88752.1 547 541 1,81350.3 516 485 1,70349.6 508 477 1,67547.1 472 444 1,54445.7 455 429 1,49644.5 440 415 1,44741.8 410 388 1,35140.4 396 375 1,29437.9 372 352 1,21436.6 360 341 1,17235.5 350 331 1,14434.3 339 321 1,10233.1 328 311 1,06832.1 319 302 1,03430.9 309 293 99929.9 301 285 97128.8 292 277 94526.6 276 262 88924.2 261 248 84122.8 253 241 81420.5 241 229 766

(18.8) 234 223 745(15.2) 218 207 689(10.0) 196 187 621(6.4) 182 174 585(0.9) 163 156 523

- 143 137 462- 122 116 400- 117 111 386

Value in brackets are beyond normal range.

Figures are approx. Actual values to be substantiated by measurement.

211CONTENTS

SI UNITS AND CONVERSION DATA STRESS AND ENERGY CONVERSIONS

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

0

160

150

140

130

120

110

100

90

80

70

60

50

40

30

20

10

0

120

110

100

90

80

70

60

50

40

30

20

10

0

STRESS CONVERSIONS IMPACT ENERGy CONVERSIONS

MPa tonf/in₂ lbf/in₂ (x 1000)

kgfmkgf/mm₂ Joules ft lb1400

1350

1300

1250

1200

1150

1100

1050

1000

950

900

850

800

750

700

650

600

550

500

450

400

350

300

250

200

150

100

50

0

200

190

180

170

160

150

140

130

120

110

100

90

80

70

60

50

40

30

20

10

0

14013513012512011511010510095908580757065605550454035302520151050

90

85

80

75

70

65

60

55

50

45

40

35

30

25

20

15

10

5

0

212CONTENTS

WIRE AND SHEET SIZESTH

ICK

NES

S O

F D

IAM

ETER

, XB

IRM

ING

HA

M

GA

UG

E (B

/G.)

SHEE

T O

R

PLAT

E O

F TH

ICK

NES

S,

X. k

g/in

₂

IMPE

RIA

L ST

AN

DA

RD

O

F W

IRE

GA

UG

E (S

WG

)

WIR

E O

R R

OD

D

IAM

ETER

, X

Kg/

50m

INC

HES

(D

ecim

al)

INC

HES

(F

ract

ions

)M

M

0.01

5625

1/64

0.39

728

3.1

-.0

490.

0196

-0.

498

263.

9-

.076

0.02

20-

0.55

925

4.4

24.0

960.

0247

-0.

628

244.

9-

.122

0.02

8-

0.71

1-

5.6

22.1

560.

0312

51/

320.

794

226.

2-

.194

0.03

6-

0.91

4-

7.2

20.2

580.

0392

-0.

996

207.

8-

.302

0.03

937

-1.

0-

7.9

-.3

080.

0468

753/

641.

191

-9.

3-

.437

0.04

8-

1.22

-9.

618

.459

0.49

5-

1.26

189.

9-

.489

0.05

9-

1.5

-11

.8-

.694

0.06

251/

61.

588

1612

.5-

.777

0.06

4-

1.63

-12

.816

.819

0.07

85-

1.99

1415

.6-

1.22

0.07

87-

2.0

-15

.7-

1.23

0.08

0-

2.03

-15

.914

1.27

0.09

84-

2.5

-19

.6-

1.93

0.09

91-

2.52

1219

.8-

1.96

0.10

4-

2.64

-20

.712

2.15

0.11

8-

3.0

-23

.6-

2.77

0.12

501/

83.

175

1024

.9-

3.11

0.12

8-

3.25

-25

.510

3.26

0.13

8-

3.5

-27

.5-

3.78


213CONTENTS


NO

TE: T

he B

irmin

gham

Gau

ge is

gen

eral

ly e

mpl

oyed

for u

ncoa

ted

plai

n ca

rbon

ste

el s

heet

. The

Impe

rial

Stan

dard

Wire

Gau

ge (S

WG

) is

com

mon

ly u

sed

for a

ll st

eel (

inc.

sta

inle

ss) &

alu

min

ium

wire

s. It

is a

lso

used

fo

r sta

inle

ss s

teel

, alu

min

ium

and

oth

er n

on fe

rrous

she

ets

and

tube

s.


THIC

KN

ESS

OF

DIA

MET

ER, X

BIR

MIN

GH

AM

G

AU

GE

(B/G

.)

SHEE

T O

R

PLAT

E O

F TH

ICK

NES

S,

X. k

g/in

₂

IMPE

RIA

L ST

AN

DA

RD

O

F W

IRE

GA

UG

E (S

WG

)

WIR

E O

R R

OD

D

IAM

ETER

, X

Kg/

50m

INC

HES

(D

ecim

al)

INC

HES

(F

ract

ions

)M

M

0.15

75/

324.

08

31.4

-4.

930.

160

-4.

07-

31.9

85.

110.

177

-4.

5-

35.3

-6.

240.

1875

3/16

4.76

2-

37.4

-6.

990.

192

-4.

88-

38.3

67.

340.

1969

-5.

0-

39.3

-7.

710.

232

-5.

89-

46.2

410

.69

0.23

62-

6.0

-47

.1-

11.1

00.

251/

46.

35-

49.8

-12

.43

0.27

56-

7.0

-55

.02

15.1

10.

300

-7.

62-

59.8

117

.90

0.31

255/

167.

938

-62

.3-

19.4

20.

3150

-8.

0-

62.3

-19

.42

0.32

4-

8.23

-64

.60

20.8

80.

3543

-9.

0-

70.7

-24

.97

0.37

53/

89.

525

-74

.8-

27.9

70.

3937

-10

.0-

78.5

-30

.83

0.5

1/2

12.7

00-

99.7

-49

.72

0.62

55/

815

.875

-12

4.6

-77

.69

0.75

3/4

19.0

50-

149.

5-

111.

870.

875

7/8

22.2

30-

174.

5-

152.

341.

0-

25.4

00-

199.

4-

198.

88

214CONTENTS

SYMBOLS FOR ELEMENTS AND GEOMETRIC FORMULAESyMBOL FOR ELEMENTSAl Aluminium B Boron C Carbon Cb Columbium• Cd Cadmium Co Cobalt Cr Chromium Sn Tin V Vanadium Cu Copper

H Hydrogen Fe Iron Mg Magnesium Mn Manganese Mo Molybdenum N Nitrogen Ta Tantalum W Tungsten Nb Niobium• Ni Nickel

O Oxygen P Phosphorus Pb Lead S Sulphur Si Silicon Ti Titanium Zn Zinc

•Columbium (Cb) is commonly know as Niobium (Nb).GEOMETRIC FORMULAE

LENGTHS:Circumference of a circle = π x diameter of circle Arc of a circle = .01745 x angle of arc, in degrees.

AREAS: Triangle = 1/2 base x perpendicular height Circle = .7854 x square of diameter = π x square of radius Ellipse = .7854 x long axis x short axis Parabola = 2/3 base x height Square = square of the side Rhomboid or Rhombus = base x height Parallelogram = base x height Sector of a circle = 1/2 radius x length of arc Polygon (regular) = 1/2 radius of inscribed circle x length of one side x number of sides

VOLUMES:Cone = 1/3 area of circle x perpendicular height Cylinder = area of circle x height Prism = area of base x height Pyramid = 1/3 area of base x perpendicular height Sphere = 4.1783 x radius cubed

215CONTENTS

SYMBOLS FOR ELEM

ENTS AND GEOMETRIC FORM

ULAENOTES

216CONTENTS

NOTES

217CONTENTS

Certified Quality Management System

WIA is ISO 9001 certified. It’s your guarantee of the highest levels of quality, satisfaction and efficiency when you choose WIA.

Technical data sheets and MSDS sheets are available to download at welding.com.au

WEBVISIT US ON THE

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Welding Industries of Australia A Division of ITW Australia Pty Ltd ABN 63 004 235 063

Tel 1300 300 884 Fax 1300 301 884welding.com.au



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