the australian welding guide 2012

1THE AUSTRALIAN

WELDING GUIDE

welding.com.au

The Ultimate Welding Reference Guide 2012

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. Its your guarantee of the highest levels of quality, satisfaction and efficiency when you choose WIA products.

1WELDING 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.

3 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

5GENERAL 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 DATAELECTRODE

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 ANALySISC Mn Si Fe

0.07 0.5 0.3 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISYield Stress 450 MPaTensile Strength 500 MPaElongation 26%CVN Impact Values 70J @ 0C

In as welded condition.

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG

PART NUMBERPacket Carton

2.0 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 3G 4G 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


DESCRIPTION AND APPLICATIONAustarc 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.





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


0.07 0.55 0.45 Bal



PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG


2.0 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 3G 4G 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 APPLICATIONAustarc 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 -40C. 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.




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

TyPICAL ALL WELD METAL MECHANICAL ANALySISYield Stress 460 MPaTensile Strength 560 MPaElongation 28%CVN Impact Values 130J @ -20C 110J @ -40C

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG


2.5 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 WELDEDCODE 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 3G 4G 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

DESCRIPTION AND APPLICATIONAustarc 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.




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

TyPICAL ALL WELD METAL CHEMICAL ANALySIS

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

TyPICAL ALL WELD METAL MECHANICAL ANALySISYield Stress 530 MPaTensile Strength 602 MPaElongation 24%CVN Impact Values 87J @ -50C

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG


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

MATERIALS TO BE WELDEDCODE 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, HA400Cast Steel AS2074 C2, C3, C7A-1, C1, C4-1, C4-2, C7A-2

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


2G 3G 4G 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

DESCRIPTION AND APPLICATIONThe 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 400C for one hour to obtain

15CONTENTS

SHIPPING APPROVALSLR 4Ym H5 ABS 3Y H5

TyPICAL ALL WELD METAL CHEMICAL ANALySISC S Mn P Si Fe

0.05 0.011 1.28 0.022 0.30 Bal



PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG


2.5 2.2 11 45 77253.2 5.0 15 26 77324.0 5.0 15 17 77405.0 5.0 15 9 7750


2G 3G 4G 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


DESCRIPTION AND APPLICATIONAustarc 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.





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


0.06 0.7 0.4 Bal


In as welded condition

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG


3.2 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.





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


0.13 0.5 0.1 Bal



PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG


2.5 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 3G 4G 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.





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


STAINCORD 309Mo-16

21CONTENTS

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Cr Ni Mo Fe

0.025 0.8 0.7 23.5 13.0 2.4 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISYield Stress 400 MPaTensile Strength 670 MPaElongation 38%


PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG


2.5 2.5 12.5 86 SC309MO253.2 2.5 12.5 55 SC309MO32

ELECTRODES - STAINLESS STEEL ELECTRODES1G

2G 3G 4G 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

DESCRIPTION AND APPLICATIONNew 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





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


TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Cr Ni Mo Fe

0.025 0.7 0.7 18.5 12.0 2.4 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISYield Stress 380 MPaTensile Strength 600 MPaElongation 40%


PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF

RODS PER KG


2.0 2.5 12.5 86 SC316202.5 2.5 12.5 55 SC316253.2 2.5 12.5 27 SC31632


2G 3G 4G 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.





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

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Cr Ni Fe

0.04 0.9 0.85 30.0 9.0 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISYield 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


2.5 2.5 12.5 52 UC312253.2 2.5 12.5 27 UC31232


2G 3G 4G 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.





3.2 350 50-100 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.

SUPERCAST Ni

27CONTENTS

TyPICAL ALL WELD METAL CHEMICAL ANALySISMn Ni S Fe0.3 97.0 0.006 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISYield Stress 220 MPaTensile Strength 400 MPaDeposit Hardness 150-170 HV (30)

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG


3.2 2.5 12.5 37 SNI32

ELECTRODES - CAST IRON ELECTRODES1G

2G 3G 4G1F

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.





3.2 350 50-100 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.

SUPERCAST Ni/Fe

29CONTENTS

TyPICAL ALL WELD METAL CHEMICAL ANALySISMn Ni S Fe0.85 57.8 0.007 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISYield Stress 300 MPaTensile Strength 500 MPaDeposit Hardness 200-220 HV (30)

PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG


3.2 2.5 12.5 39 SNIFE32

ELECTRODES - CAST IRON ELECTRODES1G

2G 3G 4G1F

30CONTENTS

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

IDENTIFICATIONCoating - Black End Tip - Plain

DESCRIPTION AND APPLICATIONAustarc 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)

ELECTRODE LENGTH (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 ...................................................................... 34-35SOLID 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/CO and CO 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/CO mixed gases and welding grade CO. 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 DATAWIRE

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

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si S P Fe

0.1 1.45 0.88 0.02 0.022 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISGas Type CO Ar+18% COYield Stress 460 MPa 480 MPaTensile Stress 560 MPa 580 MPaElongation 28% 26%CVN Impact Values 80J @ -20C 70J @ -30C

PACKAGING DATAWIRE

SIZE (mm)PACK SIZE AND TyPE PART NUMBER

0.6 5kg spool 15kg spoolES606M5KG

ES606S0.8 5kg spool 15kg spool

ES608M5KG ES608S

0.9 5kg spool 15kg spoolES609M5KG

ES609S1.0 15kg spool ES610S1.2 15kg spool ES612S1.6 15kg spool ES616S

WIRES - SOLID MIG WIRES - MILD STEEL

1G2G 3G 4G 1F 2F

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

DESCRIPTION AND APPLICATIONAustmig ESD2 is a copper coated, low alloy steel wire used for welding medium to higher strength steels, particularly where service temperatures up to 500C are encountered. ESD2 gives excellent resistance to porosity using CO or Argon based gas mixtures (i.e. Ar/CO, Ar/O, Ar/CO/O). 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




RANGE *(V)0.9 70-230 15-261.2 120-350 18-32


TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Mo Fe

0.1 1.95 0.75 0.5 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISGas Type CO Ar+18% COYield Stress 560 MPa 570 MPaTensile Stress 645 MPa 660 MPaElongation 19% 20%CVN Impact Values 35J @ -20C 50J @ -30C

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 DATAWIRE


0.9 15kg spool ESD209S1.2 15kg spool ESD209S

WIRES - SOLID MIG WIRES - LOW ALLOY STEEL

1G2G 3G 4G 1F 2F

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

DESCRIPTION AND APPLICATIONAustmig NiCrMo is a copper coated, low alloy solid wire suitable for the all positional welding of high strength steels using Argon + CO 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.




RANGE *(V)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

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Ni Cr Mo V Fe

0.07 1.22 0.37 1.42 0.29 0.24 0.07 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISGas Type Ar+18% COYield Stress 732 MPaTensile Stress 799 MPaElongation 18%CVN Impact Values 78J @ -30C

In as welded conditionNOTE: The use of less oxidizing argon based gas mixtures (ie Ar/O, Ar/CO, Ar/CO/O), will result in higher alloy recovery in the weld metal, leading to higher tensile properties.

PACKAGING DATAWIRE


0.9 15kg spool MNICRMO09S1.2 15kg spool MNICRMO12S

WIRES - SOLID MIG WIRES - LOW ALLOY STEEL

1G2G 3G 4G 1F 2F

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

DESCRIPTION AND APPLICATIONAustmig 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.




RANGE *(V)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

TyPICAL ALL WELD METAL CHEMICAL ANALySISSi 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

TyPICAL ALL WELD METAL MECHANICAL ANALySISGas Type ArYield Stress 110 MPaTensile Stress 240 MPaElongation 17%

PACKAGING DATAWIRE


1.2 6kg spool M518312S1.6 6kg spool M518316S

WIRES - SOLID MIG WIRES - ALUMINIUM

1G2G 3G 4G 1F 2F

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

DESCRIPTION AND APPLICATIONAustmig 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.




RANGE *(V)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

TyPICAL ALL WELD METAL CHEMICAL ANALySISZn Mg Mn Cr Si Fe Ti AI0.1 5.2 0.15 0.1 0.25 0.4 0.15 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISGas Type ArYield Stress 125 MPaTensile Stress 275 MPaElongation 17%

PACKAGING DATAWIRE


0.9 2kg spool 6kg spoolM5356092KG

M535609S1.0 2kg spool 6kg spool

M5356102KG M535610S

1.2 2kg spool 6kg spoolM5356122KG

M535612S1.6 6kg spool M535616S

WIRES - SOLID MIG WIRES - ALUMINIUM

1G2G 3G 4G 1F 2F

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

DESCRIPTION AND APPLICATIONAustfil 70C-6M is a metal-cored wire designed for high speed fillet and butt welding in the downhand position using Argon + 18-25% CO 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.




RANGE *(V)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


TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si S P Cu Fe

0.038 1.46 0.68 0.009 0.012 0.02 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISGas Type Ar+25%COYield Stress 628 MPaTensile Stress 587 MPaElongation 29%CVN Impact Values 51J @ -20C

PACKAGING DATAWIRE


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 CO Gas

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

DESCRIPTION AND APPLICATIONAustfil 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 CO 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.




RANGE *(V)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% CO 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


TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si S P Fe

0.03 1.28 0.44 0.01 0.013 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISGas Type COYield Stress 531 MPaTensile Stress 580 MPaElongation 26%CVN Impact Values 93J @ -20C

PACKAGING DATAWIRE


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

WIRES - FLUX CORED GAS SHIELDED WIRES

1G2G 3G 4G 1F 2F

4F

48CONTENTS

SUMMARy Rutile Type Flux Cored Joining Wire, Micro Alloyed Formulated Exclusively for use with Ar/CO 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

DESCRIPTION AND APPLICATIONAn all positional rutile micro alloyed type flux cored welding wire specifically formulated for optimum performance using Ar/CO 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 -20C 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%CO

AUSTFIL 71T-1M

49CONTENTS


SIZE (mm)WELD

POSITIONWELDING CURRENT


RANGE *(V)

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.


TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si S P B Fe

0.04 1.20 0.42 0.012 0.013 0.001 Bal



PACKAGING DATAWIRE

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 1F 2F

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

DESCRIPTION AND APPLICATIONA 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




RANGE *(V)1.2 150-300 24-311.6 200-350 24-34


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

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Ni Fe

0.04 1.24 0.29 0.37 Bal



PACKAGING DATAWIRE


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


1G2G 3G 4G 1F 2F

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

DESCRIPTION AND APPLICATIONFormulated 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.




RANGE *(V)1.2 100-350 22-341.6 200-350 24-34


TM- 71HYD

53CONTENTS

SHIPPING APPROVALSMIL-71T-1-HYD

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si S P Ni Fe

0.05 1.17 0.25 0.014 0.12 0.5 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISGas Type 100% COYield Stress 533 MPaTensile Stress 585 MPaElongation 26.6%CVN Impact Values 150J @ -18C

137J @ -40CAged 48 hours @ 104C


PACKAGING DATAWIRE


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


1G2G 3G 4G 1F 2F

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

DESCRIPTION AND APPLICATIONOffers excellent arc stability and low spatter using either CO or Ar/CO 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..




RANGE *(V)1.2 100-350 22.34


TM-811N2

55CONTENTS

SHIPPING APPROVALSABS 3YSA; DNV Y40MS; LR 3Ys

TyPICAL ALL WELD METAL CHEMICAL ANALySISShielding Gas C Mn Si P S Ni

100% CO 0.04 1.02 0.29 0.010 0.007 2.0975% Ar/25% CO 0.05 1.26 0.44 0.010 0.007 2.07

TyPICAL ALL WELD METAL MECHANICAL ANALySISGas Type 100% CO 75% Ar/25% COYield Stress 535 MPa 579 MPaTensile Stress 600 MPa 662 MPaElongation 27.5% 26%CVN Impact Values 126J @ -40C

95J @ -51C104J @ -40C 71J @ -51C


PACKAGING DATAWIRE


1.2 15kg spool S283712-K29


1G2G 3G 4G 1F 2F

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

DESCRIPTION AND APPLICATIONFabshield 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.




RANGE *(V)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

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si P S AI Fe

0.27 0.73 0.30 0.11 0.005 1.42 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISYield Stress 432 MPaTensile Stress 652 MPaElongation 25%CVN Impact Values Not Required

PACKAGING DATAWIRE


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

DESCRIPTION AND APPLICATIONFabshield 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)

WELDING CURRENT RANGE (A)

ARC VOLTAGE RANGE *(V)

TyPICAL STICKOUT

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


FABSHIELD 23

59CONTENTS


TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si S P AI Fe

0.18 0.65 0.40 0.01 0.01 1.30 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISTensile Stress 572 MPa

NOTE: Yield Stress and impact values not applicable.

PACKAGING DATAWIRE


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

1G2G 3G 4G 1F 2F

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

DESCRIPTION AND APPLICATIONFabshield 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


TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si S P AI Fe

0.28 0.34 0.15 0.008 0.003 1.04 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISYield Stress 427 MPaTensile Stress 627 MPaElongation 22%CVN Impact Values Not Required

PACKAGING DATAWIRE


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 1F 2F

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

DESCRIPTION AND APPLICATIONLow 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 -40C.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.




RANGE *(V)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

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si P S AI Fe

0.19 0.51 0.17 0.009 0.006 1.51 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISYield Stress 470 MPaTensile Stress 580 MPaElongation 25%CVN Impact Values 42J @ -40C

Diffusible Hydrogen 6.7ml/100g of weld deposited In as welded condition.

PACKAGING DATAWIRE


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 1F 2F

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.





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


ABRASOCORD 43

67CONTENTS

HARDFACING PRODUCTS - HARDFACING ELECTRODES

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Cr Nb Fe

5.0 0.7 22.0 7.0 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISSingle 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


3.2 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


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.





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


ABRASOCORD 350

69CONTENTS

HARDFACING PRODUCTS - HARDFACING ELECTRODES

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Cr Fe

0.2 0.4 0.3 2.8 Bal



PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG


3.2 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


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.





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


ABRASOCORD 700

71CONTENTS

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Cr Mo V Fe

0.7 0.3 0.5 8.5 0.3 0.5 Bal



PACKAGING DATA

ELECTRODE SIZE (mm)

PACKAGING (KG)

APPROX NO. OF RODS

PER KG


3.2 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

DESCRIPTIONTubecord 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.





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

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Cr Fe

5.5 1.5 40.0 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISSingle 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 3G 4G

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


DESCRIPTIONTubecord 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




RANGE *(V)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

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Cr Mo Nb V Mn Si Fe

4.0 26.5 0.9 7.9 0.4 0.8 1.5 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISSingle 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

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




RANGE *(V)1.2 120-340 18-32


AUSTMIG TD - 600

77CONTENTS

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Si Mn P S Cr Fe

0.45 3.00 0.40 0.025 0.020 9.00 Bal

TyPICAL ALL WELD METAL MECHANICAL ANALySISAs Welded - Two Layers 55-60 HRc

Recommended Shielding Gases:Argon/18 - 25% CO, Ar/CO or 100% CO

APPLICATIONS Excavator Blades Bucket Teeth Screw Conveyors Crushing Mills Sheer Blades

PACKAGING DATAWIRE


1.2 15kg MTD60012S

HARDFACING PRODUCTS - HARDFACING SOLID MIG WIRES1G

2G 3G 4G

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

DESCRIPTIONMcKAY 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 DATAThe 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

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Cr Fe

3.20 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 DATAWIRE

SIZE (mm)PACK SIZE

(KG) PART NUMBER1.2 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

DESCRIPTIONMcKAY 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 530C.Crack free deposits can be obtained by controlled heat input or the use of preheat.

OPERATIONAL DATAWelding 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

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Cr Mo W Fe

0.45 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)

PACK SIZE (KG) PART NUMBER

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

DESCRIPTIONMcKAY 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 (650C) wear resistance is required. Spatter level is low, slag cover is minimal and is easily removed.

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

WIRE SIZE (mm)



1.6 300-350 30-34Welding 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

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Cr Nb Fe

5.50 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

DESCRIPTIONMcKAY 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% CO.

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

WIRE SIZE (mm)



1.2 165-185 24-28Welding Current DC + *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.

McKAY VERTIWEAR-600

85CONTENTS

TyPICAL ALL WELD METAL CHEMICAL ANALySISC Mn Si Cr Mo Fe

0.40 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 TempHardness after Tempering

535C 620C55 10 Hours 54 46

20 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 3G 4G

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 .......................................................... 88-105OXy-ACETyLENE FLAME ADJUSTMENT .........106-107WELDING SyMBOLS .........................................108-115ELECTRODE 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 ... 134-135WELD 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 .................170-193COMMON WELD TROUBLES ...........................194-199SI 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 ............................................ 212-213SyMBOLS 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

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