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ESAB
Welding Consumables - Equipments - Automation - Cutting Systems
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i
OK AristoRod 13.09 66 Dual Shield II 110 87 OK Autrod 16.30 109
OK AristoRod 13.26 66 Dual Shield II 101 TC 88 OK Autrod 16.53 110
OK Autrod 13.16 67 Dual Shield B9 88 OK Autrod 16.11 110
OK Autrod 13.17 67 OK Tubrod 15.22 89 OK Autrod 16.13 111
OK Autrod 13.28 67 OK Tubrod 15.24 89 SAW Flux
OK AristoRod 13.29 68 OK Tubrod 15.27 90 OK Flux 10.61 L 112
OK AristoRod 13.13 68 OK Tubrod 14.30 90 OK Flux 10.62 112
OK AristoRod 13.31 69 Shield-Bright 308 L 91 OK Flux 10.62 L 113
OK Autrod 16.10 69 Shield-Bright 309 L 91 OK Flux 10.71 114
OK Autrod 16.11 70 Shield-Bright 309 LMo 92 OK Flux 10.71 L 115
OK Autrod 16.30 70 Shield-Bright 309 LCb 92 OK Flux 10.81 L 115
OK Autrod 16.53 71 Shield-Bright 316 L 93 OK Flux 10.81 LM 116
OK Autrod 16.75 71 Shield-Bright 317 L 93 OK Flux 10.81 LS 116
OK Autrod 16.13 71 Shield-Bright 347 94 OK Flux 10.92L 117
OK Autrod 16.33 72 Shield-Bright 308 H 94 Strip Cladding Consumables
OK Autrod 16.43 72 Shield-Bright 410 95 OK Band / Flux for Stainless Steel 118
OK Autrod 16.95 73 Shield-Bright 2209 95 Hard Surfacing Consumables
OK Autrod 1100 73 Shield-Bright 312 96 Wire & Flux Combinations 119
OK Autrod 4043 74 Shield-Bright 410 Ni Mo 96 Consumables for Ni Steels
OK Autrod 5356 74 Shield-Bright 308L Xtra 97 9% Ni Steels for LNG Tank Fabrication 120
OK Autrod 5183 75 Shield-Bright 309L Xtra 97 SMAW
OK Autrod 5556 75 Shield-Bright 309LMo Xtra 98 OK 92.26 121
OK Autrod 19.12 76 Shield-Bright 316L Xtra 98 OK 92.86 121
OK Autrod 19.30 76 Shield-Bright 347 Xtra 99 OK 92.59 122
OK Autrod 19.40 77 Arcaloy T - 409 Ti 99 GMAW
FCAW Consumables SAW Wires OK Autrod 19.81 123
Dual Shield 7100 LH 78 OK Autrod 12.08 L 100 OK Autrod 19.82 123
OK Tubrod 15.00 A 78 OK Autrod 12.22 L 100 GTAW
OK Tubrod 15.14A 79 ESAB SA 10K 101 OK TIgrod 19.81 124
Dual Shield 7100 79 ESAB SA 13K 101 OK Tigrod 19.82 124
Dual Shield 7100 Ultra 80 OK Autrod 12.40 L 102 OK Tigrod 19.85 125
Dual Shield 7100 SR 80 OK Autrod 12.24 L 102 OK Tigrod 19.93 125
Dual Shield T-5 81 OK Autrod 12.33 L 103 SAW
Dual Shield II 70 Ultra 81 OK Autrod 12.34 L 103 OK Flux 10.16 126
Coreshield 11 82 OK Autrod 13.09 L 104 Storage & Handling of Electrodes
Coreshield 8 Ni 1 82 OK Autrod 13.12 L 104 Approval in accordance with
Coreweld 70 83 OK Autrod 12.44 105 classification society rules
Coreweld Ultra 83 OK Autrod 13.10 SC 105 Calculation of Electrode
Coreweld III Ultra 84 OK Autrod 13.20 SC 106 Consumption 127
Dual Shield 8100 W 84 OK Autrod 13.40 106 Data Sheet – Pipewelding
Dual Shield 7000 A1 85 OK Autrod 13.27 107 General Recommendations
Dual Shield 8000 B2 85 OK Autrod 13.43 107 GMAW
Dual Shield 9000 B3 86 OK Autrod 13.64 108 FCAW
Dual Shield II 81 K2 86 OK Autrod 13.22 L 108 SAW
Dual Shield T - 115 87 OK Autrod 16.10 109
ii
Consumables Guide for ASTM Terroweld CF 208 OK Tubrod 14.18 228
Steels 158 Steel and Dissimilar Joining Alloys OK Tubrod 14.70 228
Quick guide for selection of Welding Dissimilar Steels 209 OK Tubrod 14.71 229
consumables 176 Terroweld DMS 210 OK Tubrod 15.40 229
ESAB 116 210 OK Tubrod 15.41 229
Reclamation Consumables OK 53.18 210 OK Tubrod 15.52 230
Conventional Hardfacing Alloys Terroweld DBL 211 OK Tubrod 15.60 230
Buffering 189 Terroweld DLH 211 OK Tubrod 15.73 230
Duroid 250 190 Durochrome 212 OK Tubrod 15.80 231
Duroid 350 190 Terroweld DS1 212 OK Tubrod 15.86 231
Duroid 650 190 Terroweld DS2 212 Gas Brazing Alloys
Duroid 650 B 191 Terroweld DS3 213 Brazing 232
ESAB 600B 191 Terroweld DS4 213 Rupatan 2 233
Duromangan 191 Terroweld DS5 214 Rupatan 14 233
Low Heat Hardfacing Alloys Terroweld DS6 214 Rupatan 35 233
Hardfacing 193 Terroweld S1 214 Rupatan 43 234
Recommended Preheating 195 Terroweld S2 215 Rupatan 50 234
Astra HTB 196 Terroweld S3 215 Rupatan 60 234
OK Selectrode 83.28 196 ESAB CSA 215 ESAB Silicon Bronze 234
ESAB 116 Ni 196 OK Selectrode 68.82 216 Ruf - Kut 234
OK Selectrode 83.40 197 OK Selectrode 68.53 216 Tig Filler Wires
OK Selectrode 84.84 197 OK 69.33 217 Crystalloy 60 235
OK Selectrode 84.78 198 Astra ZF 217 Crystalloy 61 235
Terroweld EWR 198 Non - Ferrous Alloys Crystalloy 62 235
ESAB 550 199 Welding Non - ferrous Alloys 218 Crystalloy 80 235
Astra MN 199 ESAB CN1G 219 Crystalloy 81 236
Durobell 200 ESAB CN 182 219 Crystalloy 82 236
Terroweld MN 200 ESAB Monel 219 Crystalloy 85 236
Terroweld SHR 200 OK Selectrode 92.35 220 Crystalloy 90 236
Terrowed 35 201 OK Selectrode 93.66 220 Hot Metal Spray Powders
Terroweld 65 201 OK Selectrode 93.62 221 Powder Welding 237
OK 84.80 202 OK Selectrode 93.66 221 Castcoat 20 238
OK 84.84 202 Bronzoid 1 222 Multiweld 40 238
Cast Iron Electrodes Cuttifng & Gouging Electrodes Borostrength 60 238
Welding Cast Iron 203 Cutting and Gouging 223 Tungstrength 70 239
Ferroloid 1 204 Terrocut 224 ESAB wear plates 239
Ferroloid 3 204 OK Selectrode 21.03 224 ESAB ETH 500 Plates 240
Ferroloid 4 204 Cobalarc Conversion Chart 241
Terroweld CLH 205 Cobalarc 225 Comparative Hardness Scales 242
OK Selectrode 92.18 205 Cobalarc 1M 226 Metal Selection Guide
OK Selectrode 92.58 206 Cobalarc 9 226 ESAB Consumables for
OK Selectrode 92.60 206 Cobalarc 4 227 Different Repair Work 243
ESAB 801KG 207 Cobalarc MX 227 Selection of Hard Facing
ESAB 802KG 207 Flux Cored Wires Consumables 244
Terroweld CP 208 OK Tubrod 14.17 228
iii
ESAB Consumables for Joining Power Sources - DC 276 Special Regulators 311
of Dissimilar Metals 245 Thyristorised SAW Cutting Blowpipes 312
Metal Identification Chart 246 Power Sources - AC 276 Welding & Heating Blowpipes 314
A2 / A6 Process controller PEH 276 Flash Back Arresters 316
Arc Welding Equipment Orbital TIG Welding 277 Small Cutting Machine 318
MMA Transformers Tractor Automates - Migsytrac 278 Cutting Nozzies 320
Transweld 400 249 Migsytrac - 2000 278 Welding Tips 322
THH 400/THH 630 249 Migsytrac - 3000 278 Accessories
MMA Rectifiers Tractor Automates - Roultrac 279 Accessories 324
RS 400 250 Tractor Automates - Trippletrac /
Esayweld SSr 400 / 600 250 Multitrac / Mastertac 280 PPF & Welding Accessories
Origo Arc 4001i A22 / A24 252 Roller Beds 281 Helments, Masks & Screens 330
Caddy Arc 251i A32 / A34 252 Positioners 281 Respiratory Equipment 332
Origo Arc 410C / 650C / 810C 253 Friction Stir welding 282 Spectacles, Goggles & Visors 334
653 CVCC 253 Robotics for Arc welding 283 Welding Curtains 336
EDW 350 / 400 / 500 254 Range of Robats 284 Welding Gloves 337
Power Compact 255 Accessories Safety Foodwear 338
Migmatic 1250 255 ARC Welding Accessories 285 Welding Tools and Accessories 339
Smashweld 4000T 256 Armour Range of Electrode Holders 286 Welding Cables 340
LAB 4000 256 Handyoven 286 Electrode Holders & Clamps 341
Auto K 400 / 600 257 Fusion Welding Methods
Auto K 400 Synergic 258 Choice of Fusion Welding Method 287
SCR 400 (S) 259 Welding Methods 287
MIG 3000i MA6 MIG 3001i / 4001i 260 MMA Manual Metal
Aristo MIG 5000i 261 Arc Welding
Aristo MIG U4000i / U5000i 262 MMA Manual Metal Arc Welding 289
Feed 3004 / 4804 U6 264 MIG / MAG Gas Metal
MIG Torches - Air / Water / cooled 265 Arc Welding
Easyweld SSR 400-T / 400-T Pluse 266 MAG Welding 291
Caddy TIG 1500i 266 MIG Welding 292
Origo TIG TA 24 267 TIG (GTAW) Tungsten Inert
Aristo TIG 4000i TA4 / TA 6 268 Gas Welding
Heliarc 252 / 352 AC / DC 269 TIG (GTAW Welding) 293
Caddy TIG 2200i AC/DC TA33 / Common Faults in Arc Welding
TA34 / AC/DC 270 Common Faults in Arc Welding 295
Origo TIG 3000i AC/DC TA 24 AC/DC 271
Origo TIg 4300iW AC/DC Industrial Gas Equipment
TA 24 AC/DC 272 Process Description
TIG Torches - Air water cooled 273 Process Description 301
LPH 35 / 50 / 80 / 120 274 Regulators
Powercut 650 / 900 / 1300 / 1600 274 Single Stage Regulators 304
CPRA 800 (S) / 1200 (S) 275 Double Stage Regulators 306
Welding Automation High Pressure Regulators 308
Thyristorised SAW Pipe Line Regulators 310
iv
Welding Consumables
Welding Consumables
ISO 9000 & ISO 14000
Carbon Steel Electrodes
ESAB FERROSPEED TYPICAL APPLICATIONS
Welding Consumables
A rutile coated general-purpose electrode for Chimney, machine building, repair-jobs, shaft reclamation,
MMAW ship building, steel furniture and frameworks, storage
tanks, bus and truck bodies, cement mills, rolling mills,
Classification AWS A5.1 : E 6012 barge - building etc.
IS 814 : ER 4124
TYPICAL ALL WELDMETAL PROPERTIES
DESCRIPTION
Chemical Mechanical Properties
ESAB FERROSPEED is one of the most popular and Composition (%)
wellknown welding electrodes in India for decades. ESAB C 0.085 YS 420 N/mm2
FERROSPEED is a rutile-coated electrode for welding
Si 0.20 UTS 490 N/mm2
general-purpose structures that are not subjected to
P 0.02 EL 23%
heavy dynamic loading, and is specially designed for Mn 0.40 Impact (CVN) at + 27oC 70J
higher tolerance to less cleaned plates and poor joint S 0.02
fit-ups. Unique balance of arc force and slag fluidity
makes the electrode easily manoeuvrable in all positions CURRENT RANGE & PACKING DATA
and because of its versatility and economy, has found Size Length Current Range No. of Electrodes in a
wide acceptance for welding mild steel. The weld (mm) (mm) (Amps) Carton Cardboard box
provides good penetration and an easily detachable 3.15 450 95-125 150 600
slag. The electrode has high current carrying capacity 4.00 450 125-175 100 400
and produces relatively high strength weldmetal. 5.00 450 165-250 65 260
3
ESAB FERROSPEED PLUS engineering job, pipe welding, sheet metal fabrication,
Welding Consumables
4
ESAB 28 welding of pipes, bridges, boilers and pressure vessels
Welding Consumables
storage tanks, etc.
A rutile coated radiography quality electrode for
MMAW TYPICAL ALL WELDMETAL PROPERTIES
Chemical Mechanical Properties
Classification AWS A5.1 : E 6013
Composition (%)
IS 814 : ER 4212X
C 0.08 YS 430 N/mm2
DESCRIPTION
Si 0.24 UTS 500 N/mm2
P 0.02 EL 26%
ESAB 28 is a medium heavy rutile coated mild steel Mn 0.45 Impact (CVN) at 0oC 90J
electrode designed for welding of unalloyed structural S 0.02
steels in all positions. The electrode gives smooth radio-
graphic quality weld with low spatter and smoke. Bead CURRENT RANGE & PACKING DATA
shape is uniform and finely rippled and slag is self re- Size Length Current Range No. of Electrodes in a
moval type. (mm) (mm) (Amps) Carton Cardboard box
APPROVALS 2.50 350 60-85 190 760
3.15 350 85-120 120 480
ABS Gr.2, BIS, BV Gr.2, CIB, DNV Gr.2, TElL, IRS Gr.2, 3.15 450 85-120 120 480
LRS Gr.2, MMD, NPC, PDIL. 4.00 350 120-175 75 300
WELDING CURRENT: DC (+), AC 50V 4.00 450 120-160 75 300
5.00 450 160-240 50 200
TYPICAL APPLICATIONS PACKING: Electrodes are packed in cartons and four of
It is recommended for welding structures of varying these cartons are shrink wrapped in a cardboard box.
thickness of MS plates in different type of joints and
welding ordinary grade ship steel as well as structural
steel of similar strength and composition. Suitable for
5
ESAB 46 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
TYPICAL APPLICATIONS
6
ESAB FERROWELD 1 TYPICAL APPLICATIONS
Welding Consumables
Boiler and pressure vessels, penstock, structure
A basic coated low-hydrogen electrode for
and other components under restrained conditions
MMAW and dynamic loading, ship building, steel of doubtful
composition, grey cast iron, buffer layer prior to hard
Classification AWS A5.1 : E 7016 facing etc.
IS 814 : EB 5424H3X
TYPICAL ALL WELDMETAL PROPERTIES
DESCRIPTION
Chemical Mechanical Properties
ESAS FERROWELD 1 is a basic coated, hydrogen Composition (%)
controlled electrode for welding mild, medium carbon,
low alloy, medium tensile steels, free cutting and difficult C 0.07 YS 440 N/mm2
steels, and grey cast iron (non-machinable deposits) in
Si 0.55 UTS 540 N/mm2
P 0.02 EL 30%
all positions, using AC or DC power sources for complete
Mn 1.3 Impact (CVN) at -29oC 80J
absence of porosity and cracking. The composition of S 0.02
the coating ensures high weldmetal ductility, very low
hydrogen and absence of other non-metallic inclusions. CURRENT RANGE & PACKING DATA
ESAB FERROWELD 1 allows touch welding and Size Length Current Range No. of Electrodes in a
deposits weldmetal of highest radiographic soundness (mm) (mm) (Amps) Carton Cardboard box
(IIW Black) free from under-bead cracking and high
2.50 350 60-100 170 680
notch ductility at sub zero temperatures. .
3.15 350 100-150 100 400
APPROVALS 4.00 450 120-210 65 260
5.00 450 200-280 45 180
ASS Gr.3H, BV Gr.3, 3YH, BIS, CIB, DNV Gr.3YH15,
IRS 3YH, LRS 3, 3Y, 3H, MMD PACKING: Electrodes are packed in cartons and four of
these cartons are shrink wrapped in a cardboard box.
WELDING CURRENT : DC+, AC 70V
DNV GR 3YH15, MMD, CIB PACKING: Electrodes are packed in cartons and four
of these cartons are shrink wrapped in a cardboard box.
WELDING CURRENT: DC +, AC 70V
This electriode is also available in moisture resistant
TYPICAL APPLICATIONS vacuum packed cartons, which can be used without re-
drying.
For welding heavy section of mild and medium tensile
steels that are subjected to dynamic loading. It is in-
tended for welding carbon and C-Mn steels. It is also
suitable for depositing non-machinable weld on Cast
Iron, buffer layer for hard facing, etc.
7
ESAB FERROWELD 2 TYPICAL APPLICATIONS
Welding Consumables
A basic coated low-hydrogen electrode for MMAW Boiler and pressure vessels, penstock, structural and
other components under restrained conditions and dy-
Classification AWS A5.1: E 7018 namic loading, ship building, steel of doubtful composi-
IS 814 : EB 5424H3JX tion, grey cast iron, buffer layer prior to hard facing etc.
8
OK 48.20 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Properties
A basic coated low-hydrogen electrode for MMAW
Composition (%)
Classification AWS A5.1: E 7018 C 0.06 YS 490 N/mm2
IS 814 : ES 5424H3JX
Si 0.50 UTS 560 N/mm2
P 0.018 EL 30%
DESCRIPTION Mn 1.15 Impact (CVN) at -30oC 100J
S 0.018
OK 48.20 is a heavy basic coated, hydrogen controlled
iron powder (high metal recovery of approximately CURRENT RANGE & PACKING DATA
117%) electrode with excellent running performance Size Length Current Range No. of Electrodes in a
and bead finish in flat and positional welding. It deposits (mm) (mm) (Amps) Carton Cardboard box
a tough and crack-resistant weld of high radiographic 2.50 350 70-110 140 560
quality. 3.15 450 100-150 95 360
APPROVALS 4.00 450 130-190 65 260
5.00 450 180-260 40 160
MMD
PACKING: Electrodes are packed in cartons and four
WELDING CURRENT: DC+, AC 70V of these cartons are shrink wrapped in a cardboard box.
This electrode are also be made available in moisture
TYPICAL APPLICATIONS
resistant vacuum packed cartons, which can be used
Boiler and pressure vessels, penstock, structure without redrying.
and other components under restrained conditions
and dynamic loading, ship building, steel of doubtful
composition, grey cast iron, buffer layer prior to hard
facing etc.
WELDING CURRENT: DC+, AC 70V PACKING: Electrodes are packed in cartons and four
of these cartons are shrink wrapped in a cardboard box.
TYPICAL APPLICATIONS
This electrode are also be made available in moisture
ESAB 36H (SPL) is ideal for welding of fine grained resistant vacuum packed cartons, which can be used
carbon manganese steels and medium tensile steels without redrying.
having UTS of 50-58 Kgf/mm2 and is recommended for
welding of pressure vessels, boilers, hortonspheres,
9
OK 48.20 (SPL) TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
10
ESAB VORTEX -1 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Properties
Heavy Coated Rutile Type
Composition (%)
Classification AWS A5.1 : E6013 C 0.05 YS 400 N/mm2
Mn 0.50 UTS 510 N/mm2
DESCRIPTION
Si 0.23 EL 26%
Ni 0.4 Impact (CVN) at -20oC 65J
ESAB Vortex-1 is a heavy coated rutile type electrode
S 0.020
with excellent slag detachability even in deep grooves. P 0.020
Has superior bead finish and low spatter. Suitable for
low alloy and medium tensile steels, high radiographic CURRENT RANGE & PACKING DATA
quality. Size Length No. of Electrodes in a
Cardboard
APPROVALS : BIS, ABS Gr3, MMD (mm) (mm) PCS
box
2.50 350 600 1
TYPICAL APPLICATIONS
3.15 450 400 1
Boilers and pressure vessels, shipbuilding and heavy 4.00 450 240 1
structurals. 5.00 450 140 1
WELDING CURRENT: DC+ PACKING: Electrodes are packed in cartons and four of
these cartons are shrink wrapped in a carboard box.
11
Gas Welding Fluxes
Gas Welding Fluxes REMOVAL OF FLUX RESIDUE:
Welding Consumables
12
Pipe Welding Electrodes
PIPEWELD 6010R TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Properties
Cellulose coated electrode for Pipe Welding
Composition (%)
Classification AWS A5.1 : E6010 C 0.10 YS 420 N/mm2
IS 814: EC 4410 X
Mn 0.50 UTS 500 N/mm2
P 0.02 EL 27%
DESCRIPTION Si 0.25 Impact (CVN) at -29oC 50J
S 0.02
PIPEWElD 6010R is high cellulose coated electrode
for welding of pipes. The electrode is designed to CURRENT RANGE & PACKING DATA
provide deep and complete penetration and the weld Size Length Current Range No. of Electrodes in a
bead obtained is smooth with a thin, fast freezing easily (mm) (mm) (Amps) Carton Cardboard box
removable slag, giving x-ray quality weldmetal. 2.50 350 50-80 200 800
3.15 350 90-130 130 520
APPROVALS: PDll, TElL, NPC.
4.00 350 110-160 80 320
WELDING CURRENT: DC + PACKING: Electrodes are packed in cartons and four
TYPICAL APPLICATIONS of these cartons are shrink wrapped in a cardboard box.
Also available in 10kg sheet metal cans.
PIPEWElD 6010R is designed for site welding of
carbon steel pipes and pipelines in all positions using
conventional techniques particularly for root run. It can
be used where stringent NDT requirement and testing
codes are involved.
13
OK 22.46 P TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
CURRENT RANGE
Size Length Current Range
(mm) (mm) (Amps)
3.20 350 65-120
4.00 350 90-180
5.00 350 150-240
PACKING: Available in 20Kg sheet metal cans.
14
OK 22.48 P CURRENT RANGE
Welding Consumables
Size Length Current Range
Classification Electrode AWS A5.5 : E9010-G (mm) (mm) (Amps)
3.20 350 65-120
DESCRIPTION
4.00 350 90-180
Cellulosic-coated electrode designed for sitewelding of 5.00 350 150-240
pipe and pipelines. PACKING: Available in 20Kg sheet metal cans.
WELDING CURRENT: DC +
15
Low Alloy Electrodes
OK 48.08 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
16
OK 74.46 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Hot Tensile
A low alloy, low hydrogen electrode for MMAW
Composition(%) Properties Properties
Classification AWS A5.5: E7018-A 1 C 0.06 YS 460 N/mm2 300oC 390 N/mm2
IS 1395: E49B-A 1-26Fe
Mn 0.75 UTS 550 N/mm2 400oC 360 N/mm2
Si 0.45 EL 28% 500oC 340 N/mm2
DESCRIPTION Mo 0.55
S 0.018
OK 74.46 is a low alloy, low hydrogen electrode deposit-
P 0.020
ing a ductile and creep-resistant 0.5% Mo steel deposit
for welding of Carbon-Molybdenum creep resistant pres- CURRENT RANGE & PACKING DATA
sure vessel steel. The specially designed slag system Size Length Current Range No. of Electrodes in a
allows excellent running in all positions with minimum (mm) (mm) (Amps) Carton Cardboard box
amount of spatter. OK 74.46 deposits a weldmetal with 2.50 350 75-110 135 540
good crack and creep resistance to temperature upto
3.15 450 105-150 95 380
525°C. The weld deposit is of radiographic quality.
4.00 450 140-200 60 240
APPROVALS: PDlL, IBR, NPC, TEIL. 5.00 450 190-270 35 140
WELDING CURRENT: DC +, AC 70V PACKING: Electrodes are packed in cartons and four
of these cartons are shrink wrapped in a cardboard box.
TYPICAL APPLICATIONS This electrode can also be made available in moisture
resistant vacuum packed cartons, which can be used
OK 74.46 is especially designed for the welding of 0.5%
without redrying.
Mo and similar creep resistant steels. It is extensively
used in high temperature pipelines, boiler tubes and
plates where high creep resistance is a pre-requisite.
OK 76.18 A387 -2, 12; A213-T2, T11, T12;A335-P2, P11, P12 and
German steels 13 Cr Mo 44,15 Cr Mo 5 etc.
A basic AC/DC low alloy electrode for MMAW
TYPICAL ALL WELDMETAL PROPERTIES
Classification AWS A5.5: E 8018-B2
Chemical Mechanical Hot Tensile
IS 1395: E 55B-B226Fe Composition (%) Properties Properties
17
OK 76.18 M ers etc. Steels of the type ASTM A 182-F2, F11 , F12,
Welding Consumables
A387 -2, 11, 12, A213-T2, T11, T12, A335- P2, P11, P12
A basic AC/DC low alloy electrode for MMAW and German steels 13 Cr Mo 44, 15 Cr Mo 5 etc.
OK 76.18 M is specially used to the welding of 1.25 Cr PACKING: Electrodes are packed in cartons and four
0.5 Mo and similar creep resistant steels which find ex- of these cartons are shrink wrapped in a cardboard box.
tensive use in high temperature components of power This electrode can also be made available in moisture
plants, boilers, oil- refineries, petrochemical plants, boil- resistant vacuum packed cartons, which can be used
without redrying.
ESAB 8018 - B2 electrode is a basic low hydrogen PACKING: Electrodes are packed in cartons and four
electrode for welding creep resisting steels of the 1.25 of these cartons are shrink wrapped in a cardboard box.
Cr - 0.5 Mo types, such as SA 387 Grade 11/A 335 Vacuum packed cartons also are available.
P11. The Weldmetal has extra low impurity level, and is
designed for low temperature impact toughness down
to - 18OC.
18
OK 76.18G TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Properties
A Rutile AC/DC low alloy electrode For MMAW Composition (%)
Classification AWS A5.5: E 8013-G C 0.07 YS 500 N/mm2
IS 1395: E55RG124
Mn 0.5 UTS 580 N/mm2
Si 0.25 EL 22%
DESCRIPTION Cr 1.05
Mo 0.50
OK 76.18G is a rutile-coated electrode depositing a 1.0 S 0.02
Cr/0.45 Mo/0.25 V type low alloy deposit for high tem- P 0.02
perature service up to 550°C. OK 76.18G is specially V 0.30
designed for joining plant piping and are of radiographic
CURRENT RANGE & PACKING DATA
quality.
Size Length Current Range No. of Electrodes in a
WELDING CURRENT: DC +, AC 70 V (mm) (mm) (Amps) Carton Cardboard box
2.50 350 75-110 130 520
TYPICAL APPLICATION
3.15 450 105-150 90 360
OK 76.18G are suitable for low alloy steel boiler and 4.00 450 140-200 60 240
piping applications that are operated at elevated tem- 5.00 450 190-270 40 160
peratures of up to 550OC. OK 76.18G it can also used
for fabrication of boiler heads and spares of similar com- PACKING: Electrodes are packed in cartons and four
position that find usage at petro-chemicals, refineries, of these cartons are shrink wrapped in a cardboard box.
thermal power plants etc. This electrode can also be made available in moisture
resistance vacuum packed cartons, which can be used
without redrying.
19
OK 76.28 M TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
20
ESAB KV7 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Properties
A basic coated low hydrogen electrode for welding
Composition (%)
9 Cr-1 Mo steels
C 0.06 YS 490 N/mm2
Classification AWS A5.5: E 8018-B8
Si 0.30 UTS 600 N/mm2
IS 1395: E 55 B-B 820
Cr 9.1 EL 22%
S 0.018
DESCRIPTION Mo 1.00
Mn 0.70
ESAB KV7 is basic coated all position electrode for Ni 0.20
welding of creep - resistant steels alloyed with 9Cr-1 P 0.018
Mo. The weldmetal obtained is ductile and resistant to
impact. The weldmetal is highly resistant to corrosion CURRENT RANGE & PACKING DATA
and hydrogen attack at high temperatures. The arc and Size Length Current Range No. of Electrodes in a
current carrying characteristics, minimum spatter and (mm) (mm) (Amps) Carton Cardboard box
smoke level and stable arc in all positions appeal to the 2.50 350 60-100 135 540
welder. The weldmetal is of radiographic quality and ap- 3.15 350 90-130 95 380
pearance is smooth and even. 4.00 350 110-165 60 240
WELDING CURRENT: DC+, AC (70V) 5.00 450 175-240 45 180
21
OK 73.68 alloy type is also noted for its good corrosion resistance
Welding Consumables
22
ESAB 8016 C2 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Properties
A basic coated 3.5% Ni alloyed electrode for HSLA
Composition (%)
steels
C 0.06 YS 510 N/mm2
Classification AWS A5.5: E 8016-C2
Mn 1.10 UTS 600 N/mm2
Si 0.25 EL 26%
DESCRIPTION S 0.02 Impact 9CVN) at - 80oC 60J
P 0.018 - 101oC 50J
ESAB 8016 - C2 is a medium coated, hydrogen con-
Ni 3.35
trolled all position electrode specially designed for weld-
ing nickel alloy steels. The electrode deposits a 3.5% Ni CURRENT RANGE & PACKING DATA
weld deposit which has a high tensile strength, ductility
Size Length Current Range No. of Electrodes in a
and resistance to low temperature embrittlement down
(mm) (mm) (Amps) Carton Cardboard box
to -101OC. The weldmetal is of radiographic quality.
2.50 350 70-110 130 520
WELDING CURRENT: DC+, AC 70V(min) 3.15 450 90-150 95 380
4.00 450 130-190 60 240
TYPICAL APPLICATIONS
5.00 450 150-260 35 140
For welding 3 - 3.75% Ni steels like LPG / Ethane tank-
PACKING: Electrodes are packed in cardboard
age, chemical tanks, etc. Also used for fabrication of
cartons and four of these cartons are shrink wrapped
components used in low temperature service, refinery,
in a cardboard box. The electrode can also be made
pressure vessels, valves, etc.
available in moisture resistant vacuum packed cartons,
which can be used without redrying.
23
OK 74.86 CURRENT RANGE & PACKING DATA
Welding Consumables
24
ESAB 98 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Properties
A low alloy electrode for welding high tensile low
Composition (%)
alloy steels
C 0.05 YS 580 N/mm2
Classification AWS A5.5: E 9018-M
Mn 1.00 UTS 690 N/mm2
IS 1395: E63B-M 126Fe
Si 0.4 EL 26%
Ni 1.5 Impact (CVN) at - 51oC 47J
DESCRIPTION Mo 0.30
S 0.02
ESAB 98 is a heavy coated, hydrogen controlled, iron P 0.02
powder type electrode for welding high tensile, low al- Cr 0.1
loy steels depositing x-ray quality, crack resistant welds. V 0.01
The addition of iron powder permits higher currents
CURRENT RANGE & PACKING DATA
to be used and results in improved arc characteristics
coupled with higher metal recovery. The current charac- Size Length Current Range No. of Electrodes in a
teristics are smooth with excellent operability in all posi- (mm) (mm) (Amps) Carton Cardboard box
tions and excellent slag removal. 2.50 350 60-100 130 520
3.15 450 90-125 90 360
WELDING CURRENT: DC+, AC 70V(min)
4.00 450 120-180 60 240
APPLICATIONS 5.00 450 160-240 40 160
ESAB 98 finds extensive use in pressure vessels, PACKING: Electrodes are packed in cartons and four
piping, penstock, earth moving equipment, machinery of these cartons are shrink wrapped in a cardboard box.
parts, automobile parts, chemical plants where low alloy This electrode can also be made available in moisture
Ni-CrMo steels are used. Suitable for N-A-XTRA 55 and resistant vacuum packed cartons, which can be used
N-AXTRA 60 steels. without redrying.
25
ESAB 118 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
26
ESAB 130 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Properties
A low hydrogen, low alloy electrode for welding low
Composition (%)
alloy, high strength structural steels
C 0.08 YS 880 N/mm2
Classification AWS A5.5: E 13018-G
Mn 1.70 UTS 970 N/mm2
BS 611 HJ
Si 0.45 EL 18%
IS 1395 E838 B-G 129Fe Mo 0.50 Impact (CVN) at - 27oC 90J
DESCRIPTION S 0.025 0oC 60J
Ni 2.80
ESAB 130 is an all position low hydrogen electrode de- Cr 0.90
signed to deposit high strength as well as highly duc- V 0.05
tile and tough Weldmetal for welding of fully killed high P 0.025
strength steels. The electrode deposits finely rippled
CURRENT RANGE & PACKING DATA
weldbead which is of radiographically quality. The weld-
metal is also low in diffusible hydrogen.
Size Length Current Range No. of Electrodes in a
TYPICAL APPLICATIONS (mm) (mm) (Amps) Carton Cardboard box
3.15 450 90-125 90 360
Recommended for welding very high strength steels like 4.00 450 120-180 60 240
XABO-90, penstocks, earthmoving equipment, casting 5.00 450 160-240 40 160
repair, etc.
PACKING: Electrodes are packed in cartons and four
of these cartons are shrink wrapped in a cardboard box.
This electrode can also be made available in moisture
resistant vacuum packed cartons, which can be used
without redrying.
27
ESAB FERROWELD W2 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
28
Stainless Steel Electrodes
OK 61.50 impellers and shafts, valve seats and chemical plants
Welding Consumables
and certain grades of armour steels that are difficult to
A low carbon 19/9 stainless steel electrode weld otherwise.
OK 61.50 is an AC/DC rutile coated stainless steel elec- C 0.06 YS 440 N/mm2
Mn 0.90 UTS 600 N/mm2
trode with unique low moisture absorption coating which
Cr 19.00 EL 40%
deposits low carbon 19Cr, 10Ni type metal. The unique Ni 10.00 Ferrite Content FN 4-10
flux coating allows easy striking and restriking and is Si 0.70
completely free from short-circuiting during welding. S 0.015
The arc is stable, very smooth, negligible spatter, and P 0.020
gives welds with a self-releasing slag cover that is finely
rippled and shiny. CURRENT RANGE & PACKING DATA
Size Length Current Range Packing
APPROVALS: PDlL, TEIL, NPCIL (mm) (mm) (Amps)
WELDING CURRENT: DC+, AC 65V 2.50 350 60-90 Weight Per Box : 10 Kgs
3.15 350 80-120 Weight Per carton
TYPICAL APPLICATIONS
4.00 350 120-170 (Packet) : 2 Kgs
OK 61.50 finds extensive use in fabrication of austenitic No. of Packets (Cartons)
5.00 350 150-240
stainless steels of 18Cr 8Ni type corresponding to AISI in a box : 5
types 301, 304 and 308, German steel nos. 1.4016, PACKING: Electrodes are packed in heat sealed plastic
1.4501, 1.4300, 1.4301, Continental steels V2A, Sandvik cartons and five of these cartons are shrink wrapped in
OR-2, UHB stainless 33 etc. It also finds use in building a card board box. Also available in ready to use vacuum
up stainless steel surfaces on centrifugal pumps, pack cartons.
OK 61.30 is a rutile based extra low carbon 19Cr/10Ni C 0.025 YS 570 N/mm2
Mn 0.90 UTS 450 N/mm2
type stainless steel electrode with a controlled ferrite of
Cr 19.50 EL 42%
3-8 FN that provides excellent resistance to corrosion, P 0.020 Ferrite Content FN 3-8
cracking and high temperature scaling resistance upto Ni 10.00
800°C. The enormous welder appeal that OK 61.30 en- Si 0.70
joys is due to excellent weldability in all positions, easy S 0.015
striking and restriking, stable and quite are, a slag cover
that is selfpeeling and a final bead appearance that is CURRENT RANGE & PACKING DATA
finely rippled and shiny. In most cases OK 61.30 gives Size Length Current Range Packing
acceptable results on niobium or titanium stabilised
(mm) (mm) (Amps)
austenitic stainless steels with the carbon content low
2.50 350 60-90 Weight Per Box : 10 Kgs
enough to eliminates the possibility of inter-granular
cracking 3.15 350 80-120 Weight Per carton
4.00 350 120-170 (Packet) : 2 Kgs
APPROVAL: PDIL, NPCIL, TEIL
No. of Packets (Cartons)
5.00 350 150-240
WELDING CURRENT: DC+, AC 65 V in a box : 5
29
ESAB 304B etc. are some of the steels which are widely fabricated
Welding Consumables
ESAB 304B is an extra low carbon, basic coated stainless C <0.03 YS 420 N/mm2
steel electrode with outstanding welding properties in
Cr 19.0 UTS 570 N/mm2
the vertical and overhead position. The weldmetal is
Si 0.40 EL 45%
Ni 10.50 Impact (CVN) at - 196oC 40J
highly resistant to cracking and porosity and has good
Mn 1.6 Lateral Expansion 0.42 mm
impact toughness at very low temperatures. The low S 0.015
carbon content prevents intergranular corrosion in the P 0.018
temperature range 425°C and 823°C. The slag system Mo 0.05
allows excellent welding characteristics in all positions,
slag cover that is easily detachable, and a weldbead that CURRENT RANGE & PACKING DATA
is shiny and finely rippled. The weldmetal has excellent Size Length Current Range Packing
creep strength and is of radiographic quality. (mm) (mm) (Amps)
WELDING CURRENT: DC + 2.50 350 60-90 Weight Per Box : 10 Kgs
TYPICAL APPLICATIONS 3.15 350 80-120 Weight Per carton
ESAB 304B is mainly used for welding stainless steels 4.00 350 120-170 (Packet) : 2 Kgs
having a corresponding chemistry with high ductility No. of Packets (Cartons)
5.00 350 150-240
and high impact values at low temperature cryogenic in a box : 5
applications (-196°C working temperatures). Stainless PACKING: Electrodes are packed in heat sealed plastic
steel conforming to grades AISI 301, 302, 304, 304L, 304 cartons and five of these cartons are shrink wrapped in
having very low carbon contents, BS: EN 58, 58A, 58E a Cardboard box. Also available in ready to use vacuum
pack cartons.
ESAB 304B (N) fabricated with ESAB 304B (N) and they find extensive
use in food and beverage industries, chemical and
An extra low carbon, basic type 19/9 stainless steel petrochemical industries, nuclear power industry etc.
electrode TYPICAL ALL WELDMETAL PROPERTIES
Classification AWS A5.4: E 308L-15 Chemical Mechanical Properties
Composition (%)
DESCRIPTION
ESAB 304B (N) is an extra low carbon, basic coated C 0.035 YS 345 N/mm2
Cr 20.0 UTS 595 N/mm2
stainless steel electrode with outstanding welding
Si 0.65 EL 38%
properties in the vertical and overhead position. Ni 10.00 Impact (CVN) at - 196oC 40J
The weldmetal is highly resistant to cracking and Mn 1.75
porosity and has good impact toughness at very low S 0.02
temperatures. The slag system allows excellent welding P 0.025
characteristics in all positions, slag cover that is easily Mo 0.5
detachable, and a weldbead that is shiny and finely
rippled. The weldmetal has excellent creep strength and CURRENT RANGE & PACKING DATA
is of radiographic quality. Size Length Current Range Packing
(mm) (mm) (Amps)
WELDING CURRENT: DC +
2.50 350 60-90 Weight Per Box : 10 Kgs
TYPICAL APPLICATIONS
3.15 350 80-120 Weight Per carton
ESAB 304B (N) is mainly used for welding stainless 4.00 350 120-170 (Packet) : 2 Kgs
steels having a corresponding chemistry with high
No. of Packets (Cartons)
ductility and high impact values at low temperature 5.00 350 150-240
in a box : 5
cryogenic applications (-196°C working temperatures).
Stainless steel conforming to grades AISI 301, 302, 304, PACKING: Electrodes are packed in heat sealed plastic
304L, 304 having very low carbon contents, BS: EN 58, cartons and five of these cartons are shrink wrapped in
58A, 58E etc. are some of the steels which are widely a Cardboard box. Also available in ready to use vacuum
pack cartons.
30
OK 61.80 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Properties
A niobium stabilised stainless steel electrode of the Composition (%)
19/10 type
C 0.03 YS 600 N/mm2
Classification AWS A5.4: E 347-16
Mn 0.75 UTS 400 N/mm2
IS 5206: E 19.9 Nb R 26
Cr 19.50 EL 35%
S 0.015 Ferrite Content FN 5-9
DESCRIPTION
Ni 10.00
OK 61.80 is a rutile type low carbon 19Cr/10Ni stabilised Si 0.8
stainless steel electrode. This electrode provides Nb 0.60
excellent resistance to scaling, corrosion and cracking at P 0.02
temperatures of upto 800°C. Niobium prevents harmful CURRENT RANGE & PACKING DATA
carbide precipitation to avoid intergranular cracking in
Size Length Current Range Packing
the temperature range 425°C to 850°C. The weldability
of OK 61.80 is outstanding with very easy striking and (mm) (mm) (Amps)
restriking properties. The slag system is designed to 2.50 350 60-90 Weight Per Box : 10 Kgs
provide self-lifting slag, and a bead that is smoothly 3.15 350 80-120 Weight Per carton
rippled and shiny. Weldmetal is of radiographic quality.
4.00 350 120-170 (Packet) : 2 Kgs
APPROVALS: NPCIL, TEIL No. of Packets (Cartons)
5.00 350 150-240
in a box : 5
WELDING CURRENT: DC+, AC 65V
TYPICAL APPLICATIONS PACKING: Electrodes are packed in heat sealed plastic
cartons and five of these cartons are shrink wrapped in
OK 61.80 finds extensive application for welding of a Cardboard box. Also available in ready to use vacuum
stabilised version of 19Cr/10Ni type steels corresponding pack cartons.
to AISI 321 & 347, Werkstoff Nr: 1.4541,1.4543,1.4550,
1.4552. These steels are used widely in the food and
beverage industries, chemical industries, petrochemical
industries, power plants, aircraft industries, etc.
31
ESAB 308H TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
OK 63.50 is a low carbon, rutile electrode with a unique C 0.06 UTS 580 N/mm2
Mn 0.60 YS 420 N/mm2
low moisture absorption coating depositing a weldmetal
Cr 19.5 EL 38%
of the type 18% Cr, 13% Ni, 2.8% Mo. The weldability of S 0.015 Ferrite Content FN 5-10
OK 63.50 is outstanding like any ESAB stainless steel Mo 2.5
electrodes with excellent striking and restriking proper- Ni 12.5
ties, a self peeling slag and a weld that is extremely Si 0.6
smooth and shiny. Its extreme ease of operation in all P 0.020
positions with exceedingly low spatter and stable arc
makes it a favourite of welders. CURRENT RANGE & PACKING DATA
Size Length Current Range Packing
APPROVAL: NPC, PDIL (mm) (mm) (Amps)
WELDING CURRENT: DC+, AC 50 V 2.50 350 60-90 Weight Per Box : 10 Kgs
3.15 350 80-120 Weight Per carton
TYPICAL APPLICATIONS
4.00 350 120-170 (Packet) : 2 Kgs
OK 63.50 is especially designed for the welding of No. of Packets (Cartons)
5.00 350 150-240
18Cr/13Ni/Mo type steels corresponding to AISI 316 and in a box : 5
317 type stainless steels. Commonly used in chemical PACKING: Electrodes are packed in heat sealed plastic
tanks, coils and vats that are exposed to severe cartons and five of these cartons are shrink wrapped
corrosion by sulphuric, sulphurous, hydrochloric, acetic, in a Cardboard box. Vacuum packed cartons are also
available on demand.
32
OK 63.30 also suitable for welding titanium and niobium stabilised
18-12 steels of the type SS 2344 and 2345 except when
Welding Consumables
A rutile based extra low carbon 19/12/2 stainless the corrosive conditions are severe.
steel electrode
TYPICAL ALL WELDMETAL PROPERTIES
Classification AWS A5.4: E 316L-16
IS 5206: E 19.12.2 R 26 Chemical Mechanical Properties
Composition (%)
DESCRIPTION
C 0.025 UTS 580 N/mm2
OK 63.30 is an extra low carbon, rutile electrode with
Mn 0.90 YS 400 N/mm2
a unique low moisture absorption coating depositing a
Cr 19.0 EL 40%
weldmetal of the type 18% Cr, 13% Ni, 2.8% Mo. The S 0.015 Ferrite Content FN 5-10
weldability of OK 63.30 is outstanding in all positions Mo 2.4
with both AC and DC current. It is completely free from Ni 12.5
short-circuiting during welding coupled with excellent Si 0.70
striking and restriking properties, a self-lifting slag and P 0.020
a final weld appearance that is extremely smooth and
shiny. CURRENT RANGE & PACKING DATA
APPROVALS : PDIL, NPCIL, TEIL Size Length Current Range Packing
(mm) (mm) (Amps)
WELDING CURRENT: DC+, AC 50 V
2.50 350 60-90 Weight Per Box : 10 Kgs
TYPICAL APPLICATIONS 3.15 350 80-120 Weight Per carton
OK 63.30 is especially designed for the welding of 4.00 350 120-170 (Packet) : 2 Kgs
18Cr/13Ni/Mo type steels corresponding to AISI 316
No. of Packets (Cartons)
and 316L, 317 type stainless steels. Commonly used 5.00 350 150-240
in a box : 5
in chemical tanks paper mill equipment, bleaching
equipment, chemicals plants, textile plants, whose vessel PACKING: Electrodes are packed in heat sealed plastic
surfaces are exposed to severe corrosion by sulphuric, cartons and five of these cartons are shrink wrapped in
sulphurous, hydrochloric, acetic, phosphoric, citric, a Cardboard box. Also available in ready to use vacuum
tartaric acids etc. and also for components exposed to pack cartons.
high temperatures for e.g. heat resistant castings. It is
33
ESAB 316KCR chemical plants where better corrosion resistance is
Welding Consumables
ESAB 316 KCR is especially designed for both welding PACKING: Electrodes are packed in heat sealed plastic
and cladding of 316L UREA GRADE steels, used for cartons and five of these cartons are shrink wrapped in
Urea reactors, stainless steels used for pickling plates, a Cardboard box. Also available in ready to use vacuum
pack cartons.
OK 63.80 is especially designed for the welding of Ti 4.00 350 120-170 (Packet) : 2 Kgs
and Nb stabilised stainless steels with similar base No. of Packets (Cartons)
5.00 350 150-240
composition corresponding to AISI 316 and 318 types. in a box : 5
Widely used in chemical plants handling corrosive acids PACKING: Electrodes are packed in heat sealed plastic
like Sulphuric acid, hydrochloric acid, tartaric acid, cartons and five of these cartons are shrink wrapped in
acetic acid, formic acid, citric acid etc., in paper and a card board box. Also available in ready to use vacuum
pulp industries using paper mill equipment, bleaching pack cartons.
34
OK 64.30 takes place involving sulphuric acid and sulphurous acids
Welding Consumables
and their salts. OK 64.30 is also for steel fabrications in,
An extra low carbon AC/DC stainless electrode of which post weld heat treatment is to be avoided.
the 19/12/3 type
TYPICAL ALL WELDMETAL PROPERTIES
Classification AWS A 5.4: E 317L-16
Chemical Mechanical Properties
IS 5206: E 19 123 LR 26 Composition (%)
DESCRIPTION C 0.028 YS 450 N/mm2
Mo 3.7 UTS 600 N/mm2
OK 64.30 is an extra low carbon AC/DC stainless steel
Si 0.7 EL 35%
electrode of the type 19Cr, 13Ni, 3.5 Mo with controlled Ni 12.5 Impact (CVN) at +20oC 55J
ferrite content of 5 to 10 for maximum resistance to Mn 0.8 Ferrite Content FN 5-10
intercrystalline corrosion, stress corrosion cracking, Cr 19.0
hot cracking and chemical corrosion. The weldmetal S 0.015
display excellent resistance to creep and the higher P 0.020
molybdenum reduces the susceptibility to pitting. OK
CURRENT RANGE & PACKING DATA
64.30 has excellent weldability in all positions, a slag
Size Length Current Range Packing
cover that is self peeling and a weld bead appearance
which is smooth and shiny. The welds are of radiographic (mm) (mm) (Amps)
quality. 2.50 350 60-90 Weight Per Box : 10 Kgs
3.15 350 80-120 Weight Per carton
WELDING CURRENT: DC +, AC
4.00 350 120-170 (Packet) : 2 Kgs
TYPICAL APPLICATIONS No. of Packets (Cartons)
5.00 350 150-240
in a box : 5
OK 64.30 is designed for welding stainless steel
corresponding to AIS1317, 317L, DIN W Nr: 1.4438, PACKING: Electrodes are packed in heat sealed plastic
British Standard: 317 S 12, Swedish Standard: SS-steel cartons and five of these cartons are shrink wrapped in
2367. These find extensive use where severe corrosion a Cardboard box. Also available in ready to use vacuum
pack cartons.
ESAB 317 LN acids and their salts. ESAB 317 LN is also for steel
fabrications in, which post weld heat treatment is to be
An extra low carbon AC/DC stainless electrode of avoided.
the 19/12/3 type TYPICAL ALL WELDMETAL PROPERTIES
Classification AWS A 5.4: E 317L-16 Chemical Mechanical Properties
Composition (%)
DESCRIPTION
C 0.003 UTS 520 N/mm2
ESAB 317 LN is an extra low carbon AC/DC stainless
Mo 4.5 EL 30%
steel electrode of the type 19Cr, 13Ni, 3.5 Mo with
Si 0.9 Impact (CVN) at - 4OC 27J
controlled ferrite content of 5 to 10 for maximum Ni 14.0
resistance to intercrystalline corrosion, stress corrosion Mn 1.5
cracking, hot cracking and chemical corrosion. The Cr 19.5
weldmetal display excellent resistance to creep and S 0.02
the higher molybdenum reduces the susceptibility to P 0.025
pitting. ESAB 317 LN has excellent weldability in all CURRENT RANGE & PACKING DATA
positions, a slag cover that is self peeling and a weld
bead appearance which is smooth and shiny. The welds Size Length Current Range Packing
are of radiographic quality. (mm) (mm) (Amps)
2.50 350 60-90 Weight Per Box : 10 Kgs
WELDING CURRENT: DC +, AC
3.15 350 80-120 Weight Per carton
TYPICAL APPLICATIONS 4.00 350 120-170 (Packet) : 2 Kgs
ESAB 317 LN is designed for welding stainless steel No. of Packets (Cartons)
5.00 350 150-240
in a box : 5
corresponding to AIS1317, 317L, DIN W Nr: 1.4438,
British Standard: 317 S 12, Swedish Standard: SS-steel PACKING: Electrodes are packed in heat sealed plastic
2367. These find extensive use where severe corrosion cartons and five of these cartons are shrink wrapped in
takes place involving sulphuric acid and sulphurous a Cardboard box. Also available in ready to use vacuum
pack cartons.
35
OK 67.67 in clad steels of 18/8 type. It is also used for surfacing
Welding Consumables
OK 67.67 is a rutile based, medium coated, all position C 0.06 YS 470 N/mm2
electrode depositing an alloy of 23 Cr, 12 Ni type which
Mn 0.8 UTS 600 N/mm2
has excellent resistance to corrosion and oxidation at
Cr 24.0 EL 40%
very high temperatures, up to 1100°C. OK 67.67 has an Ni 12.5 Ferrite Content FN 12-24
Si 0.70
extremely stable and smooth arc with very easy striking
S 0.015
and re-striking properties and a final slag that is self
P 0.020
peeling to reveal a very finely rippled, smooth and shiny Mo 0.02
bead. Welds are radiographically sound.
CURRENT RANGE & PACKING DATA
APPROVALS: PDIL, RDSO, NPCIL, TEIL
Size Length Current Range Packing
WELDING CURRENT: DC +, AC 50V (mm) (mm) (Amps)
2.50 350 60-90 Weight Per Box : 10 Kgs
TYPICAL APPLICATIONS
3.15 350 80-120 Weight Per carton
OK 67.67 is designed for applications requiring high 4.00 350 120-170 (Packet) : 2 Kgs
strength and corrosion resistance at high temperatures No. of Packets (Cartons)
upto 1100°C; for e.g. welding of heat resistant chrome 5.00 350 150-240
in a box : 5
steels and Cr-Ni steels of the 309 type in low sulphurous
atmospheres. It is also widely used for joining of dis- PACKING: Electrodes are packed in heat sealed plastic
similar steels like joining of mild steel to stainless steel, cartons and five of these cartons are shrink wrapped in
low alloy steels to stainless steels for welding root runs a card board box. Also available in ready to use vacuum
pack cartons.
36
OK 67.60 runs in clad steels of 18/8 type. It is also used widely for
Welding Consumables
surfacing of mild steel and for building up worn out parts
An extra low carbon, 23% Cr, 12% Ni type stainless for wear resistant steels.
steel electrode TYPICAL ALL WELDMETAL PROPERTIES
Classification AWS A 5.4: E 309L-16
Chemical Mechanical Properties
IS 5206: E 23.12LR 26 Composition (%)
DESCRIPTION
C 0.03 YS 470 N/mm2
OK 67.60 is a rutile based, extra low carbon, all position
Cr 24.0 UTS 600 N/mm2
electrode of 23Cr/12Ni type for joining of stainless steel
Ni 12.5 EL 40%
to mild steel and for surfacing of mild steel. The extra P 0.020 Ferrite Content FN 12-22
low carbon content prevents carbide precipitation and Mn 0.9
hence avoids intergranular cracking. The weld deposit Si 0.75
has excellent corrosion and oxidation resistance in S 0.015
continuous service upto 1000°C. OK 67.60 welds with Mo 0.05
a very smooth and stable are, with virtually no spatter CURRENT RANGE & PACKING DATA
and a slag cover that is self-releasing. The final weld
Size Length Current Range Packing
bead is very finely rippled and shiny. The weldmetal is
of radiographic quality. (mm) (mm) (Amps)
APPROVALS : NPCIL, TEIL, PDIL 2.50 350 60-90 Weight Per Box : 10 Kgs
ESAB 309LC 304L and 309L clad steels. It is also used as buffer in
cladding.
An extra low carbon, basic 23/12 type stainless steel TYPICAL ALL WELDMETAL PROPERTIES
electrode
Chemical Mechanical Properties
Classification AWS A 5.4: E 309L-15 Composition (%)
IS 5206: E 23.12 L B 20
C 0.03 YS 580 N/mm2
DESCRIPTION
Mn 0.9 UTS 470 N/mm2
Cr 23.5 EL 40%
ESAB 309LC is an extra low carbon all positional basic P 0.020 Ferrite Content FN 12-22
coated electrode giving austenitic weld deposit of Ni 12.5
23Cr - 13Ni type suitable for welding heat resistant Si 0.7
S 0.015
Cr-Ni alloyed steels for working temperatures upto
Mo 0.05
1000°C, If sulphurous attack does not occur. ESAB
309LC possess excellent weldability in all positions with CURRENT RANGE & PACKING DATA
a fine, stable, smooth arc with a slag system that allows
Size Length Current Range Packing
good wetting and an easily removable slag. The final
weldbead is shiny, finely rippled and smooth. Welds are (mm) (mm) (Amps)
of radiographic quality. 2.50 350 60-90 Weight Per Box : 10 Kgs
37
OK67.70 ing austenitic stainless steels to carbon steel, for weld-
Welding Consumables
38
ESAB 309LMo for surfacing and building up for wear resistance.
Welding Consumables
Recommended for welding build-up layer of turbine,
An extra low carbon, basic stainless steel electrode runners made of ferritic chromium stainless steels.
depositing a 23 Cr, 13 Ni, 2.5 Mo type weldmetal
TYPICAL ALL WELDMETAL PROPERTIES
Classification AWS A 5.4: E 309LMo-15
IS 5206: E 23.12.2 L B 20 Chemical Mechanical Properties
Composition (%)
DESCRIPTION
C 0.03 UTS 620 N/mm2
ESAB 309LMo is an extra low carbon, basic coated all
Mn 0.8 YS 440 N/mm2
position stainless steel electrode giving an austenitic
Cr 23.5 EL 35%
weld deposit of 23 Cr, 13 Ni, 2.5 Mo type. The weldmetal S 0.018 Ferrite Content FN 12-22
has excellent resistance to corrosion and oxidation at Ni 13.0
elevated temperatures of upto 1100°C in continuous Si 0.7
service, coupled with good strength. ESAB 309LMo Mo 2.50
welds with a quiet, smooth and stable arc in all positions P 0.018
with a minimum spatter. The slag cover is easily
CURRENT RANGE & PACKING DATA
detachable and the weld bead is shiny and smooth. The
weldmetal is of radiographic quality. Size Length Current Range Packing
(mm) (mm) (Amps)
WELDING CURRENT: DC +
2.50 350 40-70 Weight Per Box : 10 Kgs
TYPICAL APPLICATIONS 3.15 350 60-100 Weight Per carton
ESAB 309LMo is especially suitable for welding of 4.00 350 100-140 (Packet) : 2 Kgs
stainless steels where better toughness is required No. of Packets (Cartons)
5.00 350 140-180
compared to the rutile based electrodes of the same in a box : 5
class. ESAB 309LMo is used for the welding of 316 type PACKING: Electrodes are packed in heat sealed plastic
clad steels as well as for joining and as a buffer layer in cartons and five of these cartons are shrink wrapped in
welding of dissimilar metals e.g. mild steel to stainless a card board box. Also available in ready to use vacuum
steel, low alloy steel to stainless steel. Also suitable pack cartons.
OK 67.68 is used for the welding of AISI 309 Nb type, PACKING: Electrodes are packed in heat sealed plastic
straight chrome steels, joining stainless steels to low cartons and five of these cartons are shrink wrapped in
alloy steels and carbon steels. Also for building up on a Cardboard box. Also available in ready to use vacuum
mild steel to improve wear resistance and for building pack cartons.
up worn parts of wear resisting steels.
39
ESAB 309Cb steel to improve wear resistance, building up on worn
Welding Consumables
40
OK 67.45 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Properties
A basic coated stainless steel electrode of the 18 Composition (%)
Cr-8 Ni-6 Mn type
C 0.05 YS 450 N/mm2
Classification AWS A 5.4: E 307-15 (Nearest)
Mn 6.00 UTS 650 N/mm2
DESCRIPTION
Cr 19.0 EL 40%
S 0.015 Impact (CVN) at +20OC 90J
OK 67.45 is a basic coated austenitic stainless steel Ni 9.5 Ferrite Content FN<5
electrode giving a weldmetal of the 18 Cr-8 Ni-6 Mn type. Si 0.5
The tough weldmetal imparts excellent crack resistance, P 0.020
when welding steels of even poor weldability. OK 67.45 Mo 0.45
has excellent arc and current carrying characteristics CURRENT RANGE & PACKING DATA
in all positions giving a very smooth, quite, stable arc
Size Length Current Range Packing
and very little spatter. The slag system is fluid but
controllable, giving a slag cover that is self-peeling and (mm) (mm) (Amps)
a weldbead that is smooth, even and shiny. The weld is 2.50 350 60-90 Weight Per Box : 10 Kgs
of radiographic quality. 3.15 350 80-120 Weight Per carton
APPROVALS: CQA (Met), Ichapore, DGQA 4.00 350 120-170 (Packet) : 2 Kgs
WELDING CURRENT: DC+, AC 70V No. of Packets (Cartons)
5.00 350 150-240
in a box : 5
TYPICAL APPLICATIONS PACKING: Electrodes are packed in heat sealed plastic
OK 67.45 find extensive use for joining dissimilar steels, cartons and five of these cartons are shrink wrapped in
13 Mn steels with reduced weldability and for cladding a card board box. Also available in ready to use vacuum
carbon steels. OK 67.45 can also be used as a buffer pack cartons.
layer prior to hard surfacing. Also used for welding
Armour steels.
ESAB RSW and hot working tools, dies for plastics etc. Other ap-
plications include rebuilding chemical agitator blades,
A high alloy ‘Universal’ electrode for joining steels shafts, rolling mill spindles, bucket lips, highly harden-
of unknown composition able armour steels and for furnace parts etc.
Classification AWS A 5.4: E 312-16 TYPICAL ALL WELDMETAL PROPERTIES
IS 5206: E 29.9 R 26
DESCRIPTION Chemical Mechanical Properties
Composition (%)
ESAB RSW is a rutile coated all position electrodes for
welding of complex dissimilar alloys and high strength C 0.10 UTS 800 N/mm2
steels with low heat input, giving sound joints free from
Cr 30 YS 700 N/mm2
any cracks and fissures. It is a specially designed high
Ni 10.0 EL 28%
alloy electrode for joining steels of unknown composi- S 0.015 Impact (CVN) at +20oC 40J
tion. The weldmetal has high strength combined with Mn 2.20 Ferrite Content FN 50-75
excellent resistance against impact, heat (excellent Si 0.40
scaling resistance upto 1150°C) and corrosion. The P 0.020
Mo 0.15
ferriticaustenitic duplex structure weldmetal is highly
tolerant to dilution and stress corrosion. Also suitable CURRENT RANGE & PACKING DATA
for depositing buffer layers prior to surfacing on high
strength and high alloy steels. ESAB RSW has excel- Size Length Current Range Packing
lent weldability characteristics in all positions giving a (mm) (mm) (Amps)
slag that is easily detachable and a final weldbead that
2.50 350 50-80 Weight Per Box : 10 Kgs
is finely rippled, smooth and shiny.
APPROVALS: CQA (Met), Ichapore, DGQA 3.15 350 70-110 Weight Per carton
41
OK 67.50 in the ship building industry, chemical industries etc. OK
67.50 may also be used for joining of Duplex steels to
Welding Consumables
A rutile based stainless electrode for welding Du- mild steels. Welding of duplex steels should be made
plex Stainless Steels with low heat input.
Classification AWS A5.4: E 2209-17 TYPICAL ALL WELDMETAL PROPERTIES
EN 1600 E2293 NLR32
Werkstoff Nr.1.4462 Chemical Mechanical Properties
Composition (%)
DESCRIPTION
OK 67.50 is an acid rutile electrode specially designed C 0.03 YS 660 N/mm2
for welding of UNS31500, UNS31803 types of ferritic
Si 0.8 UTS 820 N/mm2
austenitic stainless steels (popular known as “Duplex
Mn 0.7 EL 25%
stainless steels”). The composition of weldmetal is P 0.018 CVN Impact Value
designed to give mechanical and corrosion properties S 0.01 at +20OC 50J
that fully comply with these grades for example, high Cr 22.5 Ferrite Content FN 25 - 40
Ni 8.9
resistance to stress corrosion cracking and high yield
Mo 3.00
strength. The arc and current carrying characteristics
Cu 0.1
are in the best traditions of ESAB stainless steel elec- N 0.16
trodes of the highest standards coupled with its self-re-
leasing slag and its outstanding weld bead finish makes CURRENT RANGE
OK 67.50 the welders favourite the world over for weld- Size Length Current Range
ing of Duplex Steels. (mm) (mm) (Amps)
APPROVALS: ABS, BV, CE, CWB, DNV, GL, RINA, 2.50 350 50-90
CEPROZ, VdTUV
3.2 350 80-120
WELDING CURRENT: DC +, AC
4.00 350 90-160
APPLICATIONS
OK 67.50 find extensive use in welding of duplex steels 5.00 350 150-220
of the type UNS31500, UNS31803 which need high re-
PACKING: Electrodes are available in ready to use
sistance to stress corrosion and high yield strength e.g.
vacuum pack cartons.
42
OK 68.10 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Chemical Mechanical Properties
A basic coated stainless steel electrode for
Composition (%)
depositing a ferritic weldmetal
C 0.07 YS 410 N/mm2
Classification AWS A5.4: E 410-15
Si 0.5 UTS 540 N/mm2
IS 5206: E 13 B 20
Cr 13.5 EL 26%
S 0.017
DESCRIPTION Mn 0.7
Ni 0.5
OK 68.1 0 is a basic coated stainless steel electrode Mo 0.3
giving ferritic weldmetal of 13% Cr type for welding of P 0.019
ferriticmartensitic chrome steels. OK 68.10 has excellent
welding characteristics in all positions as it welds with CURRENT RANGE & PACKING DATA
a smooth and stable arc and the slag system design Size Length Current Range Packing
allows good wetting and washing to obtain a very finely (mm) (mm) (Amps)
rippled bead and a slag that is very easily detachable.
2.50 350 70-100 Weight Per Box : 10 Kgs
WELDING CURRENT: DC + 3.15 350 90-130 Weight Per carton
43
ESAB RSQ for overlaying surfaces that take severe impact and
Welding Consumables
44
ESAB ARMOlD 1 steels or Stainless Steels can also be welded with ESAB
Welding Consumables
ARMOlD 1. The excellent work hardening characteristics
A specially designed stainless steel electrode for displayed by ESAB ARMOID-1, makes it suitable for
joining of armour plates and other crack sensitive use in reinforcing rail steels, excavator bucket teeth, for
steels surfacing of gear teeth and steel mills roll prior to hard
metal deposition.
DESCRIPTION
TYPICAL ALL WELDMETAL PROPERTIES
ESAB ARMOlD 1 is a stainless steel electrode designed Chemical Mechanical Properties
for joining of high strength and dissimilar alloys, armour Composition (%)
plates and other crack sensitive steels. ESAB ARMOlD C 0.08 UTS 735 N/mm2
1 is also suitable as a cushioning alloy under hard Cr 20.30 EL 35%
deposits and for repairing of carbon steel, alloy steel Ni 8.50 Hardness
and stainless steel components. It deposits an austenitic Mn 1.8 (As Welded Condition) 280VHN
weldmetal with sufficient residual ferrite to impart Mo 2.60 Hardness
extreme crack resistivity. The electrode has excellent Si 0.50 (Work Hardend Condition) 400VHN
operating characteristics with superior arc stability at S 0.015
low current levels. The weldmetal has excellent work P 0.020
hardening rate without deformation. The slag cover is CURRENT RANGE & PACKING DATA
easily detachable and the weld bead is shiny smooth
and finely rippled. Size Length Current Range Packing
(mm) (mm) (Amps)
APPROVAL: CQA (Met), Ichapore, DGQA
2.50 350 55-75 Weight Per Box : 10 Kgs
WELDING CURRENT: DC +, AC 70V 3.15 350 90-110 Weight Per carton
45
ESAB CHROMWELD G (Spl) TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
46
GTAW Consumables
OK TIGROD SG TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
Classification : AWS A5.18: ER 70S-G
YS 425 MPa
DESCRIPTION & APPLICATION UTS 515 MPa
General purpose TIG Welding Wire suitable for C/C-Mn
EL 26%
steel pipes, tubes, plates etc. PACKING DATA
WELDING CURRENT: DC - Size Length Packing
SHIELDING GAS: Argon (mm) (mm) (5 Kg.)
TYPICAL WIRE COMPOSITION (%) 1.2 1000 a
C Mn Si P S 1.6 1000 a
2.0 1000 a
0.08 1.3 0.60 0.014 0.024
2.4 1000 a
PACKING: The rods are packed in 5 kg cartons and
four of them in a Cardboard box.
47
OK TIGROD 12.64 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Copper coated 1.25 Cr-0.5 Mo Tig Rod Recommended for welding of pipes and tubes of match-
ing composition in Power Plants, Refineries, Fertilizer
Classification AWS A5.28: ER 80S -B2 Plants, Chemical and Petrolium Plants. Suitable for
ASTM A 335 Gr. P11, ASTM A387Gr.B, DIN 15 Cr Mo3,
DESCRIPTION ASTM A 199-76, ASTM A 200-75, ASTM A 213-760 and
similar steels.
OK TIGROD 13.16 is a tig filler rod suitable for welding
pipes and tubes of 1.25 Cr-0.5 Mo Steels. It deposits TYPICAL WIRE COMPOSITION (%)
notch free welds with excellent mechanical properties
as well as high creep resistance and toughness.The C Mn Si Cr Mo Cu S P
weld deposit is of radiographic quality.
0.08 0.60 0.50 1.30 0.60 0.25 0.012 0.014
(Contd...)
48
TYPICAL ALL WELDMETAL PROPERTIES PACKING DATA
Welding Consumables
Weldmetal Mechanical Properties Size Length Packing
Composition (%) (mm) (mm) (5 Kg.)
C 0.07 YS 510 N/mm2 1.6 1000 a
Mn 0.55 UTS 620 N/mm2
2.0 1000 a
Si 0.45 EL 26%
S 0.012 Impact (CVN) at -29oC 60J
2.4 1000 a
Cr 1.25
ACKING: The rods are packed in 5 kg cartons and
P
Cu 0.20
P 0.014
four of them in a Cardboard box.
Mo 0.55
49
OK TIGROD B3L TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Copper coated low carbon 2.25 Cr – 1 Mo Tig Rod Weldmetal Mechanical Properties
Classification Composition (%)
DESCRIPTION
OK Tigrod B3L is a TIG filler rod suitable for welding C 0.03 YS 500 N/mm2
pipes and tubes of 2.25 Cr-1 Mo Steels. It deposits
Mn 0.55 UTS 600 N/mm2
notch free welds with excellent mechanical properties
Si 0.50 EL 24%
S 0.010
as well as high creep resistance and toughness. The
Cr 2.5
weld deposit is of radiographic quality. Cu 0.15
TYPICAL APPLICATIONS P 0.010
Recommended for welding of pipes and tubes of match- Mo 1.1
ing composition in Power Plants, Refineries, Fertilizer
Plants, Chemical and Petroleum Plants. Suitable for PACKING DATA
ASTM A 335 Gr. P22,ASTM A 387 Gr. D, DIN 10 Cr Mo
Size Length Packing
910-G3, ASTM A 199-76, ASTM A 200-75, ASTM A 369-
(mm) (mm) (5 Kg.)
76D,DIN 10CrMo910 and similar steels.
CURRENT: DC+ 1.6 1000 a
TYPICAL WIRE COMPOSITION (%) 2.0 1000 a
2.4 1000 a
C Mn Si Cr Mo Cu S P Cu
ACKING: The rods are packed in 5 kg cartons and
P
0.03 0.60 0.60 2.5 1.1 0.15 0.010 0.014 0.015
four of them in a Cardboard box.
50
OK TIGROD 13.28 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Weldmetal Mechanical Properties
Classification SFA/AWS A5.28: ER80S-Ni2
Composition (%)
DESCRIPTION C 0.10 YS 540 N/mm2
Mn 1.1 UTS 630 N/mm2
OK TIGROD 13.28 is 2.4 Ni-alloyed (ER80S-Ni2), cop-
Si 0.6 EL 30%
per-coated rod for the GTAW of low-temperature, fine- Ni 2.4 Impact (CVN) at +20oC 200J
grained steels in applications such as pressure vessels, -40oC 180J
pipes and the offshore industry, with a minimum yield -60oC 150J
strength of up to 470 MPa. The wire provides good im-
pact toughness down to - 60OC. PACKING DATA
APPROVALS: VdTÜV Size Length Packing
WELDING CURRENT: DC- (mm) (mm) (5 Kg.)
1.6 1000 a
2.0 1000 a
2.4 1000 a
3.2 1000 a
51
OK TIGROD 13.37 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
1.6 1000 a
2.0 1000 a
2.4 1000 a
3.2 1000 a
52
OK TIGROD 16.10 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Weldmetal Mechanical Properties
An extra low carbon stainless steel rod of 18/8 type
Composition (%)
for TIG Welding
C 0.025 YS 461 N/mm2
Classification AWS A5.9: ER 308L
Mn 1.75 UTS 632 N/mm2
Si 0.4 EL (L=4d) 36%
DESCRIPTION S 0.018 Impact (CVN) at -196oC 84J
Cr 20.0
OK TIGROD 16.10 is 18 Cr - 8 Ni type rod for GTAW of
Ni 10.0
austenitic corrosion resisting steels. OK TIG ROD 16.10 P 0.008
is suitable for welding of AISI 301, 304, 304L and equiv-
alent grade. Also provides acceptable results on most PACKING DATA
niobium and titanium stabilised steels.
Size Length Packing
APPROVALS: PDIL, NPCIL (mm) (mm) (5 Kg.)
53
OK TIGROD 16.11 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
1.6 1000 a
2.0 1000 a
2.5 1000 a
3.15 1000 a
54
OK TIGROD 16.30 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Weldmetal Mechanical Properties
An extra low carbon stainless steel rod of the 18 Cr,
Composition (%)
12 Ni, 3 Mo type for TIG welding
C 0.020 YS 470 N/mm2
Classification AWS A5.9: ER 316L
Mn 1.8 UTS 650 N/mm2
Si 0.4 EL 35%
APPROVALS: PDIL, NPC Nb 18.5 Impact (CVN) at -196oC 50J
Cr 12
DESCRIPTION
Ni 2.7
S 0.018
OK TIGROD 16.30 is an extra low carbon stainless rod
P 0.018
for GTAW of corrosion resisting steels having composi-
tion corresponding to 18% Cr, 12% Ni and 3% Mo type, PACKING DATA
suitable for AISI 316, 316L & similar steels.
Size Length Packing
TYPICAL WIRE COMPOSITION (%) (mm) (mm) (5 Kg.)
C Mn Si Cr Ni Mo S P Cu 1.6 1000 a
2.0 1000 a
0.025 1.8 0.40 18.5 12.0 2.7 0.018 0.018 0.03
2.5 1000 a
55
OK TIGROD 16.53 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
56
OK TIGROD 16.86 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
Classification SFA/AWS A5.9: ER 2209
YS 600 N/mm2
DESCRIPTION
UTS 765 N/mm2
EL 28%
Bare corrosion resisting Duplex welding rods for weld-
Impact (CVN) at 20oC 100J
ing of austenitic - ferritic stainless alloys of 22% Cr 5% -20oC 85J
Ni 3% Mo types. -60oC 60J
OK TIGROD 16.86 has a high general corrosion resis- PACKING DATA
tance. In media containing chloride and hydrogen sul-
phide the alloy has a high resistance to intergranular, Size Length Packing
pitting and especially to stress corrosion. The alloy is (mm) (mm) (5 Kg.)
used in a variety of applications across all industrial
segments. 1.2 1000 a
1.6 1000 a
TYPICAL WIRE COMPOSITION (%) 2.0 1000 a
2.4 1000 a
C Si Mn Cr Ni Mo Cu 3.2 1000 a
<0.03 0.5 1.7 22.5 8.5 3.3 <0.3 ACKING: The rods are packed in 5 Kg cartons and
P
four of them in a Cardboard box.
57
OK TIGROD 16.13 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
58
OK TIGROD 1100 CHEMICAL COMPOSITION (Wire) %
Welding Consumables
Classification SFA/AWS A5.10: R1100 Mn V Cu Al Ti Zn
EN ISO 18273 : S Al 1100 (Al 99, 0Cu)
<0.05 <0.5 0.13 >99 <0.03 <0.1
DESCRIPTION
Typical Mechanical Properties of All Weld Metal
OK Tigrod 1100 is highly resistant to chemical attack
YS 30 N/mm2
and weathering. It is a relatively soft alloy that is very
UTS 75 N/mm2
formable and it is used extensively in thin - gauge and
EL 35%
foil products. It has good welding characteristics. One
desirable characteristic of the alloy is the bright finish ACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0
P
obtained by anodising. Non-heat treatable. mm diard and 900 or 1000 mm lengths, packed in 4.54
kg (for 900 mm length) or 5.0 Kg (for 1000 mm length)
APPROVALS : CWB, cartons.
WELDING CURRENT: AC
OK Tigrod 1450 is highly resistant to chemical attack Typical Mechanical Properties of All Weld Metal
and weathering. The alloy has a small addition of tita-
nium, which has a grain-refining effect, which reduces YS 40 N/mm2
UTS 90 N/mm2
cracking susceptibility. It has good welding characteris-
EL 35%
tics. One characteristic feature of the alloy is the bright
finishes obtained by anodising. Non-heat treatable. ACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0
P
mm diard and 900 or 1000 mm lengths, packed in 4.54
APPROVALS : VdTŰV
kg (for 900 mm length) or 5.0 Kg (for 1000 mm length)
WELDING CURRENT: AC cartons.
59
OK TIGROD 4047 WIRE COMPOSITION (%)
Welding Consumables
WELDING CURRENT: AC
DESCRIPTION <0.25 0.9 0.15 <0.05 <0.15 0.15 <0.25 <0.40 4.9
Bare welding rod suitable for welding aluminium alloys Typical Mechanical Properties of All Weld Metal
with up to 5% Mg and alloys where a higher tensile
YS 130 N/mm2
strength is required. The alloying element Zr produces
UTS 280 N/mm2
improved resistance to hot cracking during solidifica-
EL 30%
tion. Impact (CVN) at + 20OC 35J
APPROVALS : DB VdTŰV, CE ACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0
P
WELDING CURRENT: AC mm diard and 900 or 1000 mm lengths, packed in 4.54
kg (for 900 mm length) or 5.0 Kg (for 1000 mm length)
cartons.
WELDING CURRENT: AC
60
OK TIGROD 5356 WIRE COMPOSITION (%)
Welding Consumables
Classification SFA/AWS A5.10: R5356 Si Mn Cr Cu Ti Zn Fe Mg
EN ISO 18273: S Al 5356 (AlMg 5Cr (A)) <0.25 0.15 0.13 <0.05 0.11 <0.10 <0.40 5.0
DESCRIPTION
OK Tigrod 5356 is the most widely used welding alloy Typical Mechanical Properties of All Weld Metal
and can be classified as a general-purpose type filler YS 120 N/mm2
alloy. OK Tigrod 5356 is typically chosen because of
UTS 265 N/mm2
its relatively high shear strength. The 5XXX alloy base
EL 26%
material, welded with OK Tigrod 5356, with a weld pool
chemistry greater than 3% Mg and service tempera- ACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0
P
tures in excess of 65OC, is susceptible to stress corro- mm diard and 900 or 1000 mm lengths, packed in 4.54
sion cracking. The alloy is non - heat treatable. kg (for 900 mm length) or 5.0 Kg (for 1000 mm length)
cartons.
APPROVALS : CE, CWB, DB, VdTŰV, ABS, DNV, KR
WELDING CURRENT: AC
OK Tigrod 5554 is a solid aluminium rod with a content Typical Mechanical Properties of All Weld Metal
of 2.7% Mg. It is recommended for the welding of AlMg YS 110 N/mm2
alloys like 5454. Typical applications include chemical
UTS 230 N/mm2
storage tanks, automotive components like wheels and
EL 17%
frame sections. The Weldmetal is not sensitive to stress
corrosion cracking at elevated temperatures. ACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0
P
mm diard and 900 or 1000 mm lengths, packed in 4.54
APPROVALS : CWB kg (for 900 mm length) or 5.0 Kg (for 1000 mm length)
cartons.
WELDING CURRENT: AC
61
OK TIGROD 5754 WIRE COMPOSITION (%)
Welding Consumables
OK Tigrod 5754 is a solid aluminium rod with a con- Typical Mechanical Properties of All Weld Metal
tent of 3% Mg. It is recommended for welding
YS 110 N/mm2
Al-Mg alloys with less than 3% magnesium. The alloy
UTS 230 N/mm2
has relatively high strength and corrosion resistance.
EL 23%
APPROVALS : VdTŰV
ACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0
P
WELDING CURRENT: AC mm diard and 900 or 1000 mm lengths, packed in 4.54
kg (for 900 mm length) or 5.0 Kg (for 1000 mm length)
cartons.
Si Mn Cu Sn Zn Fe
62
OK TIGROD 19.40 Typical mechanical properties all weld metal
Welding Consumables
Classification SFA/AWS A5.7 ERCuAl-A1 YS 175 N/mm2
EN 14640 S Cu 1600 (CuAl8)
UTS 420 N/mm2
EL 40%
DESCRIPTION Impact (CVN) at +20oC 70J
Si Mn Al Fe Cu
Bare Cu-Ni rods for welding similar alloys, such as PACKING DATA
90Cu10Ni, 80Cu20Ni and 70Cu30Ni alloys.
Size Length Packing
The addition of nickel strengthens the weld metal and (mm) (mm) (5 Kg.)
improves corrosion resistance, particularly to salt water.
The alloy is used for the overlay welding of steels and is 1.6 1000 a
widely used for welding Cu-Ni components for desalina- 2.0 1000 a
tion plants. 2.4 1000 a
C Si Mn Fe Cu
63
GMAW Consumables
ESAB MW1 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
A Copper coated wire for MIG/MAG welding
YS 440 N/mm2
Classification AWS A5.18: ER 70S-6 UTS 520 N/mm2
EN ISO 14341 - A : G3Si1 EL 26%
IS 6419 : S4 Impact (CVN) at -30oC 50J
DESCRIPTION CURRENT RANGE & PACKING DATA
ESAB MW1 is a copper - coated, Mn - Si alloyed solid Size Current Voltage Packing in Kg.
wire for GMAW of non alloyed steel as used in general (mm) (Amp) (V) 12.5 15.0 100 250
construction, automotives, ship building and pressure
vessel fabrication. The wire has a carefully controlled 0.8 60-220 17-25 a a a r
wire chemistry and a unique surface technology provid- 1.2 90-330 18-30 a a a r
ing superior Weldmetal quality at high wire feed speeds 1.6 120-440 20-36 a a a r
and at high welding currents. The wire can be used with 2.0 150-550 21-41 a a a a
both Ar/CO2 and pure CO2 shielding gas.
PACKING: The wires are supplied in plastic or wire
WELDING CURRENT: DC+ basket spools packed in a cardboard box 12.5/15.0
kgs or 100/250 kgs Marathon pac or 100/250 kgs steel
APPROVALS: RDSO, LRS, MN DASTUR, ABS, NPCIL Bobbins.
TYPICAL WIRE COMPOSITION (%)
C Mn Si S P Cu
TYPICAL WIRE COMPOSITION (%) PACKING: The wires are supplied in plastic or wire
basket spools packed in a Cardboard box 12.0/15.0 Kgs
C Mn Si Mo P S CU or 100/250 kgs Marathon pac
0.09 1.7 0.5 0.45 0.018 0.02 0.2
64
OK ARISTOROD 12.50 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
Classification SFA/AWS A5.18 ER70S-6
EN ISO 14341-A G3 Si1 As Welded
C Si Mn P S Cu Ti+Zr
C Mn Si Mo P S Cu
65
OK ARISTOROD 13.09 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
Classification EN 440 : G2Mo
EN 12070 : G MoSi As Welded PWHT - Stress Relieved
SFA/AWS A5.28 : Er80S-G 620OC 15h
DESCRIPTION YS 515 YS 430
UTS 610 UTS 545
The non copper coated OK AristoRod 13.09 is a low-
EL 26% EL 30
alloyed, molybdenum (0.5% Mo), solid wire for GMAW Impact (CVN) at Impact (CVN) at
of creep resistant steels of the same type, such as 20OC 117J 20OC 150J
pipes in pressure vessels and boilers with a working -20OC 100J -20OC 120J
temperature of up to 500OC. -40OC 57J -40OC 90J
The AristoRod wires are suitable for operating at high CURRENT RANGE & PACKING DATA
currents with maintained disturbance free wire feeding
giving a stable arc with a low amount of spatter. Size Current Voltage
(mm) (Amp) (V)
OK AristoRod 13.09 delivered in the unique Esab
Octagonal Marathon Pac is excellent in mechanised 0.8 60-170 18-22
welding applications. 1.0 80-280 18-28
Shielding Gas: CO2, 80 Ar/20 CO2 1.2 120-350 20-33
1.6 225-480 26-38
TYPICAL WIRE COMPOSITION (%)
PACKING: Aristorod wires can be supplied on adapter
C Si Mn P S Mo Cu free 18kg wire baskets or in Marathon Pac bulk drums
0.1 0.5 1.1 0.02 0.02 0.5 0.15 charged with 250 or 475 kg, as well as plastic spools of
15kg or 18 kg.
66
OK AUTROD 13.16 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
Classification SFA/AWS A5.28 : ER 80S-B2
PWHT - Stress Relieved 620OC 1h
DESCRIPTION
YS 490 N/mm2
A copper coated, low - alloyed, chromium-molybdenum UTS 580 N/mm2
(1.3% Cr, 0.5% Mo), solid wire for GMAW of creep resis- EL 21%
tant steels like SA-387 Grade P11, A 335 Grade P11 or
similar materials. OK Autrod 13.16 is a high purity wire CURRENT RANGE & PACKING DATA
with guaranteed Bruscato factor X<15.
Size Current Voltage Packing in 15 Kg
Shielding Gas: Ar/1-5O2, Ar/20CO2, CO2 (mm) (Amp) (V) Plastic Spools
TYPICAL WIRE COMPOSITION (%)
0.8 80-170 18-22 a
C Si Mn P S Cr Mo Cu
1.0 80-280 18-28 a
0.095 0.6 0.55 0.025 0.20 1.35 0.525 0.35 1.2 120-350 20-33 a
1.6 225-480 26-38 a
67
OK ARISTOROD 13.29 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
Classification SFA/AWS A5.28 : ER 100S-G
EN ISO 16834-A : GMn3Ni1 Cr Mo As Welded PWHT - Stress Relieved
620OC 15 h
DESCRIPTION
YS 730 YS 690
The non copper coated OK AristoRod 13.29 is a low- UTS 800 UTS 750
alloyed, chromium-nickel-molybdenum (0.3% Cr, 1.4% EL 19% EL 20%
Ni, 0.25% Mo), solid wire for GMAW of high tensile Impact (CVN) at Impact (CVN) at
strength steels requiring tougher Weldmetal for critical -20OC / -40OC 70J / 55J -30OC 60J
applications. Also suitable when fairly high impact CURRENT RANGE & PACKING DATA
strength at lower temperatures is required.
Size Current Voltage
The AristoRod wires are suitable for operating at high (mm) (Amp) (V)
currents with maintained distrubance free wire feeding
0.8 80-280 18-28
giving a stable arc with a low amount of spatter.
1.0 80-280 18-28
Ok AristoRod 13.29 delivered in the unique Esab 1.2 120-350 20-33
Octagonal Marathon Pac is excellent in mechanised 1.6 225-480 26-38
welding applications.
PACKING: Aristorod wires can be supplied on adapter
Shielding Gas: 80Ar/20CO2 free 18kg wire baskets or in Marathon Pac bulk drums
charged with 250 or 475 kg, as well as plastic spools of
TYPICAL WIRE COMPOSITION (%) 15kg or 18kg.
C Si Mn P S Cr Ni Mo V
DESCRIPTION 0.105 0.7 1.55 0.015 0.015 0.6 0.6 0.2 0.30
The non copper OK AristoRod 13.13 is a low-alloyed, TYPICAL ALL WELDMETAL PROPERTIES
chromium-nickel-molybdenum (0.5% Cr, 0.5% Ni, 0.2% Mechanical Properties
Mo), solid wire for GMAW of high strength steels. But,
also suitable when welding steels where good impact As Welded PWHT - Stress Relieved
toughness is required at lower temperatures. 570OC 1h
The AristoRod wires are suitable for operating at high YS 690 YS 660
UTS 770 UTS 750
currents with maintained disturbance free wire feeding
EL 20% EL 24%
giving a stable arc with a low amount of spatter. Impact (CVN) at Impact (CVN) at
-20OC / -30OC 75J / 65J -20OC 60J
OK AristoRod 13.13 delivered in the unique Esab
CURRENT RANGE & PACKING DATA
Octagonal Marathon Pac is excellent in mechanised
welding applications. Size Current Voltage
(mm) (Amp) (V)
Shielding Gas: 80Ar/20CO2
0.8 40-170 16-22
1.0 80-280 18-28
1.2 120-350 20-33
1.6 225-480 26-38
68
OK ARISTOROD 13.31 TYPICAL WIRE COMPOSITION (%)
Welding Consumables
C Si Mn P S Cr Ni Mo Cu Ti
Classification SFA/AWS A5.28 : ER 110S-G
0.1 0.75 1.9 0.015 0.018 0.35 2.05 0.55 0.15 0.15
DESCRIPTION
TYPICAL ALL WELDMETAL PROPERTIES
The non copper OK AristoRod 13.31 is a low-alloyed,
chromium-nickel-molybdenum (0.3% Cr, 1.9% Ni, 0.5% Mechanical Properties
Mo), solid wire for GMAW of high strength steels, heat
As Welded
treated steels and fine grained constructional steels,
such as XABO90 with a minimum yield strength less YS 850 N/mm2
than 850 Mpa. UTS 900 N/mm2
EL 18%
The ArristoRod wires are suitable for operating at high Impact (CVN) at -30oC 50J
currents with maintained disturbance free wire feeding
giving a stable arc with a low amount of spatter. CURRENT RANGE & PACKING DATA
OK AUTROD 16.10 are 19 Cr - 9 Ni type bare stainless CURRENT RANGE & TYPICAL PACKING DATA
steel wires for GMAW of austenitic grades of the type
AISI 302,304, 304L and equivalent types. In most cases Size Current Voltage Packing in Kg.
OK AUTROD 16.10 gives fully acceptable results on ni- (mm) (Amp) (V) 12.5
obium and titanium stabilised austenitic stainless steels.
The wires are designed to produce excellent weld ap- 0.8 50-180 16-22 a
peal with Argon/O2 or CO2 mixtures as shielding gas. 1.2 80-280 19-28 a
1.6 100-380 19-33 a
TYPICAL WIRE COMPOSITION (%)
PACKING: The wires are supplied in plastic spools
C Mn Si Cr Ni P S packed in a Cardboard box.
69
OK AUTROD 16.11 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
Stainless steel wires of Niobium stabilised 19/9 type
for MIG welding YS 430 N/mm2
UTS 640 N/mm2
Classification AWS A5.9: ER 347 EL 35%
Impact (CVN) at +20oC 100J
DESCRIPTION
CURRENT RANGE & TYPICAL PACKING DATA
OK AUTROD 16.11 are Niobium stabilised 19 Cr-9 Ni
type wires for GMAW of welding of Niobium and Tita- Size Current Voltage Packing in Kg.
nium stabilised stainless steel type AISI 321, 347 and (mm) (Amp) (V) 12.5
348 grades. This steel finds extensive use in refineries,
chemical and petrochemical Industries, food and bever- 0.8 50-180 16-22 a
age industries etc. The wires are designed to produce 1.2 80-280 19-28 a
excellent weld appeal with Argon/O2 or CO2 mixtures as 1.6 100-380 19-33 a
shielding gas.
PACKING: The wires are supplied in plastic spools
TYPICAL WIRE COMPOSITION (%) packed in a Cardboard box.
C Mn Si Cr Ni Nb
OK AUTROD 16.30 are extra low carbon wire of 19% CURRENT RANGE & TYPICAL PACKING DATA
Cr, 12% Ni and 3% Mo type for GMAW of stainless
steel grade AISI 316, 316L and somewhat lower alloyed Size Current Voltage Packing in Kg.
types. The wires are designed to produce excellent weld (mm) (Amp) (V) 12.5
appeal with Argon/O2 or CO2 mixtures as shielding gas. 0.8 50-180 16-22 a
TYPICAL WIRE COMPOSITION (%) 1.2 80-280 19-28 a
1.6 100-380 19-33 a
C Mn Si Cr Ni Mo S P
PACKING: The wires are supplied in plastic spools
0.02 1.8 0.4 18.5 12 2.7 0.018 0.018 packed in a Cardboard box.
70
OK AUTROD 16.53 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
An extra low carbon 24% Cr, 13% Ni type stainless
steel wire for MIG welding YS 440 N/mm2
UTS 600 N/mm2
Classification AWS A5.9: ER 309L
EL 41%
DESCRIPTION Impact (CVN) at -196oC 130J
OK AUTROD 16.53 is an extra low carbon 24% Cr, 13% CURRENT RANGE & TYPICAL PACKING DATA
Ni wire for GMAW of similar alloys or dissimilar joining of
18/8 type to mild steel, carbon steel or low alloy steels. Size Current Voltage Packing in Kg.
The wires are designed to produce excellent weld ap- (mm) (Amp) (V) 12.5
peal with Argon/O2 or CO2 mixtures as shielding gas.
0.8 50-180 16-22 r
TYPICAL WIRE COMPOSITION (%) 1.2 80-280 19-28 r
1.6 100-380 19-33 r
C Mn Si Cr Ni P S
PACKING: The wires are supplied in plastic spools
0.02 1.8 0.4 24 13 0.018 0.018 packed in a Cardboard box.
C Si Mn P S Cr Ni
0.09 1.80 0.4 26 21 0.018 0.018 ACKING: The wires are supplied in plastic spools
P
packed in a Cardboard box.
71
OK AUTROD 16.33 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
A 13% Cr stainless steel wire for MIG welding
YS 400 N/mm2
Classification AWS A5.9: ER 410 UTS 550 N/mm2
E1 24%
DESCRIPTION
CURRENT RANGE & TYPICAL PACKING DATA
OK AUTROD 16.33 is a 13% Cr stainless steel wire
for GMAW of AISI 410, 410S, 420 and steels of simi- Size Current Voltage Packing in Kg.
lar compositions. Also recommended for surfacing of (mm) (Amp) (V) 12.5
machine parts, diesel motor pistons that are working in
a corrosive environment or at elevated temperatures. 0.8 50-180 16-22 a
The weldmetal is machinable and has good resistance 1.2 80-280 19-28 a
to wear in a corrosive environment. The wires are de- 1.6 100-380 19-33 a
signed to produce excellent weld appeal with Argon/O2
or CO2 mixtures as shielding gas. PACKING: The wires are supplied in plastic spools
packed in a Cardboard box.
TYPICAL WIRE COMPOSITION (%)
C Mn Si Cr Ni Mo Cu S P
TYPICAL WIRE COMPOSITION (%) PACKING: The wires are supplied in plastic spools
packed in a Cardboard box.
C Mn Si Cr Ni Mo Cu S P
72
OK AUTROD 16.95 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
Classification EN ISO 14343 G 18 8 Mn
YS 450 N/mm2
DESCRIPTION UTS 640 N/mm2
EL 41%
A continous solid corrosion resisting chromium-nickel-
Impact (CVN) at +20oC 130J
manganese wire for welding of austenitic stainless al-
loys of 18% Cr, 8% Ni, 7% Mn types. CURRENT RANGE & TYPICAL PACKING DATA
OK Autrod 16.95 has a general corrosion ressistance Size Current Voltage Packing in Kg.
similar to that of the corresponding parent metal. The (mm) (Amp) (V) 12.5
higher sillicon content improves the welding properties,
such as wetting. The product is a modified variant of 0.8 55-160 15-24 a
ER307, basically with a higher Mn content to make the 0.9 65-220 15-28 a
Weldmetal less sensitive to hot cracking. When used 1.0 80-240 15-28 a
for joining dissimilar materials the corrosion resistance 1.2 100-300 15-29 a
is of secondary importance. The alloy is used in a wide 1.6 65-220 15-28 a
range of applications across the industry such as join-
ACKING: The wires are supplied in plastic spools
P
ing of austenitic, manganese, work hardenable steels
packed in a Cardboard box.
as well as armourplate and heat resistant steels.
C Si Mn P S Cr Ni Mo Cu
73
OK AUTROD 4043 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
74
OK AUTROD 5183 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Classification SFA/AWS A5.10 ER5183 Mechanical Properties
EN ISO 18273 S Al 5183 (AlMg4,
YS 140 N/mm2
5Mn0, 7(A)) UTS 290 N/mm2
DESCRIPTION EL 25%
Impact (CVN) at +20oC 30J
OK Autrod 5183 was developed to provide the highest
strengths possible in the as welded condition of alloy AA CURRENT RANGE & PACKING DATA
5083 and other similar high magnesium alloys. The more
Size Current Voltage Weight of Packing
common OK Autrod 5356 will typically fail to meet the
(mm) (Amp) (V)
as - welded tensile requirements of AA 5083. The alloy
is typically utilised in marine and structural applications 1.0 90-210 15-26 7.3 Kg
where high strengths, high fracture toughness for impact 1.2 140-260 20-29 9.1 Kg
resistance and exposure to corrosive elements are 1.6 190-350 25-30 9.1 Kg
important. The alloy is not recommended for elevated 2.4 280-400 26-31 7.3 Kg
temperature applications due to its susceptibility to stress
corrosion cracking. The alloy is non-heat treatable. PACKING: The wires are supplied in Plastic Spools
packed in cardboard boxes. Also available in 22.7 kg
APPROVALS : ABS, DNV, CWB, KR Mini Drum and 141 Kg Marathon Pac. These unique
WIRE COMPOSITION (%) packaging is excellent for mechanised applications.
Si <0.25
Mn 0.75
Cr 0.15
Cu <0.10
Ti <0.15
Zn <0.25
Fe <0.40
Be 0.0003 (Max)
Mg 4.75
Others each 0.05 (Max)
Others total 0.15 (Max)
75
OK AUTROD 19.12 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
Classification SFA/AWS A5.7 : ERCu
EN 14640 : S Cu 1898 (Cusn1) YS 75 N/mm2
UTS 220 N/mm2
DESCRIPTION EL 30%
CVN Impact toughness at +20OC 75J
A continuous solid copper wire for welding of oxygen free,
pure copper and low alloyed copper. OK Autrod 19.12 is CURRENT RANGE & PACKING DATA
alloyed with tin, and has good flow properties. The weld Size Current Voltage Weight of Packing
is easily workable. For welding of large work pieces and (mm) (Amp) (V)
heavy thickness preheating is recommended. 0.8 60-120 20-24 15 Kg
WIRE COMPOSITION (%) 1.0 90-180 22-26 15 Kg
1.2 120-200 22-28 15 Kg
Si Mn P Cu Al Sn Pb As Fe 1.6 150-280 24-30 15 Kg
2.4 250-370 26-32 15 Kg
0.3 0.3 0.02 98.0 0.01 0.75 0.01 0.05 0 . 0 5
(Min) (Max) (Max) (Max) PACKING: The wires are supplied in Plastic Spools
packed in cardboard boxes.
76
OK AUTROD 19.40 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Mechanical Properties
Classification SFA/AWS A5.7 ERCuAl-A1
EN 14640 S Cu 6100 (CuAl8) YS 175 N/mm2
UTS 420 N/mm2
DESCRIPTION EL 40%
Impact (CVN) at +20OC 40J
A continuous solid copper wire for welding of aluminium
bronzes of the same type and over lay welding of un CURRENT RANGE & PACKING DATA
and low alloyed steels. Size Current Voltage Weight of Packing
OK Autrod 19.40 is alloyed with aluminium and is (mm) (Amp) (V)
recognised for high strength, good wear resistance and 0.8 60-165 13-17.5 15 Kg
very good corrosion resistance particularly in salt water. 1.0 80-210 12.5-18 15 Kg
The alloy is widely used for joining corrosion - resistant 1.2 150-320 16-29 15 Kg
pipes made of aluminium bronze or other speical brass PACKING: The wires are supplied in Plastic Spools
alloys. Other common applications include the overlay packed in cardboard boxes.
welding of bearings, ship’s propellers and rails. OK
Autrod 19.40 is normally welded with pure Ar as the
shielding gas.
Si <0.10
Mn <0.50
Ni 0.3
Al 7.8
Fe <0.5
Cu Balance
77
FCAW Consumables
DUAL SHIELD 7100 LH TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Typical Mechanical
All Position rutile, low-hydrogen flux cored wire Weldmetal Composition (%)
Properties of All Weldmetal
Classification SFA/AWS A5.20 E71T-1C CO2 shielding Ar/CO2 CO2 shielding Ar/CO2
gas Shielding gas gas Shielding gas
SFA/AWS A5.20 E71T-1M
C 0.06 C 0.06 YS 420 YS 460
DESCRIPTION
Si 0.45 Si 0.5 UTS 610 UTS 640
Dual Shield 7100 LH is a multi purpose cored wire and Mn 1.2 Mn 1.25 EL 22% EL 22%
is one of the most productive consumable for manual P 0.025 P 0.025 Impact Impact
and mechanised positional welding, including vertical S 0.030 S 0.030 (CVN) (CVN)
down and provides an excellent bead appearance. It is
Cr 0.2 Cr 0.2 at at
extremely welder - friendly with a soft, spatter - free arc
and is easy to obtain flat welds with a good penetra- Ni 0.5 Ni 0.5 -20 C
O
54J -20OC 54J
tion. Mo 0.2 Mo 0.2
V 0.08 V 0.08
WELDING CURRENT: DC+
Nb 0.05 Nb 0.05
SHIELDING GAS: Pure CO2 (C1) Ar / CO2 (M21) Cu 0.3 Cu 0.3
APPROVALS: DNV III YMS (H10) (M21 and C1) TYPICAL APPLICATIONS
LR 3, 3Y (M21, C1) The wire is applied in all areas that involve positional
IRS 3YS MHH (M21, C1) welding of structural steel such as shipbuilding, offshose,
ABS 3SA, 3YSA (M21, C1) civil construction and mobile machinery.
BV SA3M, SA3YMHH (M21, C1) CURRENT RANGE & PACKING DATA
Size Current Range Volts
(mm) (Amps) (V)
1.2 150-350 23-35
1.4 150-350 22-34
1.6 150-450 22-36
PACKING: Each spool is packed in polythene bags
and then packed in corrugated cardboard boxes of
15Kg/12.5Kg each. Also Available in 200 Kg Marathon
Pac®.
OKTUBROD 15.00A TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Typical Mechanical properties
A fully basic flux cored wire Composition (%) of all Weldmetal
Classification AWS A5.20: E71T-5 C 0.06 YS 450 N/mm2
DESCRIPTION
Mn 1.20 UTS 540 N/mm2
Si 0.60 EL (L=4d) 25%
OK TUBROD 15.00A is a fully basic flux cored wire pro-
S 0.015 Impact (CVN) at -30oC 80J
ducing very low hydrogen quality weldmetal with high P 0.015
resistance to cracking in joints under restraint. The
smooth metal transfer facilitates easy deposition even TYPICAL APPLICATIONS
in position welding. Fillet contour is flat, with equal leg All general fabrication work involving the multi-pass
lengths & uniform sidewall wetting. The slag system al- welding of heavy sections in tensile strength up to 530
loys for excellent welding in all positions with virtually no N/mm2 e.g. in construction, bridges, pressure vessels
spatter. The wire and slag system design prevents any and offshore structures boiler quality steels like SA
absorption of moisture and very low levels of hydrogen 51570, 285 Grade C, IS: 2002-2A and 28, IS: 2062, IS:
are achieved in the weldmet. Compared to the seamless 226 and DIN 17155 HIV, etc.
varieties, there is no inconsistency in fill-ratio and higher CURRENT RANGE & PACKING DATA
deposition rates are possible. Special surface coating of Size Current Range Volts Spool Weight Welding
the wires ensures a long shelf life and trouble free feed- (mm) (Amps) (V) (Kg) Position
ing. Weldmet are radiographically sound.
1.2 100-250 18-26 15 F.H.V.O
WELDING CURRENT: DC+ 1.6 140-350 20-32 15 F.H.
SHIELDING GAS: CO2 or Ar + 20% CO2 PACKING: Each spool is sealed in an airtight polythene
APPROVALS: ABS 3SA, 3YSA; DNV IIIYMS; BV SA, bag and packed in a corrugated box of 15Kg. Also Avail-
3MH, LR 3S, 3YS H15 able in 200 Kg Marathon Pac®.
78
OK TUBROD 15.14A TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Weldmetal Typical Mechanical properties
An all-positional rutile flux cored wire Composition (%) of all Weldmetal
Classification AWS A5.20: E71T-1 C 0.03 YS 480 N/mm2
DESCRIPTION
Mn 1.30 UTS 580 N/mm2
Si 0.50 EL (L=4d) 30%
OK TUBROD 15.14A is an all-positional flux cored wire S 0.02 Impact (CVN) at -18oC 80J
designed for optimum performance when using 100% P 0.02 - 29OC 50J
CO2 gas. The smooth metal transfer facilitates easy APPLICATIONS
deposition even in positional welding. Fillet contour is
flat, with equal leg lengths & uniform sidewall wetting. It is designed for all position single and multi-pass
The slag coverage is complete and easy to remove. welding of mild and medium tensile carbon steels upto
The slag system allows excellent welding in all posi- 510 N/mm2. For e.g. fabrication in chemical machinery
tions with virtually no spatter. Compared to conventional equipment, structures and steel frames in construction,
low hydrogen electrodes, OK TUBROD 15.14A absorbs shipbuilding, automobile industry, building of heavy
no moisture and ensures much lower H2 levels in the infrastructure such as bridges, towers, in steel industry,
deposited weldmet. Compared to the seamless variet- rolling stocks etc. It performs well over normal rust and
ies available, OK TUBROD 15.14A due to its unique mill scale.
method of manufacture presents no inconsistency in fill- CURRENT RANGE & PACKING DATA
ratio and also has higher deposition rates. Further the
Size Current Voltage Weight of Packing
special surface coating provided to the wires assures a
(mm) (Amp) (V)
very long shelf life and easier wire feeding. Weldmet are
radiographically sound. 1.2 100-230 18-26 15 Kg
1.6 150-350 20-32 15 Kg
WELDING CURRENT: DC +
PACKING: Each spool is sealed in an airtight polythene
SHIELDING GAS: CO2 or Ar + 20% CO2 bag and packed in a corrugated box of 15Kg each. Also
APPROVALS: ABS 3SA 3YSA, BV SA3YM, DNV III- Available in 200 Kg Marathon Pac®.
YMS, LR 3S 3YS
DUAL SHIELD 7100 TYPICAL ALL WELDMETAL PROPERTIES
FCAW wire for mild steel and 490/mm2 class high Wire Typical Mechanical properties
tensile strength steel Composition (%) of all Weldmetal
Classification ASME SFA/AWS A5.20 E71T-1 C 0.040 YS 491 N/mm2
DESCRIPTION
Si 0.572 UTS 563 N/mm2
Mn 1.270 EL (L=4d) 30%
Dual Shield 7100 is a multi purpose all position flux
P 0.013 Impact (CVN) at
cored wire for use with CO2 gas. S 0.008 0oC 101J
WELDING CURRENT: DC+ Cr 0.028 -18oC 58J
SHIELDING GAS: CO2 Ni 0.017
Mo 0.005
APPROVALS: ABS 2SA 2YSA H10 (C1) V 0.019
BV SA2YM HH (C1) Nb 0.012
DNV II YMS H10 (C1) Cu 0.017
GL 2YH10S (C1)
KR RSW 51G(52G) HH (C1)
LR 2S 2YS H15 (C1)
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (A) (V) Spool (Kg) Pail (Kg)
1.2 Flat 140-330 22-34
Vertical - up 140-270 22-28 5, 12.5, 15 100, 200
1.4 Flat 160-390 23-35
Vertical - up 150-280 22-28 12.5, 15 100, 200
1.6 Flat 170-460 24-36
Vertical - up 160-280 23-28 12.5, 15 300
PACKING: Each spool is sealed in an airtight polythene bag and packed in a corrugated box.
79
DUAL SHIELD 7100 Ultra TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
FCAW wire for mild steel and 490N/mm2 class high Weldmetal Mechanical Properties
tensile steel Composition As Welded PWHT - Stress Relieved
(%) (CO2) 621OC 8 hrs
Classification ASME SFA/AWS A5.20 E71T-9
C 0.038 YS 518 N/mm2 YS 470 N/mm2
DESCRIPTION
Si 0.528 UTS 587 N/mm2 UTS 550 N/mm2
Dual Shield 7100 SR is an all position flux cored wire
Mn 1.289 EL 31% EL 32%
with a uniquely balanced formulation to provide greater P 0.014 Impact Impact
deposition and improved welding productivity. This wire S 0.005 (CVN) at (CVN at
has good mechanical properties in stress relieved con- Cr 0.022 -18oC 95J -18oC 76J
Ni 0.370 -29oC 59J -29oC 47J
dition as well as in as welded.
Mo 0.002
WELDING CURRENT: DC+ V 0.017
SHIELDING GAS: CO2 Nb 0.014
Cu 0.019
APPROVALS: ABS, BV, DNV, GL, KR, LR, NK, CCS
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg) Pail (Kg)
1.2 Flat 140-330 22-34
Vertical - up 140-270 22-28 5, 12.5, 15 100, 200
1.4 Flat 160-390 23-34
Vertical - up 150-280 22-28 12.5, 15 100, 200
1.6 Flat 170-460 24-36
Vertical - up 160-280 24-28 12.5, 15
PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box.
80
DUAL SHIELD T-5 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Basic slag type FCAW wire for mild steel and 490N/ Weldmetal Mechanical Properties
mm2 class high tensile strength steel Composition As Welded
Classification ASME SFA/AWS A5.20 E70T-5/T-5MJ (%) (75% Ar / 25% CO2)
DESCRIPTION C 0.058 YS 440 N/mm2
Si 0.637 UTS 547 N/mm2
Dual Shield T-5 is a basic slag flux cored wire which
Mn 1.368 EL 32%
produces crack resiatant, highly ductile weld deposits. P 0.013 Impact
The small diameter wires, such as 1.2mm & 1.4mm di- S 0.008 (CVN) at
ameters can be used out - of position. The arc charac- Cr 0.027 -18OC 130J
teristics are globular but can be improved with the use Ni 0.016 -29OC 110J
of argon mixtures. Weldmetal analysis is similar to an Mo 0.004 -40OC 95J
E7018 or E7018-1 low hydrogen electrode. V 0.002 -51OC 80J
Nb 0.003
WELDING CURRENT: DC RP Cu 0.018
SHIELDING GAS: CO2 or Ar / CO2
APPROVALS: ABS, BV, DNV, GL, LR
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.2 Flat 140-280 22-31
Vertical - up 140-240 22-26 5, 12.5, 15
1.4 Flat 160-300 23-33
Vertical - up 150-260 22-27 12.5, 15
1.6 Flat 170-320 24-35
Vertical - up - - 12.5, 15
PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of
5Kg/15Kg/12.5Kg each.
81
CORESHIELD 11 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Self - Shielded FCAW wire for mild steel and 490N/ Weldmetal Typical Mechanical properties
mm2 class high tensile strength steel Composition (%) of all Weldmetal
Classification : ASME SFA/AWS A5.20 E71T-11 C 0.210 YS 440 N/mm2
DESCRIPTION
Si 0.370 UTS 600 N/mm2
Mn 0.610 EL 25%
Coreshield 11 is excellent for use on single or multiple
P 0.013
pass, lap, fillet and butt welds on mile steels in all weld- S 0.003
ing position. It meets the requirements for classification Cr 0.040
E71T-11 in AWS specifiction A5.20, and offers smooth Ni 0.020
arc action, full slag coverage, easy slag removal, and Mo 0.010
low spatter. Bead appearance and weld edges are V 0.009
smooth and no shielding gas is required. A1 1.600
Cu 0.013
WELDING CURRENT: DC -
SHIELDING GAS: None (Self - shielding)
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.0 Flat 170-240 17-23 12.5 / 15
Vertical - up 170-240 17-23
1.2 Flat 180-270 19-25 12.5 / 15
Vertical - up 180-270 19-25
1.6 Flat 200-300 22-28 12.5 / 15
Vertical - up 200-300 22-28
PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 15Kg/12.5Kg
each.
82
COREWELD 70 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Metal type FCAW wire for mild steel and 490N/mm 2
Weldmetal Typical Mechanical properties
class high tensile strength steel Composition (%) of all Weldmetal
Classification : ASME SFA/AWS A5.18 E70C-6M
C 0.048 YS 448 N/mm2
DESCRIPTION
Si 0.582 UTS 549 N/mm2
Coreweld 70 is a metal cored wire that combines the
Mn 1.375 EL 31%
high deposition rates of a rutile slag flux - cored elec- P 0.014 Impact (CVN) at
trode with the high efficiencies of solid wire. S 0.012 -18OC 62J
WELDING CURRENT: DC+ Cr 0.023 -29OC 48J
SHIELDING GAS: Ar / CO2 Ni 0.014
APPROVALS: ABS, BV, DNV, GL, LR Mo 0.001
V 0.004
Nb 0.002
Cu 0.015
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg) Pail (Kg)
1.2 Flat 180-350 24-33 12.5 / 15 100 / 200
Vertical - up 140-220 20-24
1.4 Flat 200-430 26-34 12.5 / 15 100 / 200
Vertical - up 150-240 21-25
1.6 Flat 300-500 27-35 12.5 / 15 300
Vertical - up - -
2.0 Flat 350-550 28-36 25 -
Vertical - up - -
2.4 Flat 400-600 29-37 25 -
Vertical - up - -
PACKING: Each spool is sealed in an airtight polythene bags and then packed in a corrugated cardboard box of
15Kg/12.5Kg/25Kg each.
83
COREWELD 111 ULTRA TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
FCAW wire for weather - proof steel Weldmetal Typical Mechanical properties
Composition (%) of all Weldmetal
Classification ASME SFA/AWS A5.29 E81T-W2
DESCRIPTION C 0.035 YS 515 N/mm2
Dual Shield 8100 W is an all - position flux cored wire
Si 0.492 UTS 593 N/mm2
Mn 0.925 EL (L=4d) 30%
developed specifically to color match with the low alloy,
P 0.013 Impact (CVN) at
high strength weathering grade steels such as ASTM S 0.007 -5oC 98J
588 & 242. Cr 0.539 -29oC 35J
WELDING CURRENT: DC+ Ni 0.605
Mo 0.004
SHIELDING GAS: Pure CO2 or Ar / CO2
V 0.016
APPROVALS: ABS 3SA 3YSA H10 (C1) Nb 0.010
Cu 0.490
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg) Pail (Kg)
1.2 Flat 140-300 21-30
Vertical - up 140-240 21-25 12.5, 15 100, 200
1.4 Flat 160-360 22-32
Vertical - up 150-260 21-26 12.5, 15 100, 200
1.6 Flat 170-410 23-34
Vertical - up 160-270 22-27 12.5, 15
PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of
15Kg/12.5Kg each.
84
DUAL SHIELD 7000 A1 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
FCAW wire for 0.5% Mo heat resistant steel Weldmetal Mechanical Properties
Classification ASME SFA/AWS A5.29 E81T-A1 Composition As Welded PWHT - 620OC 1 hr
(%) (CO2) (CO2)
DESCRIPTION
C 0.048 YS 503 N/mm2 YS 470 N/mm2
Dual Shield 7000 - A1 is an all - position wire recom-
Si 0.475 UTS 684 N/mm2 UTS 550 N/mm2
mended for 0.5% Mo steels. It is used in the fabrication
Mn 0.789 EL 28% EL 32%
and erection of boilers, pressure piping and tubing and P 0.016 Impact Impact
other pressure vessel applications. 75% Ar / 25% CO2 S 0.007 (CVN) at (CVN at
shielding gas mixture may be used to improve arc char- Cr 0.028 10oC 43J 10oC 31J
acteristics, increase wetting action, decrease penetra- Ni 0.019 -18oC 27J -18oC 20J
tion, and provide easier arc control for out - of - position Mo 0.480
V 0.016
welding.
Nb 0.009
WELDING CURRENT: DC+ Cu 0.022
SHIELDING GAS: CO2 or 75% Ar/ 25% CO2
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.2 Flat 140-330 22-34
Vertical - up 140-270 22-28 5, 12.5, 15
1.4 Flat 160-390 23-34
Vertical - up 150-280 22-28 12.5, 15
1.6 Flat 170-430 24-36
Vertical - up 160-280 24-28 12.5, 15
PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of
5Kg/15Kg/12.5Kg each.
FCAW wire for 0.5 - 1.25% Cr - 0.5% Mo heat resis- Weld Matel Mechanical Properties
tant steel Composition As Welded PWHT - 690OC 1 hr
Classification ASME SFA/AWS A5.29 E81T-B2 (%) (CO2) (CO2)
PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of
5Kg/15Kg/12.5Kg each.
85
DUAL SHIELD 9000 - B3 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
FCAW wire for 2.25% Cr-1% Mo heat resistant steel Weldmetal Mechanical Properties
Classification ASME SFA/AWS A5.29 E91T-B3 Composition As Welded PWHT
DESCRIPTION (%) (CO2) 690OC 1 hr
Dual Shield 9000 - B3 is an all - position flux cored C 0.053 YS 717 N/mm2 YS 606 N/mm2
Si 0.517 UTS 822 N/mm UTS
2
692 N/mm2
wire which contains 2.25% Cr - 1% Mo. The Weldmetal
Mn 0.538 EL 20% EL 22%
analysis is similar to an E9018 - B3 low hydrogen elec- P 0.015
trode. S 0.006
WELDING CURRENT: DC+ Cr 0.268
Ni 0.019
SHIELDING GAS: CO2 or 75% Ar/ 25% CO2
Mo 1.066
V 0.015
Nb 0.011
Cu 0.024
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.2 Flat 140-330 22-34
Vertical - up 140-270 22-28 5, 12.5, 15
1.4 Flat 160-390 23-34
Vertical - up 150-280 22-28 12.5, 15
1.6 Flat 170-430 24-36
Vertical - up 160-280 24-28 12.5, 15
PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of
5Kg/15Kg/12.5Kg each.
86
DUAL SHIELD T - 115 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Basic slag type FCAW wire for mild steel and 760N/ Weldmetal Mechanical Properties
mm2 class high tensile strength steel Composition As Welded
Classification ASME SFA/AWS A5.29 E110T5-K4 (%) (75% Ar / 25% CO2)
DESCRIPTION C 0.069 YS 702 N/mm2
Si 0.592 UTS 813 N/mm2
Dual Shield T - 115 is a basic slag flux cored wire de-
Mn 1.375 EL 21%
signed for applications requiring a high strength weld P 0.014 Impact
deposit. This wire produces weld deposits which are S 0.009 (CVN) at
resistant to cracking in heavy sections or under high re- Cr 0.234 -29OC 59J
straint. The metal analysis is similar to an E11018-M low Ni 2.185 -51OC 38J
hydrogen electrode. Mo 0.455
V 0.003
WELDING CURRENT: DC+ Nb 0.004
SHIELDING GAS: Ar / CO2 Cu 0.021
APPROVALS: ABS E110T5 - K4 (M21)
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.2 Flat 140-330 22-34
Vertical - up 140-270 22-28 5, 12.5, 15
1.4 Flat 160-390 23-34
Vertical - up 150-280 22-28 12.5, 15
1.6 Flat 170-460 24-36
Vertical - up 160-280 24-28 12.5, 15
PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of
5Kg/15Kg/12.5Kg each.
FCAW wire for mild steel and 760N/mm2 class high Weldmetal Typical Mechanical properties
tensile strength steel Composition (%) of all Weldmetal
Classification ASME SFA/AWS A5.29 E110T1-K3 C 0.053 YS 705 N/mm2
DESCRIPTION
Si 0.298 UTS 830 N/mm2
Mn 1.600 EL (L=4d) 19%
Dual Shield II 110 is an all - position flux cored wire that
P 0.014 Impact (CVN) at
combines a high stength deposit with excellent impact S 0.007 -18oC 45J
toughness. Cr 0.027 -29oC 38J
This wire was designed to join high strength steel such Ni 1.813
as HY-100 and T-1 in the as welded or stress relieved Mo 0.375
conditon. The Weldmetal analysis is similar to an E11018 V 0.018
Nb 0.013
- M low hydrogen electrode.
Cu 0.016
WELDING CURRENT: DC+
SHIELDING GAS: CO2 or 75% Ar / 25% CO2
APPROVALS: ABS E110T1 - K3 (M21)
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.2 Flat 140-330 22-34
Vertical - up 140-270 22-28 5, 12.5, 15
1.4 Flat 160-390 23-34
Vertical - up 150-280 22-28 12.5, 15
1.6 Flat 170-460 24-36
Vertical - up 160-280 24-28 12.5, 15
PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of
5Kg/15Kg/12.5Kg each.
87
DUAL SHIELD II 101TC SHIELDING GAS: CO2
Welding Consumables
FCAW wire for mild steel AND 620N/mm2 class high APPROVALS: ABS E91T1-K2(C1)
tensile strength steel TYPICAL ALL WELDMETAL PROPERTIES
Classification ASME SFA/AWS A5.29 E91T1-K2 Weldmetal Typical Mechanical properties
(E91T1-K2) Composition (%) of all Weldmetal
DESCRIPTION
C 0.058 YS 565 N/mm2
Dual Shield II 101TC is an all - position wire developed
Si 0.637 UTS 649 N/mm2
to meet the U.S. Navy qualification tests for hydrogen
Mn 1.368 EL (L=4d) 28%
levels of less than 5ml / 100g of Weldmetal. This wire P 0.013 Impact (CVN) at
produces exceptional mechanical properties and low S 0.008 -18oC 112J
temperature impact toughness. It is intended for use Cr 0.027 -29oC 94J
Ni 0.016 -51oC 65J
on HY-80, ASTM A 70, A514 and A517 or other similar
Mo 0.004
HSLA steels. V 0.002
WELDING CURRENT: DC+ Nb 0.003
Cu 0.018
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.2 Flat 140-280 22-32
Vertical - up 140-250 22-27 5, 12.5, 15
1.4 Flat 160-300 23-32
Vertical - up 150-270 22-28 12.5, 15
1.6 Flat 170-330 24-34
Vertical - up 160-280 24-28 12.5, 15
PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of
5Kg/15Kg/12.5Kg each.
88
OK TUBROD 15.22 Cr-1 Mo steels, which are used principally in power pip-
Welding Consumables
ing and boiler work for the fabrication of plates, pipes,
A 2.25 Cr, 1 Mo alloyed basic flux cored wire tubes, castings and forging conforming to ASTM speci-
Classification AWS A 5.29: E90T5-B3 fications.
TYPICAL WELDMETAL PROPERTIES
DESCRIPTION
Weldmetal Mechanical Properties
OK TUBROD 15.22 is a basic low hydrogen flux cored
Composition As Welded PWHT - Stress Relieved
wire depositing a 2.25 Cr, 1 Mo alloy designed for creep (%) at 690OC / 1 hr
resistant steels of similar composition and intended for C 0.06 YS 630 N/mm2 YS 550 N/mm2
service at around 600°C. Typical applications include Mn 0.637 UTS 730 N/mm2 UTS 650 N/mm2
fabrication and repair in the power generation field. Si 1.368 EL 20% EL 22%
Stress relief to be carried out at 690°C. The flux-cored Mo 0.013
wire welds with a very smooth and stable arc and de- Cr 0.008
posits a very thin slag that is easily removable. The S 0.027
P 0.016
weldbead is smooth and shiny with a flat bead profile.
SHIELDING GAS: CO2 or 80% Argon with 20% CO2 or CURRENT RANGE & PACKING DATA
45% CO2 + 2.3% O2 Size Current Voltage Weight of Packing
APPLICATIONS (mm) (Amp) (V)
1.2 120-250 18-26 16 Kg
OK TUBROD 15.22 is designed for single and multi- 1.6 130-350 20-32 16 Kg
pass welding in the flat and for horizontal fillets of 2.25
PACKING: The wires wrapped in polythene bags are
packed in corrugated cardboard boxes.
OK TUBROD 15.24 impact properties and to help resist weld cracking. It can
be used for single and multi-pass welding. One typical
A 1 Ni alloyed basic flux cored wire appli~ation is in the construction and repair of offshore
Classification AWS A 5.29: E80T5-G platforms and containment vessels.
DESCRIPTION TYPICAL WELDMETAL PROPERTIES
OK TUBROD 15.24 is a fully basic low hydrogen flux Weldmetal Typical Mechanical properties
cored wire depositing a 1 Ni alloy designed for high Composition (%) of all Weldmetal
strength combined with low temperature toughness C 0.06 YS 540 N/mm2
for service down to -50°C and has good CTOD-perfor-
Mn 1.5 UTS 600 N/mm2
mance. This applies to both the as welded and stress
Si 0.5 EL (L=4d) 28%
relieved condition. Shielding gas could be CO2 or Ar mix- Ni 0.8 Impact (CVN) at - 50oC 100J
S 0.02
tures. Typical applications include fabrication and repair
P 0.01
in the power industry. The flux-cored wire welds with a
very smooth and stable arc and deposits a very thin slag CURRENT RANGE & PACKING DATA
that is easily removable. The weld bead is smooth and Size Current Voltage Weight of Packing
shiny with a flat bead profile. (mm) (Amp) (V)
SHIELDING GAS: CO2 or Argon with 20% CO2 1.2 100-250 18-26 16 Kg
APPROVALS: IN (DVA), MOD 1.6 140-350 20-32 16 Kg
APPLICATIONS PACKING: The wires wrapped in polythene bags are
OK TUBROD 15.24 is designed for good low temperature packed in corrugated cardboard boxes.
89
OKTUBROD 15.27 APPLICATIONS
Welding Consumables
A basic flux cored wire for HSLA steels OK TUBROD 15.27 is used for the welding of quenched
and tempered steels as N-A-XTRA 90, N-A-XTRA
Classification AWS A 5.29: E110T5-G 100, HY100, etc. which are used for offshore jack-up
structures and general structural fabrication of high
DESCRIPTION tensile steels for low temperature service.
OK TUBROD 15.27 is a fully basic low hydrogen flux TYPICAL WELDMETAL PROPERTIES
cored wire depositing a 2.5 Ni alloy designed for weld-
ing of high tensile strength steels such as HY 100. It is Weldmetal Typical Mechanical properties
also suitable for welding high tensile steels with a low Composition (%) of all Weldmetal
temperature toughness requirement down to -50°C. The C 0.06 YS 750 N/mm2
wire is capable of welding in all positions and uses the
Mn 1.6 UTS 820 N/mm2
dip transfer mode for the vertical-up technique, which
Si 0.5 EL (L=4d) 21%
can be further enhanced by the synergic pulsed pro- Ni 2.5 Impact (CVN) at - 50oC 80J
cess. The flux-cored wire welds with a very smooth and
stable arc and deposits a very thin slag that is easily CURRENT RANGE & PACKING DATA
removable. The weldbead is smooth and shiny with a
Size Current Voltage Weight of Packing
flat bead profile.
(mm) (Amp) (V)
SHIELDING GAS: CO2 or Argon with 20% CO2 1.2 100-250 18-26 16 Kg
1.6 140-350 20-32 16 Kg
WELDING CURRENT : DC-
PACKING: The wires wrapped in polythene bags are
APPROVALS : MOD, Q2N packed in corrugated cardboard boxes.
OK TUBROD 14.30 stabilised grades 321 and 347 types, except when the
corrosive conditions are very severe.
A rutile flux cored wire for welding 18 Cr, 8 Ni steels
TYPICAL WELDMETAL PROPERTIES
for welding of stainless steel
Wire Typical Mechanical properties
Classification AWS A5.22: E308LT0-1 Composition (%) of all Weldmetal
DESCRIPTION C 0.03 YS 410 N/mm2
Mn 1.6 UTS 535 N/mm2
OK TUBROD 14.30 is a flux cored tubular wire designed
Cr 19.0 EL (L=4d) 40%
for the welding of stainless steels containing 18-20% Cr Si 0.4
and 8-12% Ni in all positions. It can also be used for Ni 10.0
welding the stabilised grades 321 and 347 types in most
cases, except when the environmental corrosive condi- CURRENT RANGE & PACKING DATA
tions are very severe. The slag volume is thin and its
Size Current Voltage Weight of Packing
removal effortless with a final weldbead that is smooth,
(mm) (Amp) (V)
shiny and with an exceptional finely rippled appearance.
1.2 150-250 25-32 15 Kg
Due to the extremely stable DC+ arc, spatter levels are
virtually nonexistent. 1.6 200-350 26-34 15 Kg
SHIELDING GAS: Ar/CO2, CO2 PACKING: The spools are packed in sealed polythene
bags and then packed in corrugated carboard boxes.
APPROVALS: TUV, LR, DB, VdTÜV
TYPICAL APPLICATIONS
90
SHIELD - BRIGHT 308 L TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Weldmetal Mechanical Properties
FCAW wire for 18% Cr - 8% Ni stainless steel, For
Composition As Welded As Welded
all - position welding
(%) (CO2) (Ar / CO2)
Classification ASME SFA/AWS A5.22 E308LT1-1(4) C 0.024 YS 400 N/mm2 YS 403 N/mm2
DESCRIPTION
Si 0.752 UTS 570 N/mm UTS
2
593 N/mm2
For welding types 301, 302, 304, 304L, 308 and 308L
Mn 1.118 EL 50% EL 50%
of stainless steel. May be used for welding types 321 P 0.020 Impact
S 0.005 (CVN) at
and 347 if service temperature does not exceed 500OF
Cr 19.21 -0OC 49J
(260OC). Low carbon content minimizes carbide precipi- Ni 10.00
tation. Ferrite values will lower as impact toughness in- Mo 0.101
creases. Carbon content 0.04% maximum. V 0.052
WELDING CURRENT: DC+ Nb 0.022
Cu 0.140
SHIELDING GAS: CO2 or Ar / CO2
Ferrite No. FN 3-9
APPROVALS: ABS E308LT1-1(C1)
DNV 308L (C1)
LR 304L (C1)
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.0 Flat 100-170 23-27
Vertical - up 100-150 21-25 12.5
1.2 Flat 130-250 25-31
Vertical - up 130-200 23-28 12.5
1.6 Flat 170-320 25-33
Vertical - up 160-250 24-30 12.5
PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.
91
SHIELD - BRIGHT 309 LMo TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
FCAW wire for dissimilar metals, For all - position Weldmetal Mechanical Properties
welding Composition As Welded As Welded
Classification: ASME SFA/AWS A5.22E309LMoT1-1(4) (%) (CO2) (75% Ar / 25% CO2)
DESCRIPTION C 0.029 YS 517 N/mm2 YS 550 N/mm2
Si 0.632 UTS 645 N/mm2 UTS 700 N/mm2
Designed for welding type 316 clad steels on the first
Mn 0.967 EL 33% EL 33%
pass in cladding steels or for welding dissimilar met- P 0.019
als such as Mo-containing austenitic stainless steels to S 0.009
carbon steels. Used in paper mills and in power plants. Cr 23.02
Carbon content 0.04% maximum. Ni 13.01
Mo 2.622
WELDING CURRENT: DC+ V 0.072
SHIELDING GAS: CO2 or 75% Ar / 25% CO2 Nb 0.018
APPROVALS: DNV 309MoL (C1) Cu 0.152
Ferrite No. FN 17-23
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
0.9 Flat 120-200 24-30
Vertical - up 100-150 21-25 12.5
1.2 Flat 150-270 25-31
Vertical - up 130-200 23-28 12.5
1.6 Flat 200-350 25-33
Vertical - up 160-250 24-30 12.5
PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.
FCAW wire for dissimilar metals, For all - position Weldmetal Typical Mechanical properties
welding Composition (%) of all Weldmetal
Classification : ASME SFA/AWS A5.22E309LCbT1-1(4) As Welded (CO2)
DESCRIPTION C 0.024 YS 501 N/mm2
Shield - Bright 309LCb is an all - position flux cored wire.
Si 0.750 UTS 653 N/mm2
It containes Nb alloy element which inhibits carbide pre-
Mn 1.062 EL (L=4d) 34%
cipitation to prevent intergranular corrosion at elevated P 0.022 Impact (CVN) at
temperatures. Shield Bright 309LCb is recommended S 0.007 0oC 52J
Cr 24.20
for welding types 347 or 321 stainless clad steels, or
Ni 12.84
type 347 stainless steel to carbon steel.
Mo 0.080
WELDING CURRENT: DC+ V 0.067
SHIELDING GAS: CO2 or Ar / CO2 Nb 0.778
Cu 0.145
Ferrite No. FN19-25
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
0.9 Flat 100-170 23-27
Vertical - up 100-150 21-25 12.5
1.2 Flat 130-250 25-31
Vertical - up 130-200 23-28 12.5
1.6 Flat 170-320 25-33
Vertical - up 160-250 24-30 12.5
PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.
92
SHIELD - BRIGHT 316 L TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
Weldmetal Mechanical Properties
FCAW wire for low carbon 18% Cr - 12% Ni - 2% Mo Composition As Welded As Welded
stainless steel For all - position welding (%) (CO2) (75% Ar / 25% CO2)
Classification: ASME SFA/AWS A5.22 E316LT1-1(4) C 0.029 YS 430 N/mm2 YS 456 N/mm2
DESCRIPTION
Si 0.805 UTS 570 N/mm UTS
2
595 N/mm2
For welding type 316 stainless. Contains molybdenum
Mn 1.093 EL 42% EL 42%
which resists pitting corrosion induced by sulphuric and P 0.022 Impact
S 0.007 (CVN) at
sulphurous acids, chlorides and cellulose solutions.
Cr 22.70 -0OC 39J
Used widely in the rayon, dye and paper making indus- Ni 12.66
tries. Carbon content 0.04% maximum. Mo 0.080
WELDING CURRENT: DC+ V 0.067
Nb 0.022
SHIELDING GAS: CO2 or Ar / CO2
Cu 0.145
APPROVALS: ABS E316LT1-1(C1) Ferrite No. FN 5-15
BV 316L (C1)
DNV 316L MS (C1)
LR 316L (C1)
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.0 Flat 100-170 23-27
Vertical - up 100-150 21-25 12.5
1.2 Flat 130-250 25-31
Vertical - up 130-200 23-28 12.5
1.6 Flat 170-320 25-33
Vertical - up 160-250 24-30 12.5
PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.
FCAW wire for 18% Cr - 12% Ni - 3% Mo - N Stainless Weldmetal Typical Mechanical properties
steel For all - position welding Composition (%) of all Weldmetal
Classification : ASME SFA/AWS A5.22 E317LT1-1(4) C 0.03 YS 421 N/mm2
DESCRIPTION
Si 0.75 UTS 560 N/mm2
Mn 1.05 EL (L=4d) 43%
Recommended for welding type 317 stainless steel to
P 0.02
give a maximum of 0.04% carbon in the weld deposit. S 0.01
The higher molybdenum content, as compared to type Cr 19.5
316L, further reduces susceptibility to pitting corrosion. Ni 12.9
Used in the pulp and paper industry and in other severe Mo 3.5
corrosion applications involving sulfuric and sulfurous Cu 0.15
acids and their salts. Ferrite No. FN10-20
WELDING CURRENT: DC+
SHIELDING GAS: CO2 or Ar / CO2
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.0 Flat 120-200 24-30 12.5 / 15
Vertical - up - -
1.2 Flat 150-270 25-31 12.5 / 15
Vertical - up - -
1.6 Flat 200-350 25-33 12.5 / 15
Vertical - up - -
PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.
93
SHIELD - BRIGHT 347 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
FCAW wire for 18% Cr - 8% Ni - Cb Stainless steel Weldmetal Typical Mechanical properties
Composition (%) of all Weldmetal
Classification: ASME SFA/AWS A5.22E347T1-1(4)
DESCRIPTION As Welded (CO2)
Developed to weld types 347, 304, 304L and 321 stain- C 0.02 YS 431 N/mm2
less, where service temperatures are below 316. The
Si 0.8 UTS 598 N/mm2
addition of columbium helps minimize chromium car-
Mn 1.1 EL (L=4d) 55%
bide precipitation while providing improved corrosion P 0.02
S 0.01
resistance.
Cr 19.3
WELDING CURRENT: DC RP Ni 10.0
SHIELDING GAS: CO2 or Ar / CO2 Cb 0.4
Cu 0.15
Ferrite No. FN 8-12
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.0 Flat 120-200 24-30 12.5 / 15
Vertical - up - -
1.2 Flat 150-270 25-31 12.5 / 15
Vertical - up - -
1.6 Flat 200-350 25-33 12.5 / 15
Vertical - up - -
PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 15Kg/12.5Kg
each.
94
SHIELD - BRIGHT 410 WELDING CURRENT: DC+
Welding Consumables
FCAW wire for 13% Cr stainless steel For all - posi- SHIELDING GAS: CO2 or Ar / CO2
tion welding TYPICAL ALL WELDMETAL PROPERTIES
Classification: ASME SFA/AWS A5.22 E410T1-1(4) Weldmetal Typical Mechanical properties
DESCRIPTION Composition (%) of all Weldmetal
Shield Bright 410 is 13% Cr martensitic stainless steel PWHT : 750OC / 1 hr (CO2)
flux cored wire. It is used for overlay welding on valve
sheet surface of its martensite structure in as - welded C 0.055 YS 480 N/mm2
condition which shows high hardness and wear resisting
Si 0.484 UTS 570 N/mm2
Mn 0.597 EL 25%
properties. It will be showed good ductility and excellent
P 0.021
corrosion resistance after post weld heat treatment at S 0.008
600-850 and it is suitable for welding of AISI 410, 403, Cr 12.701
420J1, and 420J2. Ni 0.219
Recommended for welding remove dirt such as oil and Mo 0.010
dust from the groove. Normally, pre-heat is necessary V 0.071
at 200-400. Nb 0.013
Cu 0.036
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.0 Flat 100-170 23-27
Vertical - up 100-150 21-25 12.5
1.2 Flat 130-250 25-31
Vertical - up 130-200 23-28 12.5
1.6 Flat 170-320 25-33
Vertical - up 160-250 24-30 12.5
PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg
each.
95
SHIELD - BRIGHT 312 TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
FCAW wire for 29%Cr - 9%Ni stainless steel For all Weldmetal Mechanical Properties
- position welding Composition As Welded As Welded
Classification: ASME SFA/AWS A5.22 E312T1-1(4) (%) (CO2) (75% Ar / 25% CO2)
DESCRIPTION C 0.075 YS 620 N/mm2 YS 625 N/mm2
Si 0.752 UTS 810 N/mm2 UTS 813 N/mm2
For welding type 312 stainless steel. Highly crack resis-
Mn 1.102 EL 24% EL 28%
tant of austenite - ferritic electrode with a ferrite content P 0.023
of 50%. Also highly suitable for stress compensating S 0.003
buffer layers on parent metals sensitive to cracking. Cr 28.50
Ni 9.65
WELDING CURRENT: DC+
Mo 0.097
SHIELDING GAS: CO2 or Ar / CO2 V 0.088
Nb 0.026
Cu 0.156
CURRENT RANGE & PACKING DATA Ferrite No. FN 50-60
96
SHIELD - BRIGHT 308L XTRA TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
FCAW wire for 18%Cr - 8%Ni stainless steel For flat Weldmetal Mechanical Properties
and horizontal position welding Composition As Welded As Welded
Classification: ASME SFA/AWS A5.22 E308LT0-1(4) (%) (CO2) (75% Ar / 25% CO2)
DESCRIPTION C 0.029 YS 427 N/mm2 YS 432 N/mm2
Si 0.512 UTS 575 N/mm2 UTS 585 N/mm2
Designed for welding types 301, 302, 304, 304L, 308,
Mn 1.390 EL 42% EL 41%
308L steels. Ideal where service temperatures are be- P 0.021 Impact
low 500OF (260OC). Low carbon content helps minimize S 0.005 (CVN) at
carbide precipitation. Carbon content 0.04% maximum. Cr 19.45 -100OC 30J
Ni 9.90
WELDING CURRENT: DC+
Mo 0.082
SHIELDING GAS: CO2 or Ar / CO2 V 0.054
APPROVALS: ABS E308LT0-1(C1) Nb 0.011
DNV 308L (C1) Cu 0.154
LR 308L (C1) Ferrite No. FN 5-15
FCAW wire for 22%Cr - 12%Ni stainless steel For flat Weldmetal Mechanical Properties
and horizontal position welding Composition As Welded As Welded
(%) (CO2) (75% Ar / 25% CO2)
Classification : ASME SFA/AWS A5.22 E309LT0-1(4)
C 0.029 YS 453 N/mm2 YS 473 N/mm2
DESCRIPTION
Si 0.632 UTS 579 N/mm UTS
2
592 N/mm2
Developed to be used when welding most mild or car-
Mn 1.548 EL 38% EL 38%
bon steels to type 304. The higher percentages of Cr P 0.019 Impact
and Ni provide the necessary crack resistance. Carbon S 0.004 (CVN) at
content 0.04% maximum. Cr 24.44 -100OC 24J
Ni 12.70
WELDING CURRENT: DC+ Mo 0.085
SHIELDING GAS: CO2 or Ar / CO2 V 0.052
APPROVALS: ABS E309LT0-1(C1) Nb 0.013
DNV 309L MS (C1 and M21) Cu 0.143
Ferrite No. FN 17-29
97
SHIELD-BRIGHT 309LMo XTRA TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
FCAW wire for 22%Cr - 12%Ni-2%Mo stainless steel Weldmetal Typical Mechanical properties
For flat and horizontal position welding Composition (%) of all Weldmetal
Classification: ASME SFA/AWS A5.22 E308LT0-1(4) As Welded (CO2)
DESCRIPTION
C 0.03 YS 559 N/mm2
Designed for welding type 316 clad steels on the first
Si 0.55 UTS 725 N/mm2
pass in cladding steels or for welding dissimilar metals
Mn 1.4 EL (L=4d) 39%
such as molybdenum-containing austenitic stainless P 0.02 Ferrite No 18-26
steels to carbon steels. Used in paper mills and power S 0.01
plants. Carbon content 0.04% maximum. Cr 23.3
Ni 13.6
WELDING CURRENT: DC+
Mo 2.6
SHIELDING GAS: CO2 or Ar / CO2 Cu 0.15
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.0 Flat 120-200 24-30 12.5 / 15
Vertical - up - -
1.2 Flat 150-270 25-31 12.5 / 15
Vertical - up - -
1.6 Flat 200-350 25-33 12.5 / 15
Vertical - up - -
PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 15Kg/12.5Kg
each.
FCAW wire for 18%Cr - 12%Ni-2%Mo stainless steel Weldmetal Mechanical Properties
For flat and horizontal position welding Composition As Welded As Welded
Classification : ASME SFA/AWS A5.22 E316LT0-1(4) (%) (CO2) (75% Ar / 25% CO2)
98
SHIELD-BRIGHT 347 XTRA TYPICAL ALL WELDMETAL PROPERTIES
Welding Consumables
FCAW wire for 18%Cr - 8%Ni-Cb stainless steel For Weldmetal Typical Mechanical properties
flat and horizontal position welding Composition (%) of all Weldmetal
Classification: ASME SFA/AWS A5.22 E347T0-1(4) As Welded (CO2)
DESCRIPTION
C 0.029 YS 427 N/mm2
Developed to weld types 347, 304, 304L and 321 stain-
Si 0.512 UTS 575 N/mm2
less, where service temperatures are below 316. The
Mn 1.390 EL (L=4d) 42%
addition of columbium helps minimize chromium car- P 0.021 Impact (CVN) at -100OC 30J
bide precipitation while providing improved corrosion S 0.005 Ferrite No 3-10
resistance. Cr 19.45
Ni 9.90
WELDING CURRENT: DC+
Mo 0.082
SHIELDING GAS: CO2 or Ar / CO2 V 0.054
Nb 0.47
Cu 0.154
CURRENT RANGE & PACKING DATA
Size Position Current Range Volts Weight of Packing
(mm) (Amps) (V) Spool (Kg)
1.0 Flat 120-200 24-30 12.5
Vertical - up - -
1.2 Flat 150-270 25-31 12.5
Vertical - up - -
1.6 Flat 200-350 25-33 12.5
Vertical - up - -
PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg
each.
Metal type FCAW wire for 12%Cr stainless steel Weldmetal Typical Mechanical properties
Composition (%) of all Weldmetal
Classification : SFA/AWS A5.22 E409T0-G
DESCRIPTION C 0.034 UTS 500 N/mm2
Arcaloy T-409Ti is a metal cored wire designed to match
Si 0.479 EL 20%
Mn 0.456
the corrosion resistance and mechanical properties of
P 0.011
type 409Ti stainless steel. This material is widely used S 0.013
in automotive exhaust systems. Cr 11.78
WELDING CURRENT: DC+ Ni 0.016
Mo 0.009
SHIELDING GAS: Ar or 98 Ar / 2% O2
V 0.030
Nb 0.006
Ti 0.820
PACKING: Each spool is seald in an airtight polythene bag and then packed in a corrugated cardboard box of
15Kg/12.5Kg each.
99
SAW Wires
OK AUTROD 12.08L TYPICAL WIRE COMPOSITION (%)
Welding Consumables
PACKING: The wires are packed in corrugated cardboard boxes in case of 25kg packs. Also available in 400/700kg
steel or fibre drums or 100/200 kgs steel bobbins.
100
ESAB SA10K TYPICAL WIRE COMPOSITION (%)
Welding Consumables
A copper-coated Mn alloyed wire for SAW C Mn Si S P Cu
Classification AWS A5.17 : EH 10K 0.08 1.45 0.15 0.02 0.02 0.2
Classification AWS A5.17 : EM13K 0.08 1.25 0.4 0.02 0.02 0.2
101
OK AUTROD 12.40L TYPICAL WIRE COMPOSITION (%)
Welding Consumables
102
OK AUTROD 12.33L TYPICAL WIRE COMPOSITION (%)
Welding Consumables
A copper-coated Mo alloyed solid wire for SAW C Mn Si S P Mo Cu
Classification AWS A5.23: EA3K 0.10 1.80 0.55 0.018 0.018 0.5 0.25
103
OK AUTROD 13.09L TYPICAL WIRE COMPOSITION (%)
Welding Consumables
Classification AWS A5.23 EG 0.08 1.05 0.60 0.03 0.03 0.50 0.17 0.009 0.008
PACKING: The wires are packed in corrugated cardboard boxes. Also available in bulk drums / spiders of 280/500/1000 Kgs.
104
OK AUTROD 12.44 TYPICAL WIRE COMPOSITION (%)
Welding Consumables
Mn-Mo alloyed, copper coated wire for submerged C Mn Si S P Mo
arc welding
0.11 2.0 0.15 0.015 0015 0.5
Classification AWS A5.23: EA3
PACKING DATA
DESCRIPTION
Size Packing
OK AUTROD 12.44 is a Mn-Mo-alloyed, copper coated (mm) 30Kg
wire for the submerged arc welding of high tensile steel
2.50 a
and steel for low temperature work. Also for creep re-
3.2 a
sistant steels (0.5% Mo), structural steels, ship building
4.0 a
steels, pressure vessel steels, etc. If can be combined
with OK Flux 10.62.
TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES
105
OK AUTROD 13.20SC TYPICAL WIRE COMPOSITION (%)
Welding Consumables
106
OK AUTROD 13.27 TYPICAL WIRE COMPOSITION (%)
Welding Consumables
Copper - coated, low-alloyed, 2% Ni electrode for C Mn Si Ni
the submerged arc welding
0.08 1.0 0.2 2.3
Classification AWS A5.23: ENi2
PACKING DATA
DESCRIPTION
Size Packing
OK AUTROD 13.27 is a copper - coated, low - alloyed, (mm) 30Kg
2% Ni electrode for the submerged arc welding of low-
2.50 a
alloyed and low - temperature steels for applications in
3.2 a
the offshore industry, for example. It can be combined
4.0 a
with OK Flux 10.62 and OK Flux 10.71.
107
OK AUTROD 13.64 TYPICAL WIRE COMPOSITION (%)
Welding Consumables
108
OK AUTROD 16.10 TYPICAL WELDMETAL COMPOSITION WITH OK
Welding Consumables
FLUX 10.92L
An extra low carbon stainless steel wire of 18/8 type
for SAW with OK Flux 10.92L Weldmetal Mechanical properties
Composition (%)
Classification AWS A5.9: ER 308L
C 0.025 YS 365 N/mm2
Cr 20.00 UTS 580 N/mm2
DESCRIPTION
Mn 1.8 EL 35%
OK AUTROD 16.10 are 18 Cr-8 Ni type bare stainless Ni 10.00 Impact (CVN) at - 196oC 40J
Si 0.60
steel wires for submerged arc welding of austenitic cor-
S 0.015
rosion resisting steels. The arc and current carrying P 0.017
characteristics assure excellent welder performance
of outstanding bead and surface finish. OK AUTROD PACKING DATA
16.10 is intended for welding of austenitic corrosion re-
sisting steels such as AISI, 301,304, 302L and equiva- Size Packing
lent types. (mm) 25Kg
C Mn Si Cr Ni Mo S P 2.50 a
3.15 a
0.025 1.8 0.4 19 12 2.7 0.015 0.015 4.0 a
109
OK AUTROD 16.53 TYPICAL WELDMETAL COMPOSITION WITH OK
Welding Consumables
FLUX 10.92L
An extra low carbon 24% Cr, 13% Ni stainless steel
wire for SAW Weldmetal Mechanical properties
Composition (%)
Classification AWS A5.9: ER 309L
C 0.025 YS 440 N/mm2
Cr 24.00 UTS 600 N/mm2
DESCRIPTION
Mn 1.8 EL (L=4d) 35%
OK AUTROD 16.53 are 24% Cr, 13% Ni type bare stain- Ni 13.00 Impact (CVN) at - 60oC 110J
Si 0.40
less steel wires with extra low carbon for submerged arc
S 0.015
welding and cladding of austenitic corrosion resisting P 0.017
steel. The arc and current carrying characteristics as-
sure excellent weld appeal. OK AUTROD 16.53 is suit- PACKING DATA
able for similar alloys in wrought or cast form and also
for joining dissimilar steels such as “18 - 8” to mild steel Size Packing
or carbon steel or low alloy steel. (mm) 25Kg
C Mn Si Cr Ni Nb S P PACKING DATA
2.50 a
3.15 a
4.0 a
110
OK AUTROD 16.13 TYPICAL WELDMETAL COMPOSITION WITH OK
Welding Consumables
FLUX 10.92L
An austenitic stainless steel wire for welding 25 Cr,
20 Ni type of steels by SAW with OK Flux 10.92L Weldmetal Mechanical properties
Composition (%)
Classification AWS A5.9: ER 310
C 0.10 YS 310 N/mm2
Cr 26 UTS 540 N/mm2
DESCRIPTION
Mn 1.7 EL 36%
OK AUTROD 16.13 are fully austenitic welding wires for Ni 21 Impact (CVN) at - 196oC 60J
Si 0.40
submerged arc welding of heat resistant steels of the 25
S 0.015
Cr-20 Ni type needing to withstand scaling at tempera- P 0.017
tures of upto 1100°C-1150°C. The arc and current char-
acteristics of the wire help a smooth weld performance PACKING DATA
giving outstanding bead finish.
Size Packing
TYPICAL WIRE COMPOSITION (%) (mm) 25Kg
C Mn Si Cr Ni S P 2.50 a
3.15 a
0.11 1.90 0.45 26.8 20.80 0.015 0.015 4.0 a
111
SAW FLUXES
OK FLUX 10.61L with impact strength requirements down to -51OC.
Welding Consumables
PACKING: OK FLUX 10.61L are packed in plastic lined paper bags containing 25 kg.
OK FLUX 10.62 ness, strength and CTOD values. Especially suitable for
narrow gap welding due to good slag detachability and
An agglomerated high basic Non-alloying flux for smooth side wall blending. Produces low oxygen weld-
SAW metal (approx 300 ppm) with hydrogen contents lower
than 5ml/100g. Operates optimally at the lower end of
Classification AWS A5.17: F7 A8/F6P8-EM12K the voltage range. This flux has a high current carry-
F7A8/F7P8-EH12K ing capacity on both AC and DC. Especially suitable for
F7A6/F7P6-EH14 narrow gap welding due to good slag detachability and
AWS A5.23: F8A6/F7P6-EA2-A2 smooth side wall blending.
F8A6/F8P6-EA4-A4
F9A8/F9P8-EA3-A3 BASICITY INDEX: 3.2
F8P2-EB2R-B2
F8P2-EB3R-B3 HYDROGEN: 5ml/100g max of weldmetal (redried flux)
F7A6/F7P8-ENil-Nil GRAIN SIZE: 0.2-1.6 mm
F8A10/F8P8-EG-G
F8A10/F8P10-EnI2-Ni2 REDRYING: 300+/- 25OC/2-4 hrs
F10A8/F9P6-EG-F3
F11A8/F10P8-EG-G APPLICATIONS
112
TYPICAL WELDMETAL PROPERTIES
Welding Consumables
Chemical Composition (%) Mechanical Properties
OK Flux Yield Stress Tensile EI. Impacts values
10.62 C Mn Si Ni Cr Mo N/mm2 N/mm2 (%) Charpy V Notch
OK Flux
J Temp (OC)
Autrod
12.22 0.07 1.0 0.30 - - - 410 500 33 90 -40
12.24 0.07 1.0 0.22 - - 0.5 500 580 25 60 -40
12.40 0.08 1.9 0.12 - - - 530 620 26 50 -40
12.32 0.10 1.6 0.35 - - - 475 570 28 110 -40
12.34 0.10 1.45 0.21 - - 0.5 540 620 24 60 -40
12.44 0.08 1.9 0.21 - - 0.5 600 700 27 65 -50
13.10SC 0.08 0.7 0.22 - 1.1 0.5 500 610 26 80 -29
13.20SC 0.08 0.6 0.20 - 2.0 0.85 525 620 25 80 -29
13.21 0.06 1.0 0.25 0.9 - - 470 560 28 70 -40
13.24 0.08 1.4 0.3 0.9 - 0.2 530 620 25 70 -60
13.27 0.06 1.0 0.25 0.9 0.5 - 490 570 27 80 -60
13.40 0.07 1.5 0.26 0.9 - 0.5 650 730 23 60 -50
13.43 0.08 1.35 0.25 2.2 0.6 0.5 700 795 21 65 -50
PACKING: OK FLUX 10.62 is packed in plastic lined paper bags containing 25 kg.
OK FLUX 10.62 L smooth side wall blending. Produces low oxygen weld-
metal (approx 300 ppm) with hydrogen contents lower
An agglomerated high basic Non-alloying flux for than 5ml/100g. Operates optimally at the lower end of
SAW the voltage range. This flux has a high current carry-
ing capacity on both AC and DC. Especially suitable for
Classification AWS A5.A:17: F7 A8/F6P8-EM12K narrow gap welding due to good slag detachability and
F7A8/F7P8-EH12K smooth side wall blending.
F7A6/F7P6-EH14
AWS A5.23: F8A6/F7P6-EA2-A2 BASICITY INDEX: 3.2
F8A6/F8P6-EA4-A4
F9A8/F9P8-EA3-A3 HYDROGEN: 5ml/100g max of weldmetal (redried flux)
F8P2-EB2R-B2 GRAIN SIZE: 0.2-1.6 mm
F8P2-EB3R-B3
F7A6/F7P8-ENil-Nil REDRYING: 300+/- 25OC/2-4 hrs
F8A10/F8P8-EG-G
F8A10/F8P10-EnI2-Ni2 APPROVALS: IBR
F10A8/F9P6-EG-F3
APPLICATIONS
F11A8/F10P8-EG-G
For offshore constructions, pressure vessels includ-
Flux Classification EN760 SA FB 1 55
ing those for nuclear industries requiring good CTOD
AC H5
values, power generation, shipbuilding, piep mills, civil
DESCRIPTION constructions, transport industries, etc, OK Flux 10.62L
is designed for single and multiwire procedures for butt
Agglomerated fluoride basic flux for Submerged Arc fillet welds of mild, medium and high tensile steels as
welding, primarily for multi run welding. For highest well as low alloyed steels. Works equally well on DC
demands on impact properties, low temperature tough- and AC current. Single layer and multilayer welding of
ness, strength and CTOD values. Especially suitable for unlimited plate thickness, with impact strength down to
narrow gap welding due to good slag detachability and 40/60OC, when used with an appropriate alloyed wire by
SAW. The weldmetal can be suitably controlled.
113
TYPICAL WELDMETAL PROPERTIES
Welding Consumables
PACKING: OK FLUX 10.62 L is packed in plastic lined paper bags containing 25 kg.
An agglomerated high basic non-alloying flux for GRAIN SIZE: 0.2-1.6 mm (10 x 65 mesh)
SAW HYDROGEN: Max 5ml/100g of weldmetal (redried flux)
Classification AWS A5.17: F7A2-F6P2-EL8 REDRYING: 300 +/- 25OC / 2-4 hrs
F7 A4-F7P4-EM12K
F7A4-F7P4-EH14 APPROVALS: LRS, IRS, ABS, DNV, CE, DB, NAKS/
AWS A5.23 F8 A2-EA2-A4/F7P0 HAKC
EA2-A4
APPLICATIONS
Flux Classification : EN 760 SA AB 1 67 AC H5
For general constructions, pressure vessels, ship build-
DESCRIPTION ing, pipe mills, wind tower production, transport indus-
tries, etc. Designed for single and multi wire procedures
Agglomerated aluminate-basic flux for Submerged Arc for butt and fillet welds. Suitable for DC and AC welding.
Welding. General purpose flux with excellent welding Single layer and multilayer welding of unlimited plate
performance suitable for all kinds of steels. High impact thickness.
toughness values. Fits to a large range of SAW Wires.
TYPICAL WELDMETAL PROPERTIES
Chemical Composition (%) Mechanical Properties
OK Flux Yield Stress Tensile EI. Impacts Values
10.71 / OK C Mn Si Mo N/mm2 N/mm 2
(%) Charpy V Notch
Autrod J Temp (OC)
12.08 L 0.08 1.05 0.5 - 400 500 32 80 -29
12.22 L 0.08 1.5 0.5 - 440 530 30 50 -40
12.40 L 0.09 2 0.45 - 460 540 28 40 -40
12.24L 1.4 0.45 0.5 530 590 38 30 -40
PACKING: OK FLUX 10.71 are packed in plastic lined paper bags containing 25 kg.
114
OK FLUX 10.71L BASICITY INDEX: 1.5
Welding Consumables
An agglomerated basic slightly Si and moderately GRAIN SIZE: 0.2-1.6 mm
Mn alloying flux for SAW Hydrogen : Max 5ml/100g of weldmetal (redried flux)
Classification AWS A5.17: F7A2-F6P2-EL8 REDRYING: 300 +/- 25OC/2-4 hrs
F7 A4-F7P4-EM12K
F7A4-F7P4-EH14 APPROVALS: LRS, IRS, ABS, DNV, RDSO, F1, F2,
AWS A5 23: F8A2 - EA2-A4/F7P0-EA2-A4 F4, NPC, IBR
Fluck Classification EN 760 SA AB 67 AC H5 APPLICATIONS
DESCRIPTION For general constructions, pressure vessels, ship build-
ing, pipe mills, wind tower production, transport indus-
Agglomerated aluminate - basic flux for Submerged Arc tries, etc. Designed for single and multi wire procedures
Welding. General purpose flux with excellent welding for butt and fillet welds. Suitable for DC and AC welding.
performance suitable for all kinds of steels. High impact Single layer and multilayer welding of unlimited plate
toughness values. Fits to a large range of SAW Wires. thickness.
TYPICAL WELDMETAL PROPERTIES
Chemical Composition (%) Mechanical Properties
OK Flux Yield Stress Tensile EI. Impacts values
10.71 L C Mn Si Cr Ni Mo N/mm2 N/mm2 (%) Charpy V Notch
OK Autrod J Temp (OC)
12.08L 0.06 1.05 0.5 - - - 405 500 32 80 -29
12.22L 0.08 1.5 0.5 - - - 440 530 30 50 -40
12.40L 0.07 2 0.45 - - - 460 540 28 40 -40
12.24L 0.07 1.4 0.45 - - 0.5 530 590 38 30 -40
PACKING: OK FLUX 10.71 L are packed in plastic lined paper bags containing 25 kg.
115
OK FLUX 10.81LM BASICITY INDEX: 0.65
Welding Consumables
PACKING: OK FLUX 10.81 LS is packed in plastic lined paper bags containing 25 kg.
116
OK FLUX 10.92L BASICITY INDEX: 0.88
Welding Consumables
An agglomerated neutral chromium alloying flux for GRAIN SIZE: 0.2-1.6 mm
welding of stainless steel
REDRYING: 300OC/2 hrs
Classification EN 760 SACS2Cr DC
APPROVAL: NPC
DESCRIPTION
TYPICAL APPLICATIONS
OK FLUX 10.92L is a chromium alloying agglomerat-
ed flux specially designed for butt welding of stainless OK FLUX 10.92L is especially suitable for butt welding
steels. The chromium alloying effect from OK FLUX of stainless steels and for strip cladding with stainless
10.92L compensates for the chromium losses in the steel strips. Strip cladding can be carried out with strips
arc during welding. It is also excellent for strip cladding of up to 100 mm in width. Due to the Chromium com-
with stainless steel strips. The strip cladding process is pensating effect of the flux, the typical weldmetal com-
stable over a wide range of currents and speeds. Very position is close to the chemical composition of the wire
smooth overlapping between adjacent beads giving an used.
outstanding aesthetic as well as mechanical finish. Di-
rect current and positive polarity give maximum flexibil-
ity when choosing welding parameters.
TYPICAL WELDMETAL PROPERTIES
Chemical Composition (%) Mechanical Properties
OK Flux Yield Stress Tensile EI. Impacts values
10.92/ C Mn Si Cr Ni Mo N/mm2 N/mm2 (%) Charpy V Notch
OK Autrod J Temp (OC)
16.10 0.025 1.8 0.6 20 10 - 365 580 35 40 -196
16.30 0.025 1.8 0.6 19 12 2.7 385 580 32 55 -60
16.53 0.025 1.8 0.4 24 13 - 440 600 35 110 -60
16.11 0.025 1.75 0.7 19 9.8 Nb=0.7 440 650 32 70 -60
16.13 0.1 1.7 0.4 26 21 - 310 540 35 60 -196
PACKING: OK flux 10.92L is packed in plastic lined paper bags containing 25 kg.
117
Strip Cladding Consumables
OK BAND/FLUX FOR ity and restricted dilution rates are required, electroslag
Welding Consumables
Notes:
1) Other types of strips also available on demand.
2) OK 10.05,10.10 Flux is to be redried at 300-305°C for 2 hrs. before use.
3) Typical Weldmetal composition is available on demand.
4) OK Band 309L ESW together with OK 10.10 produces 308L type weld deposit (single layer).
5) OK Band 309L Nb ESW together with OK 10.10 produces 347 type weld deposit (single layer).
6) OK Band 309L Mo ESW together with OK 10.10 produces 316L type weld deposit (single layer).
118
Hard Surfacing Consumables
WIRE & FLUX COMBINATIONS FLUXES
Welding Consumables
Wires and Fluxes for overlaying by SAW ESAB AGGLOWELD HFG and AGGLOWELD HFG are
agglomerated basic fluxes designed for hardsurfacing
DESCRIPTION applications by providing necessary alloying elements
to the weld deposit. ESAB AGGLOWELD HFG Weld-
ESAB hardsurfacing Consumable are ideal for surfacing metal is a tough machinable alloy resisting compressive
components that are worn-out or to resist wear against load, without micro fissuring and also has resistance to
abrasion and impact with work hardening properties. fatigue and impact. ESAB AGGLOWELD HFS can pro-
duce deposits of higher hardness with suitable wire.
WIRES
TYPICAL APPLICATIONS
ESAB WRAS has the following composition. OK
AUTOROD 12.08L and 12.40L could also be used. Suitable for overlaying of scraper blades, cane cutting
knives, bucket body, chutes, guides, plough shear, cam
TYPICAL WIRE COMPOSITION (%) WRAS
rollers, gate valve seats, road graders, roll reclamation,
C Mn Si Cr S P crane wheels, earth moving equipment, crusher equip-
ment etc. Suitable for building of machine components
0.35 1.5 0.5 1 0.03 0.03 such as cams, gears, splines, sprockets, railway equal-
izer beams, sugar mill pinions, rims, tractor sprockets,
gear teeth, wobblers, pump shafts, crane wheel, pulley
brakes, cable drums skid wheels pulley brakes, track
rollers, Crane wheels, ditcher rolls etc.
119
Consumables for Ni Steels
9% Ni STEELS FOR LNG TANK FABRICATION
Welding Consumables
DESCRIPTION
LNG Storage tanks are usually fabricated from 9% Ni steels to provide a combination of properties at a reasonable
price. Quenched & tempered 9% Ni Steels has excellent low temperature properties and is not susceptible to under
bead cracking or excessive hardening in the HAZ on account of its low carbon. Esab offers a complete range of
proven consumables, which have been used in over 30 global installations.
The tensile strength of the high Nickel alloy Weldmetal is close to that of 9% nickel steels and has high resistance
to brittle fracture, good impact strength at -196°C, lateral expansion, side bend test and yield strength properties.
Special Stainless Steel Consumables are also available for LNG transport tanks and associated piping. Please refer
section on stainless steel consumables elsewhere in this book.
APPLICATIONS
The MMA electrodes are designed to weld on AC, largely to eliminate the magnetic arc blow problem of 9% nickel
steels. SAW is preferred for cicumferential welds and MMA for the vertical welds. Smaller diameter wires (1.6mm)
deliver better impact values. 9% nickel steels can be welded without pre and post weld treatment up to 60 mm, as
per ASME code, OK 92.55 is Preferred, when higher impact values are specified.
*Including Tantalum
120
Consumables for Ni Steels
SMAW
Welding Consumables
Weldmetal Typical Mechanical properties
Classification SFA/AWS A5.11 ENiCrFe-3 Composition (%) of all Weldmetal
DESCRIPTION C 0.03 YS 410 N/mm2
A nickel - based electrode for welding nickel alloys such
Si 0.5 UTS 640 N/mm2
as inconel 600 and similar Inconel alloys, cryogenic
Mn 6.6 EL 40%
steels, martensitic to austenitic steels, dissimilar Cr 15.8 Impact Values +20OC 100J
steels, heat-resistant steels and castings with limited Ni 67 -196OC 80J
Nb 1.7
weldability.
Cu <0.5
WELDING CURRENT: DC+ Ti <0.5
APPROVALS: ABS, SEPROS, UDT. Ta <0.3
Fe 8.8
Welding Parameters
Diameter Length Welding Arc voltage,
(mm) mm Current, A V
2.5 300 45-70 22
3.2 350 70-105 23
4.0 350 90-130 24
5.0 350 120-170 25
121
OK 92.59 TYPICAL WELDMETAL PROPERTIES
Welding Consumables
Welding Parameters
Diameter Length Welding Arc voltage,
(mm) mm Current, A V
2.5 300 50-70 20
3.2 350 60-90 21
4.0 350 80-120 22
122
Consumables for Ni Steels
GMAW
Welding Consumables
Weldmetal Typical Mechanical properties
Classification SFA/AWS A5.14 ERNiCrMo-13 Composition (%) of all Weldmetal
DESCRIPTION C <0.01 YS 550 N/mm2
A continous, solid, Ni-Cr-Mo electrode for welding high-
Si 0.3 UTS 750 N/mm2
alloyed materials of the 20Cr-25Ni type with 4-6% Mo
Mn 2.1 EL 45%
and Ni-based alloys of a similar type. It can also be Cr 66 Impact Values -110OC 120J
welded in combination with carbon steels. The weld Ni <0.3
Mo 29
metal has very good corrosion resistance over a wide
range of applications in oxidising and reducing media.
Welding Parameters
WELDING CURRENT: DC+
Diameter wire feed Welding Arc voltage,
APPROVALS: VdTÜV
(mm) m/min Current, A V
0.8 5-18 70-190 20-27
1.0 6-13 100-200 21-27
1.2 6-10 160-280 24-30
1.6 4-8 200-350 25-32
123
Consumables for Ni Steels
GTAW
124
OK TIGROD 19.85 TYPICAL WELDMETAL PROPERTIES
Welding Consumables
Weldmetal Typical Mechanical properties
Classification SFA/AWS A5.14 ERNiCr-3 Composition (%) of all Weldmetal
DESCRIPTION C <0.01 YS 440 N/mm2
A nickel-based, corrosion - and heat - resistant, 20% Cr,
Si <0.5 UTS 670 N/mm2
3% Mn, 2.5% Nb rod for the GTAW of high - alloyed steel,
Mn 3.0 EL 40%
heat - resistant steel, corrosion - resistant steel, 9% Ni Cr 20 Impact Values +20OC 150J
steels and similar steels with high notch toughness at Ni >67.0 -196OC 100J
Cu <0.5
low temperatures. It is also suitable for joining dissimilar
Ti <0.7
metals of the types mentioned above. OK Tigrod 19.85 Fe <3.0
is usually welded with pure Ar as the shielding gas.
WELDING CURRENT: DC - Welding Parameters
APPROVALS: UDT, VdTÜV Diameter Length Weight of
(mm) mm rods / box, Kg
1.6 1000 5
2.0 1000 5
2.4 1000 5
3.2 1000 5
125
Consumables for Ni Steels
SAW
DESCRIPTION OK Autrod 19.82 - ABS, LR, DNV, BV, GL, RS, CL,
VdTÜV
OK Flux 10.16 is an agglomerated, non-alloying flux for
submerged arc welding. OK Flux 10.16 is specially de- OK Autrod 19.85 - ABS, LR, DNV, BV, GL, RS, CL,
signed for butt welding with nickel based alloyed wire VdTÜV
and cladding with nickel based alloy strips. The well BASICITY INDEX: 2.4
- balanced flux composition minimises silicon transfer
from the flux to the welding metal, thereby minimising
the risk of hot cracking when welding with nickel - based
alloys. OK Flux 10.16 can only be used on DC when butt
PACKING: OK FLUX 10.16 are packed in plastic lined paper bags containing 25 kg.
126
STORAGE AND HANDLING It is recommended not to redry covered electrodes more
than three times.
Welding Consumables
RECOMMENDATIONS FOR THE STORAGE,
REDRYING AND HANDLING OF ESAB COVERED Holding Oven
ELECTRODES. The holding oven is used for intermediate storage to
General Information avoid moisture pick-up in the coating of low - hydrogen
electrodes and acid rutile stainless electrodes. The
All covered electrodes are sensitive to moisture re- electrodes which should be stored in the holding oven
absorption to a greater or lesser degree. Care must be are:
taken during storage and handling to prevent moisture 1. Electrodes that have been redried.
being re-absorbed.
2. Electrodes that have been removed from thier
Storage hermetically - sealed container.
Covered electrodes of any type will pick up moisture 3. Electrodes that are considered to be in good
only very slowly if they are stored under the following condition and are transferred directly from the store
climatic conditions: room after unpacking.
Redrying temperatures and holding times are specified Check if the protective foil still contains a vacuum. If the
on the label and in the product specification. vacuum has been lost, redry the electrodes before use.
The redrying temperature is the temperature in the bulk Cut open the protective foil at one end.
of the electrodes. Do not take out more than one eletrode at a time,
The redrying time is measured from the point at which thereby, ensuring that the remaining electrodes are still
the redrying temperature has been reached. protected inside the package. Put the top back on the
plastic capsule.
Do not stack more than four layers of electrodes in the
Discard or redry electrodes that have been exposed to
redrying oven.
the atmosphere in an opened VacPac® for more than
8 hours.
127
STORAGE AND HANDLING RECOMMENDATIONS l Addition of new flux must be done with the proportion
FOR OK TUBROD / DUALSHIELD / COREWELD / of at least one part new flux to three parts recycled
Welding Consumables
Cored wire should be stored in conditions which prevent Foreign material such as millscale, dross etc. should
the accelerated deterioration of products or packaging. be removed by a suitable system such as sieving.
All cored wires should avoid direct contact with water
or moisture. This could take the form of rain or the Redrying
condensation of moisture on a cold wire. When handled and stored as above, the ESAB
Cored wires must be stored in dry conditions. The relative fluxes can normally be used as they are.
humidity and temperature should be monitored and the If, however, a severe application is considered,
temperature should not fall below the dew point. as given by the applicable material specification,
To avoid condensation, the wire should be kept in the redrying of the flux is recommended.
original packaging and, if necessary, left to warm up to Furthermore, if the flux, due to unfavourable handling
at least the ambient temperature before opening the or storage, has picked up moisture, redrying
package. can return the flux to its original state regarding
Other hydrogen-containing substances, such as oil, moisture.
grease and corrosion, or substances that could absorb
Redrying shall be performed as follows:
moisture must also be avoided on the wire surface.
Agglomerated fluxes : 300 +/- 25OC for about 2-4
Products must be stored in such a way as to avoid
hours.
damage during storage.
Redrying must be done on shallow plates with a
STORAGE AND HANDLING RECOMMENDATIONS
flux height not exceeding 50 mm. Redried flux, not
FOR OK FLUX
immediately used, must be kept at 150 +/- 25OC before
ESAB fluxes, have a guaranteed as-manufactured use.
moisture content from the factories. This moisture content
is well - controlled by internal ESAB specifications. Before
transport, each pallet is shrink wrapped in plastic foil.
This precaution action is done in order to maintain the
as-manufactured moisture content as long as possible.
Flux should never be exposed to direct wetness such
as rain or snow.
Storage
Recycling
128
HANDWELDING ELECTRODES consult BS 5135: 1984 or SS 064025. If the EC dimension
of the plates and heat input are known, these standards
Welding Consumables
Official approval will state whether heating is necessary and the level at
which it should take place.
In addition to the official approval given in this catalogue,
many electrodes are approved by shipping societies, Tension cannot be avoided when welding, as steel
Defence authorities, railway boards, private companies expands when heated, although correct planning and
and so on. Information about the different types of heat treatment can reduce tension considerably.
approval is available on request.
Hydrogen forms from water in the surroundings and from
Tensile properties the electrode coating. The water is divided into oxygen
and hydrogen in the arc and the hydrogen in particular
Unless otherwise stated, tensile properties refer to all has a strong tendency to dissolve in the weld metal and
weld metal test pieces prepared according to the rules initiate cold cracking.
of the classification societies using 4 and 5 mm diameter
electrodes. Conclusion : Dry basic electrodes when there is risk of
cold cracking.
Welding current
Labelling
Maximum and minimum values are given. The most
suitable welding current depends largely on the size The electrode type is clearly marked on the coating of
of the workpiece, the welding position and the type of each electrode near the grip end, e.g. ESAB 36H.
joint.
Cold cracking
2. Sufficient stress
129
GENERAL INFORMATION The evenness of the weld and the smooth transition of
the base material make joints produced with rutile elec-
Welding Consumables
130
Cellulose electrodes
Welding Consumables
Cellulose electrodes are easy to use in all welding posi-
tions and are particularly good for vertical and overhead
welding. Cellulose electrodes are recommended for all-
positional welding where the mechanical properties of
the deposit are of the greatest improtance and radio-
graphic requirements must be met. Vertical and over-
head welding often require an electrode one size larger
in comparison to electrodes with other types of coating.
Cellulose electrodes are extremely good for vertical-
down welding.
131
Approval in accordance with Toughness level
This catalogue provides information about the welding H5, H10, H15 low - hydrogen welding consumables
position, current/polarity, low hydrogen and grading.
DP deep penetration
Non-alloyed and low-alloyed steels
Stainless steel and other high-content alloyed
Consumables are divided into three categories based steels
on their tensile strength level:
Grades of stainless steel for which the welding consum-
Normal stength steel : Indicated by the numbers 1, 2 able is approved are indicated with respect to one or
or 3 (e.g. 3.3M) that the electrode is to be used in steel more of the types of stainless steels : 304L, 304LN,
with a minimum yield strength (ReH) of 305 and a ten- 316LN and so on.
sile strength (Rm) of 400-560 MPa.
The abbreviation SS/CMn indicates approval for joining
High strength Steel : Indicated by 2Y, 3Y, 4Y, 5Y (ReH any of the austenitic types of stainless steel to any ofthe
min 375 and Rm 490-660 MPa) and 2Y40,3Y40, 4Y40 normal strength or higher tensile ship steels. Dup/CMn
(ReH min 400 and Rm 510-690 MPa) indicates approval for joining any of the duplex types of
stainless steel to any of the normal strength or higher
Extra high strength steel : Indicated by 3Y42, 4Y42, tensile ship steels.
5Y42 up to 5Y69 and so on for the different strength
steel categories, where the numbers 42....69 symbolize The system described for grading the consumables in
a yield strength in MPa indicating that the electrodes accordance with the rules of the classification societies
can be used for extra high tensile steels. changes as new steels appear on the market and some-
times there are changes to the approval ratings which
might mean that the handbook may not be currently up-
to date. To ensure that valid information is used, please
request the latest issued Product Data Sheet for the
consumables and / or the latest edition of the “List of
Approved Consumables” and approval certificates from
the most recent annual repeat test.
132
Calculation of electrode consumption
Welding Consumables
In the tables, joint cross section, theoretical joint volume and kg weld metal per metre length of welded joint are given.
The electrode consumption per metre of welded joint is obtained by dividing the number of kg of weld metal by N,
where N is the kg of weld metal per kg of electrode and is given for each electrode on thier respective pages.
1 0 2 0.02
1.5 0.5 3 0.02
2 1 4 0.03
Flat 3 1.5 7 0.05
4 2 17 0.13
5 2 21 0.16
6 2.5 27 0.21
Flat 7 3 36 0.28
1 0 2.5 0.02
1.5 0.5 4 0.03
2 1 5 0.04
Horizontal-Ver tical 3 1.5 9.5 0.07
4 2 22 0.17
5 2.5 25 0.20
6 3 32 0.25
Horizontal-Ver tical 7 3 42 0.33
4 2 9 0.07
5 2 10.5 0.08
6 2.5 13 0.10
7 3 16 0.13
4 2 10.5 0.08
5 2 16 0.13
6 2.5 18 0.14
Overhead 7 3 21 0.16
133
134
Welding Consumables
The first run and backing run V-joints: Weld metal weights
Position Plate thickness Weight/length Electrode diam
mm kg/m mm
Flat 6–12 0.10 3.25
Flat > 12 0.15 4
Vertical > 8 0.15 3.25
Horizontal-Vertical > 8 0.15 3.25
Overhead > 10 0.10 3.25
Calculation of electrode consumption
Corner welds: Actual joint volumes and weld metal weights
Welding Consumables
Plate Section
thickness size
mm mm2 cm3/m kg/m cm3/m kg/m cm3/m kg/m cm3/m kg/m
2 2 3.5 0.03 3 0.02 3.5 0.03 3.5 0.03
3 4.5 7 0.05 7 0.05 7 0.05 7.5 0.06
4 8 9 0.07 9 0.07 9.5 0.07 10.5 0.08
5 12.5 13 0.10 13.5 0.11 14.5 0.11 16 0.13
6 18 18.5 0.15 19.5 0.15 21 0.16 22 0.17
7 24.5 25.5 0.20 26.5 0.21 27.5 0.22 31.5 0.25
8 32 33 0.26 34.5 0.27 36 0.28 40.5 0.32
9 40.5 41.5 0.33 43 0.34 45.5 0.36 51 0.40
10 50 51.5 0.40 53.5 0.42 56 0.44 64 0.50
11 60.5 63 0.49 67 0.53 72 0.57 78.5 0.62
12 72 74.5 0.58 79 0.62 84.5 0.66 93 0.73
15 113 116 0.91 123 0.97 132 1.04 141 1.11
18 162 167 0.31 174 1.37 190 1.49 204 1.60
20 200 206 1.62 206 1.62 227 1.78 252 1.98
22 242 248 1.95 255 2.00 275 2.16 204 2.39
25 323 329 2.58 331 2.60 370 2.90 405 3.18
Throat Section
thickness size
mm mm2 cm3/m kg/m cm3/m kg/m cm3/m kg/m cm3/m kg/m
2 4 5 0.04 6 0.05 5.5 0.04 5.5 0.04
2.5 6.5 7.5 0.06 8.5 0.07 8 0.06 8.5 0.07
3 9 10.5 0.08 12.5 0.10 11 0.09 12 0.09
3.5 12.5 14 0.11 16 0.13 15 0.12 16.5 0.13
4 16 18 0.14 21 0.16 19.5 0.15 22 0.17
4.5 20.5 22.5 0.18 26 0.20 24.5 0.19 26.5 0.21
5 25 27.5 0.22 31.5 0.25 30.5 0.24 33 0.26
5.5 30.5 33.5 0.26 37 0.29 36 0.28 40.5 0.32
6 36 40 0.31 42 0.33 43 0.34 47.5 0.37
6.5 42.5 46.5 0.37 49.5 0.39 51 0.40 56 0.44
7 49 54.5 0.43 57 0.45 56 0.44 65 0.51
7.5 56.5 60.5 0.47 65 0.51 64 0.50 73.5 0.58
8 64 70 0.55 73.5 0.58 76.5 0.60 82.5 0.65
9 81 88 0.69 94 0.74 95 0.75 109 0.86
10 100 108 0.85 114 0.89 116 0.91 130 1.02
11 121 131 1.03 138 1.08 143 1.12 157 1.23
12 144 155 1.22 162 1.27 169 1.33 188 1.48
13 169 179 1.41 190 1.49 195 1.53 220 1.73
14 196 207 1.62 224 1.76 227 1.78 257 2.02
15 225 237 1.86 248 1.95 264 2.07 294 2.31
135
The weight of welding electrodes or welding wire neces-
sary to complete a given weld joint may be calculated by PROCESS DEPOSITION
Welding Consumables
WEIGHT PER UNIT LENGTH OF WELDMETAL Gas Shielded Flux Cored Wires 85%
Calculating the weight of weldmetal requires than we Self Shielded Flux Cored Wires 82%
consider the following items. * Shielded Metal Arc (Stick 300 mm long) 59%
1. Area of cross-section of the weld * Shielded Metal Arc (Stick 350 mm long) 62%
2. Length of the weld * Shielded Metal Arc (Stick 450 mm long) 66%
4. Weight of the weldmetal per cubic centimetre It must be remembered that when deposition tests are per-
formed in the laboratory, the deposition efficiency is calculated
The area of the cross-section (the triangle) in the fillet by the formula:
weld shown below is equal to one half the base times
the height. The volume of the weld is equal to the area Weight of metal deposited
times the length, and the weight of the weld then, is the Deposition Efficiency = Weight of electrode consumed
volume times the weight of the material (steel) per cubic
centimetre. This does not take stub loss into consideration. The
chart below shows how the length of the stub effects the
laboratory-established efficiency.
136
The following tables show the estimated weight of consumables for some of the common weld joints.
Welding Consumables
Fillet Size Weldmetal Weight of electrode/Wire
L (mm) Required Kg/m required per unit length of weld (Kg/m)
SMAW GMAW FCAW Metal
Cored
3 0.04 0.06 0.04 0.05 0.04
5 0.09 0.15 0.10 0.11 0.10
6 0.16 0.26 0.17 0.19 0.17
8 0.25 0.40 0.26 0.29 0.27
10 0.36 0.58 0.38 0.43 0.39
13 0.64 1.04 0.67 0.76 0.70
Horizontal Fillet Weld
16 1.00 1.62 1.06 1.18 1.09
19 1.44 2.33 1.53 1.70 1.57
25 2.56 4.14 2.70 3.02 2.79
137
WElGHT PER METER OF WELDMETAL FOR FILLET WELDS AND ELEMENTS OF COMMON BUTT JOINTS
Welding Consumables
INSTRUCTION
2. Divide the cross-section into right triangles, rectangles and sketch in the desired reinforcement.
3. Dimension the thickness, angles, angle leg length, root opening and the length and height of the reinforcement.
4. Total the weight per meter of each of the elements from the chart for the weight per meter of the weld.
138
DATA SHEETS - PIPE WELDING
Welding Consumables
ESAB Pipe Welding Electrodes
Joint Preparation
The most common steels used for oil and gas cross
country pipelines conforming to API 5 L, 5 LS, and 5
LX.
139
Table 1, shows the chemical requirements to API Stan- Table 1: Chemical requirements
dard 5 LX for the individual line pipe steel grades.
Welding Consumables
140
General recommendations Choice of welding Process
GMAW
Welding Consumables
Short arc or spray arc
GMAW - Gas Metal Arc Welding The electrodes for gas metal arc welding listed in these
pages are suitable for short arc welding in the smallest
The electrodes and joint faces should be clean. This diameters and for spray are welding in diameters 1.2-
is particularly important when welding aluminium and 2.4 mm. Short arc welding (welding with short circuiting
aluminium alloys. The shielding gasses which are used droplet transfer) can be carried out in all positions and
must be of a purity suitable for welding. Moisture in the is the best jprocess for welding sheet material approxi-
gas can produce porous welds. mately 0.8-3 mm thick and for making the root run in
Shielding gas for mild and low-alloy steels prepared butt joints.
Carbon dioxide, CO2, is the cheapest and most com- Spray arc welding (welding with finely divided free flight
monly used gas and, in most cases, it produces satis- drop transfer) is carried out at higher currents and volt-
factory welds in both mild and low alloy steel. ages than short arc welding and is therefore generally
faster and more economical than short arc welding for
Mixed gas, of which the most commonly used consists plate thicknesses exceeding 2 - 3 mm. It is only used
of 80% Ar + 20% CO2, is clearer than pure CO2 but pro- for weldingin the horizontal or horizontal/vertical posi-
duces a softer arc, quieter welding, better bead appear- tions. The gas consumption is 6-10 litres/min for short
ance and less spatter. It is therefore often used, in spite arc welding and 12-20 litres/min for spray arc welding.
of its higher price, for welding sheet steel 0.8-1.5 mm The higher the welding current, the higher the gas flow
thick, which is more difficult to weld with pure CO2. A required.
further advantage of mixed gas is the higher quality, in
particular notch toughness, compared with CO2. For this Welding technique
reason, mixed gas is often recommended for welding The welding gun is normally held in the right hand, which
low-alloy steels, such as creep-resistant steels, even means that the weld is made from right to left with the
in thicknesses greater than 1.5 mm. Mixed gas of the gun directed away from the deposited weld at an angle
80/20 type, in which the argon is of a lower purity, is also of 75-80O between the electrode and the workpiece,
available. These gases are less expensive than those thereby giving the operator a good view of the weld pool
based on pure argon and can often be used with equally and the joint. This produces a smoother weld bead than
good results. if the gun is directed towards the finished weld.
One drawback of argon/CO2 mixtures is that they lead Abbreviations
to increased ozone formation, compared with pure CO2,
when used as shielding gas in arc welding. MIG welding = metal inert gas welding = metal arc weld-
ing in an atmosphere consisting mainly of an inert gas
Another drawback when using the mixture is that the such as argon.
current load capacity of the welding gun is reduced by
about 30% compared with welding with CO2. MAG welding = metal inert gas welding = metal arc
welding in an atmosphere consisting mainly of an inert
Shielding gas for stainless and heat resistant gas such as argon.
steels
MAG welding = metal active gas welding = metal arc
Argon containing 1% oxygen is normally used for weld- welding in an atmosphere consisting of an active gas,
ing stainless and heat-resistant steels, but argon con- usually carbon dioxide. Gas mixtures containing 20% or
taining 2% O2 or 5% O2 is also available. The latter more CO2 are usually classified as active.
produces a more fluid weld pool.A shielding gas which
consists of 98% argon + 2% CO2 has gained favour for
MIG welding stainless steels. It can often replace argon/
helium mixtures, Which are used to help fusion when
welding thick stainless steel, and can very often replace
argon/oxygen mixtures.
141
DATA SHEET - GTAW/GMAW
Solid wire classification for GTAW/GMAW
Welding Consumables
ER 70 S - X
E indicates a filler
wire/rod
x C Mn Si S P Ti Zr AI Cu
2 0.07 0.90 0.40 0.035 0.025 0.05 0.02 0.05 0.5
/1 .40 /0.70 -0.15 -0.12 -0.15
3 0.06 0.90 0.45 0.035 0.025 - - - 0.5
/0.15 /1.40 /0.75
4 0.06 1.00 0.65 0.035 0.025 - - - 0.5
/0.15 /1.50 /0.85
6 0.06 1.40 0.80 0.035 0.025 - - - 0.5
/0.15 /1.85 /1.15
7 0.07 1.50 0.50 0.035 0.025 - - - 0.5
/0.15 /2.00 /0.80
Chemical Compositions are not specified, however requirements shall be agreed to by the
G
purchaser & supplier.
142
GENERAL RECOMMENDATIONS
FCAW as feed rolls and torch consumables. A move to cored
wire MIG/MAG from the use of manual arc will obviously
Welding Consumables
Introduction involve the purchase of new equipment but the undis-
puted increase in productivity will usually guarantee a
In recent years, pressure to increase productivity and return on capital invested in less than one year.
reduce costs has been the main diving force behind the
adoption of flux cored wires by fabricators. Productiv- Deposition
ity, ease of use and quality are the three main virtues
on which the increasing popularity of Flux cored wires The higher deposition rate from cored wires relies upon
rest. the I2R heating effect that is greater than with solid wires,
for a given current.
The welding processes with which flux cored wire must
mainly compete are MMAW and semi automatic weld- With the solid wire the total cross section carries all of
ing with solid wire (MIG/MAG). The superior productiv- the current but with metal cored wires a partial amount
ity and the accompanying improved economics of flux is carried by the core and in the case of flux cored wire
cored wire welding over MMAW are very apparent. all of the current is conducted by the tube. Thereby the
Even at the same duty cycle as MMAW cored wire pro- current density and heating effect ensures a higher
cess can give much higher productivity because it can burn-off rate from cored wires.
operate at much higher current densities.
Economics
143
There are a number of factors to be considered and can for a given wire size will cater to 90% of flat and HV ap-
be summarised as follows: plications. The weld cross-section is controlled by the
Welding Consumables
l Positional Rutile Flux Cored Wires when used with Due to superior sidewall fusion obtained particularly
Argon rich gas offer spray transfer welding with a from the metal cored wires the combined angles of
high level of operator appeal. preparations can generally be reduced. A V-butt joint for
instance that would normally need a 60° included angle
l Basic Flux Cored Wires produce a higher and more for manual arc welding can be reduced to 45° thereby
consistent level of mechanical properties. They saving plate and hence weldmetal to fill the joint.
also produce radiographic standard deposits with
ease when compared to both rutile and metal cored
wires.
OPERATING CONDITIONS
Polarity
144
WELDING TECHNIQUES
Welding Consumables
Torch angles
145
Torch angles and manipulation
Vertical butt-welds
Welding Consumables
A torch angle of 100 above the horizontal may be used for Triangular weaves for single pass fillets. If necessary
root passes to assist arc stability and penetration control. subsequent weld runs should be deposited using
techniques similar to that for Filling vertical butt joints.
No weaving is necessary for single pass fillets when
using OK Tubrod 15.15
Single Pass
146
Travel Speed ing is recommended and this type of wire is eminently
suitable for use with these materials and the speed of
Welding Consumables
Travel speed has an important influence on penetration. welding will be significantly higher.
For example when using a 1.6mm metal cored wire at
305A an increase in travel speed from 30cms/min to Metal Cored (EX1T-G) and Fully Basic (EX1T-5)
60cms/min approximately doubles penetration beyond
the root of a fillet. At speeds in excess of 80/100 cms/ These two groups may be treated as one with regard
min penetration will decrease. Similarly a reduction in to positional welding techniques. To maintain optimum
penetration will occur if the welding speed should fall to control welding is limited to the 1.0mm and 1.4mm sizes
below 30cms/min, as the arc can impinge on the molten and is restricted to the dip transfer mode where greater
welder skill is involved. The manipulation required be
pool in preference to the base material.
similar to that used for solid wire in that initial passes
In addition the use of slow travel speeds should be in the vertical position are completed using a triangular
avoided when low temperature impact properties are re- weave motion.
quired. While the joint may be filled in fewer passes the
This is to ensure that the weld profile remains flat and
individual weld deposits will be of large cross-section
not peaked, which would otherwise occur leading to
and therefore impact resistance will be reduced. Apart
possible lack of fusion defects at the edges after further
from this, in the case of flux cored wires there is the ob-
welding as in the case of multipass joints.
vious difficulty of slag control to be considered.
The conventional straight weave may be used but only
Positional Welding
in circumstances when the face of the previous pass is
The majority of Tubrod cored wires are capable of posi- wide enough such that the effect of heat sink will main-
tional welding in the smaller sizes. However, the choice tain a flat profile automatically.
of consumable must be given careful consideration in Whilst the dip transfer method is slow and often demand-
relation to the proposed applications because the vari- ing in terms of operator concentration the arc energy is
ous ranges require quite different manipulation tech- greater than with solid wire and the possibility of defects,
niques for optimum results. especially cold lapping is substantially reduced.
Rutile (EX1 T-1) Types The root pass in an open butt weld, where full penetra-
tion is required from one side is always the most diffi-
This type of wire allows the use of the spray transfer
cult regardless of welding process or position. However,
mode in all positions including overhead and as such
when using Tubrod metal and basic cored wires the use
affords very high deposition rates. In addition, the ex-
of dip transfer and vertical down welding can be used
ceptional fusion Characteristics that results will have
to good advantage. Excellent results can be achieved
significant effect on the production of defect free welds.
more easily if it is rapid and dispensing with a root face
This is particularly relevant when compared to solid wire
can reduce plate preparation costs.
that by necessity can only be used for positional weld-
ing in the dip transfer mode. The reduced depth of fu- Fillet joints may be welded using either the vertical up
sion involved together with the greater degree of skill or vertical down techniques. The choice will depend on
and concentration demanded will increase the risk of the thickness of material and degree of root penetra-
fusion related defects. Dualshield 7100 LH can achieve tion desired. Multi-pass joints should be completed on
in excess of 4kg/hr in the vertical position compared to a similar basis to that of butt welds using the vertical up
manual arc at approximately 2kg/ hr. technique.
147
Metal cored wire essary to reduce the amount of heat in the weld pool to
accommodate poor fit-up or out of position welding. An
Welding Consumables
Electrode extension increase in the stickout length and the extra electrical re-
sistance that results will produce a cooler less fluid weld
This term describe the distance between the contact tip pool. Similarly any decrease in electrode extension will
of the torch and the work piece, some times described have the effect of increasing welding current and this
as ‘electrode stickout’. The current conditions should be characteristic can be of benefit in controlling penetra-
set for the job in hand but during welding it may be nec- tion; especially where inconsistent fit-up is encountered.
148
When operating with dip transfer an extension of 12 mm
will suffice for most applications whereas spray transfer
Welding Consumables
produces a greater amount of radiated heat and should
have an extension of approximately 20-30 mm.
EXTENSION MM 12 18 25 25
WIRE FEED M/Min 5.8 5.8 5.8 8.4
CURRENT AMPS 350 320 280 350
DEP RATE KGS/HR 4.7 4.7 4.7 6.5
149
DATA SHEET - FCAW
Flux cored wires classification E 71T-X E80T-X
Welding Consumables
x C Mn Ni Cr Mo V AI
Carbon - Molybdenum steel electrodes
A1 0.12 1.25 - - 0.40-0.65 - -
Chromium - Molybdenum steel electrodes
B2 0.05 - 0.12 1.25 - 1.0-1.5 0.40-0.65 - -
B2L 0.05 1.25 - 2.0-2.5 0.90-1.20 - -
B3 0.05 - 0.12 1.25 - 2.0-2.5 0.90-1.20 - -
B3L 0.05 1.25 - 2.0-2.5 0.90-1.20 - -
Nickel steel electrodes
Ni1 0.12 1.50 0.80-1.10 0.15 0.35 0.05 1.80*
Ni2 0.12 1.50 1.75-2.75 - - - 1.80*
Ni3 0.12 1.50 2.75-3.75 - - - 1.80*
Manganese - Molybdenum steel electrodes
D1 0.12 1.25-2.00 - - 0.25-0.55 - -
D2 0.15 1.65-2.25 - - 0.25-0.55 - -
D3 0.12 1.00-1.75 - - 0.40-0.65 - -
All other low alloyed electrodes
K2 0.15 0.50-1.75 1.00-2.00 0.15 0.35 0.05 1.80*
K4 0.15 1.20-2.25 1.75-2.60 0.20-0.60 0.20-0.65 0.03 -
W2 0.12 0.5-1.3 0.4-0.8 0.45 - 0.70 - - Cu = 0.3-0.75
150
Cored Wire Fault Finding POSSIBLE CAUSE REMEDY
REMEDY
Welding Consumables
POSSIBLE CAUSE LACK OF FUSION
Refer to notes on electrode
POROSITY Current too low extension
Insufficient shielding gas Check recommended flow rate Electrode extension too long for Adjust travel speed to suit desired
Excessive electrode extension Reduced extension . refer notes current being used degree of penetration
Replace Incorrect or inconsistent travel Refer to welding techniques
Gas Nozzle too short
speed
Plate condition and impurities Remove non-metallic substances Torch angel or direction of travel Modify preparation
Equipment fault on gas control Check for leaks and air ingestion Narrow joint preparation Modify preparation
151
General recommendations for 3. The arc voltage must be kept constant. Increased
arc voltage results in higher flux consumption. If the
Submerged Arc Welding
Welding Consumables
152
DATA SHEET - SAW
SAW Classification
Indicates a solid
Welding Consumables
electrode
Indicates the minimum tensile
strength of the weldmetal, welded
in accordance with AWS
specifictions.
F X X X - E X X X
Indicates Flux
xxx C Mn Si
Low Manganese Electrodes
EL8 0.10 0.25/0.60 0.07
EL8K 0.10 0.25/0.60 0.10/0.25
EL12 0.04/0.12 0.25/0.60 0.10
Medium Manganese Electrodes
EM12 0.06/0.15 0.80/1 .25 0.10
EM12K 0.05/0.15 0.80/1.25 0.10/0.35
EM13K 0.06/0.16 0.90/1.40 0.35/0.75
EM14K 0.06/0.19 0.90/1.40 0.35/0.75
EM15K 0.10/0.20 0.80/1.25 0.10/0.35
Hi91:1 Manganese Electrodes
EH11 K 0.07/0.15 1.40/1.85 0.80/1.15
EH12K 0.06/0.15 1.50/2.00 0.25/0.65
EH14 0.10/0.20 1.70/2.20 0.10
153
Welding data and joint preparation
Welding Consumables
Typical welding data and recommended joint preparation for submerged arc welding mild steel and carbon-manga-
nese structural steels with OK Flux 10.40, OK Flux 10.47, OK Flux 10.70, OK 10.71, OK Flux 10.72, OK Flux 10.76
and OK Flux 10.81.
154
Typical welding data and for submerged arc fillet welding mild steel and carbon-manganese structural steels with OK
Flux 10.47, OK Flux 10.71 and OK Flux 10.81.
Welding Consumables
Type of joint Plate Wire Throat Arc Welding Welding
thickness diameter thickness voltage current speed
mm mm mm V A cm/min.
Single welding head
≥6 3 3 30–32 500 100
≥8 4 4 30–32 450 60
≥10 4 5 30–32 650 50
≥15 4 – 36 750 45
≥20 4 – 36 750 40
Twin wire
– 2x1.6 4 32 800 120
– 2x2.0 5 34 300 110
Two welding heads + ~
– 4 4 +32 800 140
~38 700
– 4 4 +32 800 140
~38 700
– 4 4 +32 800 140
~38 700
– 4 5 +32 800 90
~35 700
155
Submerged arc welding “18/8” stainless steel. Joint preparation and typical welding data for filler materials OK Autrod
16.10 + OK Flux 10.92, 10.93 and similar OK - combinations.
Welding Consumables
5 10 4 1 34 500 40
2 34 600 50
70° 12 4 1 34 500 35
2 34 600 40
5 14 4 1 34 550 35
2 34 600 35
156
Table 3: Typical welding data for different types of joint OK Flux 10.61 Land 10.62
Welding Consumables
Type of Joint Plate Wire Run Arc Voltage Welding Welding
Thickness mm No. V Current Speed
mm A m/h
6 3 1 29 350 40
3 2 30 425 40
8 3 1 31 450 40
3 2 31 500 40
10 4 1 30 500 40
4 2 30 575 40
12 5 1 30 600 40
5 2 30 650 40
16 5 1 32 750 35
5 2 32 800 35
20 6 1 31 950 23
6 2 32 950 23
25 6 1 31 1000 21
6 2 31 1000 21
30 6 1 31 1000 20
6 2 30 1050 20
35 6 5.1 :1* 30 1050 23
2 32 900 30
6 5.2:1** 30 1100 25
6 2 32 900 30
* First side
** Second side
6.0 5 32 800 30
6.5 5 31 850 30
7.0 5 30 900 30
3.5 4 29 650 60
4.5 4 29 650 50
5.5 4 29 650 40
157
CONSUMABLES GUIDE FOR ASTM STEELS
ASTM Class or Recommended Consumables
Welding Consumables
158
ASTM Class or Recommended Consumables
Welding Consumables
Designation grade SMAW GTAW/GMAW FCAW SAW
159
ASTM Class or Recommended Consumables
Welding Consumables
160
ASTM Class or Recommended Consumables
Welding Consumables
Designation grade SMAW GTAW/GMAW FCAW SAW
A-214/ A-214M ESAB 28, ESAB ESAB MW1, OK Dualshield 7100 OK Autrod
36H Tigrod S2 LH 12.22L, OK Flux
10.71/10.81L
A-216/ A-216M Grade OK 76.18 OK Autrod Dualshield 8000B2 OK Autrod 13.10,
WCA 13.16 OK Flux 10.62
Grade ESAB 98 OK Tigrod / Aris- OK Autrod 13.44,
WCB and torod 13.29 OK Flux 10.62
WCC
A-217/ A-217M Grade OK 74.46 OK Tigrod / Dualshield 7000A1 OK Autrod 13.09,
WC1 Autrod 13.09 OK Flux 10.62
Grade ESAB 98 OK Tigrod / Aris- OK Autrod 13.44,
WC4 torod 13.29 OK Flux 10.62
Grade OK 76.28 OK Tigrod / Dualshield 9000B3 OK Autrod 13.20,
WC5 and Autrod 13.17 OK Flux 10.62
WC9
Grade OK 76.18 OK Tigrod / Dualshield 8000B2 OK Autrod 13.10,
WC6 and Autrod 13.16 OK Flux 10.62
WC11
C5 ESAB KV4 OK Tigrod /
Autrod 13.32
C12 ESAB KV7 OK Tigrod /
Autrod 13.37
C12A ESAB KV7M OK Tigrod / Dualshield B9 OK Autrod 13.35,
Autrod 13.38 OK Flux 10.93
CA15 OK 68.10 OK Tigrod / Arcaloy 409-Ti OK Autrod 410, OK
Autrod 410 Flux 10.92L
A-225/ A-225M Grade C ESAB 118 OK Aristorod Dualshield T-115 OK Autrod 13.43,
and D 13.29 OK Flux 10.62
A-234/ A-234M Grade Ferroweld W2 Dualshield 8100W
WPB,
WPC
Grade OK 74.46 OK Tigrod / Dualshield 7000A1 OK Autrod 13.09,
WP1 Autrod 13.09 OK Flux 10.62
Grade OK 76.18, OK OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
WP12- 76.18 M 13.16, OK Ti- OK Flux 10.62
CL1, grod B2L
WP12-
CL2,
WP11-
CL1,
WP11-
CL2,
WP11CL3
Grade OK 76.28 , OK OK Tigrod Dualshield 9000B3 OK Autrod 13.20
WP22- 76.28M 13.17, OK Ti- and OK Flux 10.62
CL1, grod B3L
WP22CL3
Grade ESAB KV4, ESAB OK Tigrod 13.32
WP5 KV4L
161
ASTM Class or Recommended Consumables
Welding Consumables
162
ASTM Class or Recommended Consumables
Welding Consumables
Designation grade SMAW GTAW/GMAW FCAW SAW
TP309Cb ESAB 309Cb
TP310S OK 67.13
TP316, OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316L Xtra OK Flux 10.92L
TP317, OK 64.30 OK Tigrod 317L Shieldbright 317L
317L Xtra
TP321, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
347, 348 OK Flux 10.92L
TP321H, OK 61.80 OK Tigrod 347H Shieldbright 347 OK Autrod 347H,
347H, OK Flux 10.92L
348H
A-250/A-250M Grade T1, OK 74.46 OK Tigrod / Dualshield 7000A1 OK Autrod 13.09 ,
T1a, T1b Autrod 13.09 OK Flux 10.62
Grade T2, OK 76.18, OK OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
T11, T12 76.18 M 13.16, OK Ti- OK Flux 10.62
grod B2L
Grade OK 76.28 , OK OK Tigrod Dualshield 9000B3 OK Autrod 13.20
T22 76.28M 13.17, OK Ti- and OK Flux 10.62
grod B3L
A-266/A-266M Grade 1 ESAB 36H ESAB MW1, OK Dualshield 7100 OK Autrod 12.40
Tigrod S2 LH and OK Flux 10.71
Grade 2 , OK 76.18 OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
3 and 4 13.16, OK Ti- OK Flux 10.62
grod B2L
A-268/A-268M TP405, OK 68.10 , OK OK Tigrod 410 Arcaloy 409-Ti OK Autrod 410, OK
409, 410 68.15 Flux 10.92L
TP410 OK 68.25 OK Tigrod PZ 6166 / Shield- OK Autrod 16.79,
(UNS S 410NiMo bright 410NiMo OK Flux 10.93
41500)
TP429, ESAB 430 OK Tigrod 430 Arcaloy 436 OK Autrod 430, OK
430 Flux 10.92L
A-276 Type 201, OK 61.50 OK Tigrod 16.10 Shieldbright 308, OK Autrod 16.10,
202, 302, 308L OK Flux 10.92L
304, 308
Type 304L OK 61.30 OK Tigrod 16.10 Shieldbright 308L OK Autrod 16.10 /
OK Flux 10.92L
Type ESAB 304B(N) OK Tigrod
304N, LN 16.10N
Type 309, OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
309S Autrod 16.53 OK Flux 10.92L
Type 310, OK 67.13
310S
Type 314, OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316 Xtra OK Flux 10.92L
Type 317 OK 64.30 OK Tigrod 317L Shieldbright 317L
Xtra
Type 327, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
347, 348 OK Flux 10.92L
163
ASTM Class or Recommended Consumables
Welding Consumables
164
ASTM Class or Recommended Consumables
Welding Consumables
Designation grade SMAW GTAW/GMAW FCAW SAW
Grade 3 ESAB 8016 C2 , OK Tigrod / - OK Autrod 13.27,
and 4 OK 73.79 Autrod 19.81 OK Flux 10.62
Grade 7 Filarc 75S OK Tigrod 13.28 - OK Autrod 13.27,
and 9 OK Flux 10.62
Grade 8 OK 92.45, OK OK Tigrod / - OK Autrod
92.55 Autrod 19.82 ; 19.82/19.85, OK
19.85 Flux 10.16 / 10.90
Grade 10 Filarc 88S OK Tigrod 13.28 Filarc PZ 6138 OK Autrod 13.27,
OK Flux 10.62
A-334/A-334M Grade 1 ESAB 36H(Spl) OK Tigrod Dualshield 7100HI OK Autrod 12.24,
and 6 S2(Spl)/ OK /OK Tubrod 15.19 OK Flux 10.62
Autrod 13.23
Grade 3 ESAB 8016 C2 OK Tigrod / - OK Autrod 13.27,
Autrod 19.81 OK Flux 10.62
Grade 7 Filarc 75S OK Tigrod 13.28 - OK Autrod 13.27,
OK Flux 10.62
Grade 8 OK 92.45, OK OK Tigrod / - OK Autrod
92.55 Autrod 19.82 ; 19.82/19.85, OK
19.85 Flux 10.16 / 10.90
A-335/A-335M Grade P1 OK 74.46 OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 , OK
and P2 Autrod 13.09
Grade P5, ESAB KV4, ESAB OK Tigrod 13.32
P5b, P5c KV4L
Grade P9 ESAB KV7 OK Tigrod 13.37
Grade OK 76.18, OK OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
P11, P12 76.18 M 13.16, OK Ti- OK Flux 10.62
grod B2L
Grade OK 76.28 , OK OK Tigrod Dualshield 9000B3 OK Autrod 13.20,
P21, P22 76.28M 13.17, OK Ti- OK Flux 10.62
grod B3L
Grade ESAB KV7M, OK OK Tigrod 13.38 Dualshiled B9 OK Autrod 13.35,
P91 76.98 OK Flux 10.93
A-336/A-336M F1 OK 74.46 OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 , OK
Autrod 13.09
F3V ESAB KV11
F11 OK 76.18, OK OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
classes 76.18 M 13.16, OK Ti- OK Flux 10.62
2&3, F12 grod B2L
F5, F5A ESAB KV4, ESAB OK Tigrod 13.32 Dualshiled B6
KV4L
F6 OK 68.10 , OK OK Tigrod 410 Arcaloy 409-Ti OK Autrod 410, OK
68.15 Flux 10.92L
F9 ESAB KV7 OK Tigrod 13.37 Dualshiled B9 OK Autrod 13.35,
OK Flux 10.93
F91 ESAB KV7M, OK OK Tigrod 13.38 Dualshiled B9 OK Autrod 13.35,
76.98 OK Flux 10.93
165
ASTM Class or Recommended Consumables
Welding Consumables
166
ASTM Class or Recommended Consumables
Welding Consumables
Designation grade SMAW GTAW/GMAW FCAW SAW
CF8, OK 61.50, ESAB OK Tigrod Shieldbright 308, OK Autrod 16.10
CF8A, 308H 16.10, OK Ti- 308L / 308H, OK Flux
CF8C, grod 308H 10.92L
CF10
CF8M, OK 63.50 OK Tigrod 316H Shieldbright 316, -
CF10M Xtra
CH8, OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
CH10, Autrod 16.53 OK Flux 10.92L
CH20
CK20, OK 67.13 OK Tigrod / Shieldbright 310 -
HK30, Autrod 16.13 Extra
HK40
A-352/A-352M LCA, Ferroweld W2 - - -
LCB, LCC
LC1 OK 74.46 OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 , OK
Autrod 13.09
LC2 OK 73.68 OK Tigrod 13.28 - -
LC2-1 ESAB 120 - - -
LC3 OK 73.79 - - -
LC9 OK 92.45, OK OK Tigrod / - -
92.55 Autrod 19.82 ;
19.85
CA6NM OK 68.00 , OK OK Tigrod 410 PZ 6166 / Shield- OK Autrod 16.79,
68.25, ESAB NiMo bright 410NiMo OK Flux 10.93
410NiMo
A-353/A-353M OK 92.45, OK OK Tigrod / - OK Autrod 19.82,
92.55 Autrod 19.82, 19.85/OK Flux
19.85 10.16, 10.90
A-358/A-358M Grade OK 61.50, ESAB OK Tigrod Shieldbright 308, OK Autrod 16.10
304, 304H 308H 16.10, OK Ti- 308L / 308H, OK Flux
grod 308H 10.92L
Grade OK 61.30 OK Tigrod 16.10 Shieldbright 308L OK Autrod 16.10 /
304L OK Flux 10.92L
Grade ESAB 304B(N) OK Tigrod
304N, LN 16.10N
Grade OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
309S Autrod 16.53 OK Flux 10.92L
Grade ESAB 309Cb
309Cb
Grade OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316, 316L Xtra OK Flux 10.92L
Grade OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
321, 347, OK Flux 10.92L
348
A-369/A-369M FPA, FPB ESAB 28, ESAB ESAB MW1, OK Dualshield 7100 OK Flux 10.81L
36H , OK 48.20 Spl Aristorod 12.50 LH /10.71, OK Autrod
12.08L/12.22L /
12.40L
167
ASTM Class or Recommended Consumables
Welding Consumables
168
ASTM Class or Recommended Consumables
Welding Consumables
Designation grade SMAW GTAW/GMAW FCAW SAW
A-387/A-387M Grade OK 76.18, OK OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
2,12,11 76.18 M 13.16, OK Ti- OK Flux 10.62
grod B2L
Grade 22, OK 76.28 , OK OK Tigrod Dualshield 9000B3 OK Autrod 13.20
22L 76.28M 13.17, OK Ti- and OK Flux 10.62
grod B3L
Grade 5 ESAB KV4, ESAB OK Tigrod 13.32 Dualshield B6
KV4L
Grade 9 ESAB KV7 OK Tigrod 13.37 Dualshield B9 OK Autrod 13.35,
OK Flux 10.93
Grade 91 ESAB KV7M , OK OK Tigrod 13.38 Dualshield B9 OK Autrod 13.35,
76.98 OK Flux 10.93
A-403/A-403M WP/CR OK 61.50 OK Tigrod 16.10 Shieldbright 308 OK Autrod 16.10 /
304, 304N OK Flux 10.92L
WP/CR OK 61.30 , ESAB OK Tigrod Shieldbright 308L, OK Autrod 16.10,
304L 304B 16.10, OK Au- 308L Xtra OK Flux 10.92L
trod 16.10
WP/CR ESAB 308H OK Tigrod Shieldbright 308L OK Autrod 308H,
304H 308H OK Flux 10.92L
WP/CR OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
309 Autrod 16.53 OK Flux 10.92L
WP/CR OK 63.50 OK Tigrod 316H Shieldbright 316,
316, 316N Xtra
WP/CR OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316L, Xtra OK Flux 10.92L
316LN
WP/CR OK 64.30 OK Tigrod 317L Shieldbright 317L
317L, Xtra
317LN
WP/CR OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
321, 347, OK Flux 10.92L
348
WP/CR OK 61.80 OK Tigrod 347H Shieldbright 347 OK Autrod 347H,
347H, OK Flux 10.92L
348H
A-409/A-409M TP304 OK 61.50 OK Tigrod 16.10 Shieldbright 308, OK Autrod 16.10,
308L OK Flux 10.92L
TP304L OK 61.30 , ESAB OK Tigrod Shieldbright 308L, OK Autrod 16.10,
304B 16.10, OK Au- 308L Xtra OK Flux 10.92L
trod 16.10
TP309S OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
Autrod 16.53 OK Flux 10.92L
TP309Cb ESAB 309Cb
TP310S OK 67.13 OK Tigrod 16.13
TP316 OK 63.50 OK Tigrod 316H Shieldbright 316,
Xtra
TP316L OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
Xtra OK Flux 10.92L
169
ASTM Class or Recommended Consumables
Welding Consumables
170
ASTM Class or Recommended Consumables
Welding Consumables
Designation grade SMAW GTAW/GMAW FCAW SAW
A-479/A-479M 302, 304, OK 61.50 OK Tigrod 16.10 Shieldbright 308, OK Autrod 16.10,
304H, 308L OK Flux 10.92L
304N
304L, OK 61.30 , ESAB OK Tigrod Shieldbright 308L, OK Autrod 16.10,
304LN 304B 16.10, OK Au- 308L Xtra OK Flux 10.92L
trod 16.10
309S OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
Autrod 16.53 OK Flux 10.92L
309Cb ESAB 309Cb
310S OK 67.13 OK Tigrod 16.13
316, 316N OK 63.50 OK Tigrod 316H Shieldbright 316,
Xtra
316L, OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316LN Xtra OK Flux 10.92L
321, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
321H, OK Flux 10.92L
347, 348
403, 410, OK 68.10 , OK OK Tigrod 410 Arcaloy 409-Ti OK Autrod 410, OK
414, 405, 68.15 Flux 10.92L
430
A-487/A-487M 11A, 12A, ESAB 118 OK Aristorod Dualshield T-115 OK Autrod 13.43,
16A, 4B, 13.29 OK Flux 10.62
4D, 4E,
8B
8C, 9B, ESAB 120
9D, 10A,
11B, 12B,
13B, 6A,
6B, 7A,
14A, 10B
A-508/A-508M 1, 1A, 2, ESAB 98 OK Tigrod / Aris- OK Autrod 13.44,
3, 2A, 3A, torod 13.29 OK Flux 10.62
4B
4,5 ESAB 118 OK Aristorod Dualshield T-115 OK Autrod 13.43,
13.29 OK Flux 10.62
4A, 5A ESAB 120
A-513/A-513M 1008- Pipeweld 6010R, ESAB MW1, OK Dualshield 7100LH OK Autrod 12.24,
1035 Pipeweld 6010 Tigrod S2 OK Flux 10.71
plus,
A-515/A-515M All ESAB 28, ESAB ESAB MW1, OK Dualshield 7100 OK Flux 10.81L
36H , Pipeweld Aristorod 12.50 LH /10.71, OK Autrod
6010 R, OK 48.20 , OK Tigrod S2 / 12.08L/12.22L /
Spl S2 spcl 12.40L
A-516/A-516M All ESAB 28, ESAB ESAB MW1, OK Dualshield 7100 OK Flux 10.81L
36H , Pipeweld Aristorod 12.50 LH /10.71, OK Autrod
6010 R, OK 48.20 , OK Tigrod S2 / 12.08L/12.22L /
Spl S2 spcl 12.40L
A-517/A-517M All ESAB 118, ESAB OK Aristorod Dualshield T-115 OK Autrod 13.43,
120 13.29 OK Flux 10.62
171
ASTM Class or Recommended Consumables
Welding Consumables
172
ASTM Class or Recommended Consumables
Welding Consumables
Designation grade SMAW GTAW/GMAW FCAW SAW
173
ASTM Class or Recommended Consumables
Welding Consumables
174
ASTM Class or Recommended Consumables
Welding Consumables
Designation grade SMAW GTAW/GMAW FCAW SAW
C ESAB 36H, OK ESAB MW1, OK Dualshield 7100
48.20 Tigrod S2 Ultra
A-724-88 All Esab 118 OK Tubrod 15.24
A727-87 OK 74.46 OK Tigrod 13.09 DS 7000 A1
A737-87 B OK 73.08 OK Tigrod 13.14 OK Tubrod 15.24A
C Esab 118 OK Tubrod 15.27A
A738-87a A Ferroweld W DS 8100W
B&C DS 8100W
B11 OK 76.18 OK Tigrod 13.16 OK Tubrod 15.20
A739-81a
OK 76.28 OK Tigrod 13.17 OK Tubrod 15.22
B22
A-765-87 I OK 73.08 OK Tigrod 13.14 OK Tubrod 15.24
II OK 73.68 OK Tubrod 14.04
175
176
Welding Consumables
–40°C Charpy V
OK 73.08
–60°C Charpy V
Welding Consumables
177
178
Welding Consumables
Welding Consumables
179
180
Welding Consumables
Mild steel Yes Requirements min. yield 375 MPa (55 000 psi) OK Tubrod 14.00S/OK Flux 10.71
stress OK Tubrod 15.00S/OK Flux 10.71
No
No 1.0 Mo 2.25 Cr
–50°C Charpy V
OK Tubrod 15.24S/OK Flux 10.62
OK Tubrod 15.25S/OK Flux 10.62
–60°C Charpy V
6. Wires for stainless steels. Selection by wire classification
EN 10088-1 Designation Werkstoff. No AISI C Cr Ni Mo Other elements MIG OK Autrod TIG OK Tigrod
Austenitic
X10CrNi18-8 1.4310 302 < 0.12 18 8 16.10 16.10
X5CrNi18-10 1.4301 304 < 0.07 18 10 16.10 16.10
X6CrNiTi18-10 1.4541 321 < 0.08 18 11 Ti 0.7 16.11 16.11, 16.10
X6CrNiNb18-10 1.4550 347 < 0.08 18 11 Nb 0.7 16.11 16.11, 16.10
X8CrNiS18-9 1.4305 303 < 0.12 18 9 S 0.2 16.53 16.53, 309L
X2CrNi18-9 1.4307 304L < 0.03 18 10 16.10 16.10
X2CrNiN18-10 1.4311 304LN < 0.03 18 10 N 0.15 16.10 16.10
304N < 0.08 18 9 N 0.15 16.10 16.10
X3CrNiMo17-13-3 1.4436 316 < 0.05 18 12 2.5 16.30 16.30
X5CrNiMo17-12-2 1.4401 316 < 0.05 18 12 2.5
X2CrNiMo17-12-2 1.4404 316L < 0.03 18 12 2.5
X2CrNiMo18-14-3 1.4435 316L < 0.03 18 13 2.5 16.38 16.38
X6CrNiMoTi17-13-2 1.4571 316Ti < 0.08 18 12 2.5 Ti 0.7 318Si, 16.30 318Si, 16.30
X2CrNiMoN17-13-3 1.4429 316LN < 0.03 18 12 2.5 N 0.5 16.30 16.30
X12CrMnNiN 1.4372 202 < 0.15 18 5 Mn 8 16.95 16.95
X2CrNiMo18-15-4 1.4438 S31703 < 0.03 18 16 3.5 317L 317L
X1NiCrMoCuN25-20-5 1.4539 N08904 < 0.03 20 25 4.5 Cu 1.5 385 385
X1CrNiMoCuN20-18-7 1.4547 S31254 < 0.02 20 18 6.2 Cu 0.8, N 0.2 19.81, 19.82 19.81, 19.82
X1NiCrMoCu31-27-4 1.4563 N08028 < 0.02 27 31 3.5 Cu 1.5 19.81, 19.82 19.81, 19.82
- 1.4652 S32654 < 0.02 24 22 7.3 Cu 0.5, N 0.5 19.81 19.81
X9CrNiSiNCe21-11-2 1.4835 S30815 < 0.10 21 11 N 0.17 + Ce 310 310
Austenitic-ferritic (Duplex)
1.4162 S32101 0.03 21.5 1.5 Mn 5 16.86 16.86
X2CrNiN23-4 1.4362 S32304 < 0.03 23 4 N 0.10 16.86 16.86
X2CrNiMoN22-5-3 1.4462 S31803 < 0.03 22 5 3 N 0.10 16.86 16.86
X2rNiMoN25-7-4 1.4410 S32750 < 0.03 25 7 4 N 0.25 16.88 16.88
X2CrNiMoCuWN25-7-4 1.4501 S32760 < 0.03 25 6 3 N 0.25 W 0.7 16.88 16.88
Welding Consumables
181
182
Welding Consumables
EN 10088-1 Designation Werkstoff. No AISI C Cr Ni Mo Other elements MIG OK Autrod TIG OK Tigrod
Ferritic-martensitic
X6Cr13 1.4000 403 < 0.08 13 16.10 16.10
X2CrNi12 1.4003 S41050 < 0.03 12 0.7 16.10 16.10
X12Cr13 1.4006 410 0.1 13 16.53 16.53
Ferritic
X6Cr17 1.4016 430 < 0.08 16.5 430Ti, 430LNb, 16.10 430Ti, 16.10
16.10 16.10
X6CrTiNb18 1.4509 441 < 0.03 18 Ti, Nb 430Ti, 430LNb 430Ti
X6CrTi17 1.4510 439 < 0.8 17 Ti 430Ti 430Ti
X2CrMoTi18-2 1.4521 S44400 < 0.03 18 2 16.30 16.30
- - 446 < 0.20 26 16.13 16.13
7. The most common fluxes and wires for SAW of stainless steels
European standard German DIN 17440 England France SS USA Recommended SAW
EN 10082-1 AFNOR steel AISI consumables
Designation No Designation Werkst. BS 970; NFA 35-572 to No OK Flux + OK Autrod
steel steel Nr. 1=Part 1 NFA 35-578
BS 1449;
2=Part 2
X 6 Cr 13 1.4000 X 7 Cr 13 1.4000 403 S 17 Z 6 C 13 2301 403 10.92L+16.10 or 308H/10.92L+16.10
X 12 Cr 13 1.4006 X 10 Cr 13 1.4006 410 S 21 Z 12 C 13 2302 410 10.92L+16.10 or 308H/10.92L+16.10
X 20 Cr 13 1.4021 X 20 Cr 13 1.4021 420 S 37 Z 20 C 13 2303 420 10.92L+16.10 or 308H/10.92L+16.10
X 30 Cr 13 1.4028 X 30 Gr 13 1.4028 420 S 45 Z 30 C 13 2304 – 10.92L+16.10 or 308H/10.92L+16.10
X 6 Cr 17 1.4016 X 6 Cr 17 1.4016 430 S 17 Z 8 C 17 2320 430 10.92L+16.11 or 308H/10.92L+16.10
X 17 Cr Ni 16-2 1.4057 X 20 Cr Ni 17 2 1.4057 431 S 29 Z 15 CN 16.02 2321 431 10.92L+16.11 or 10.92L+16.11
– 1.47491) – Z 10 C 24 2322 446 10.92L+16.13
X 8 Cr Ni Mo 27 5 21) 1.44601) – – 2324 329 10.92L+2209 or 2509/10.94+2509
X 2 Cr Ni N 23-4 1.4362 – – 2327 S32304 10.92L+2209 or 2509/10.94+2509
X 2 Cr Ni Mo N 22-5-3 1.4462 – – 2377 S31803 10.92L+2209 or 2509/10.94+2509
X 2 Cr Ni Mo N 25-7-4 1.4410 – – 2328 S32750 10.94+2509
X 2 Cr Ni Mo Ca WN 25-7-4 1.4501 – – – S32760 10.94+2509
X 10 Cr Ni 18-8 1.4310 – – 302 S 31 Z 10 CN 18.09 2331 302 10.92L+16.10 /10.92L+16.10
X 5 Cr Ni 18-10 1.4301 X 5 Cr Ni 18 10 1.4301 304 S 31 Z 6 CN 18.09 2332 304 10.92L+16.10 /10.92L+16.10
X 5 Cr Ni 18-10 (1.4301) (X 5 Cr Ni 18 10) (1.4301) (304 S 15) (Z 6 CN 18.09) 2333 (304) 10.92L+16.10 /10.92L+16.10
X 6 Cr Ni Ti 18-10 1.4541 X 6 Cr Ni Ti 18 10 1.4541 321 S 31 Z 6 CNT 18.10 2337 321 10.92L+16.11 or 10.92L+16.11
X 6 Cr Ni Nb 18-10 1.4550 X 10 Cr Ni Nb 18 10 1.4550 347 S 31 Z 6 CNNb 18.10 2338 347 10.92L+16.11 or 10.92L+16.11
X 3 Cr Ni Mo 17-13-3 1.4436 (X 5 Cr Ni Mo 17 13 3) 1.4436) (316 S 33) (Z 6 CND 17.12) 2343 (316) 10.92L+16.30 or 10.92L+16.30
X 5 Cr Ni Mo 17-12-2 (1.4401) (X 5 Cr Ni Mo 17 12 2 (1.4401) (316 S 31) (Z 6 CND 17.11) 2347 (316) 10.92L+16.30 or 10.92L+16.30
X 2 Cr Ni Mo 17-12-2 1.4404 X 2 Cr Ni Mo 17 13 2 1.4404 316 S 11 Z 2 CND 17.12 2348 316 L 10.92L+16.30 or 10.92L+16.30
X 6 Cr Ni Mo Ti 17-12-2 1.4571 X 6 Cr Ni Mo Ti 17 12 2 1.4571 320 S 31 Z 6 CNDT 17.12 2350 316 Ti (10.92L+16.30) or (10.92L+16.30)
X 2 Cr Ni 18-9 1.4307 X 2 Cr Ni 18 10 1.4306 304 S 11 Z 2 CN 18.10 2352 304 L 10.92L+16.10 or 308H/10.92L+16.10
X 2 Cr Ni Mo 18-14-3 1.4435 X 2 Cr Ni Mo 18 14 3 1.4435 316 S 3 Z 2 CND 17.13 2353 316 L 10.92L+16.10 or 10.92L+16.10
(EN 10095) 1.4845 X 12 Cr Ni 25 211) 1.48451) (310 S 24) (Z 12 CN 25-20) 2361 310 S 10.92L+310
X 8 Cr Ni 25-21
X 2 Cr Ni Mo 18-15-4 1.4438 X 2 Cr Ni Mo 18 16 4 1.4438 – Z 2 CND 19.15 2367 317 L 10.92L+317L or 10.92L+317L
X 2 Cr Ni N 18-10 1.4311 X 2 Cr Ni N 18 10 1.4311 – Z 2 CN 18.10 Az 2371 304 LN (10.92L+16.10) or (10.92L+16.10)
X 2 Cr Ni Mo N 17-13-3 1.4429 X 2 Cr Ni Mo N 17 13 3 1.4429 – Z 2 CND 18.10 Az 2375 316 LN (10.92L+16.30) or (10.92L+16.30)
1) not standard
Welding Consumables
183
9. MIG and TIG wires for aluminium
Welding Consumables
Base material
184
CHOOSE THE CORRECT OK OK 68.81 and OK 68.82 - austenitic - ferritic
Welding Consumables
OK 92.18, OK 92.58, OK 92.35 - non-ferrous.
The conditions to be considered when choosing the cor- 3. Working conditons for the repaired workpiece
rect electrode, wire and flux for hardfacing and mainte-
nance are summarised in the following outline. a) Type of wear : abrasive, erosive or cavitation
A classification of weld metal resistance to different To resist abrasive wear by sharp - edged blast
kinds of working condition can be found in Table 1. stone and ore, a hard surface or a work-harden-
ing surface is required or desirable.
The working conditons for an object that is going to be
repaired are often known. The table provides informa- Recommended:
tion about suitable electrodes and the different kind of OK 84.78, OK 84.80
attack which must be taken into account.
OK 84.58, OK 83.65
The recommended OK electrodes, wires and fluxes for
some of the most common objects for hardfacing and OK 86.28, OK 86.08
maintenance by welding can be found in Table 2.
To resist erosive wear, a hard surface and a
Short rules for choosing the correct type of weld fine-grained microstructure in the weld metal is
metal alloy for hardfacing and cladding required.
With regard to: Recommended :
1. Type of wear OK 84.80
2. Working conditons OK 84.78
3. Machinability requirements OK 85.65, OK 84.58
Useful information when choosing the correct type of OK 83.65
alloy
OK 84.52
1. The compositon of the material to be welded when
deciding. Cavitation attacks in water turbines can usually
be prevented by cladding with austenitic elec-
a) Which types of welding alloy are usable and trodes.
suitable
OK 63.35 is the most frequently - used elec-
b) If preheating is favourable trode for this purpose, but the following are also
suitable :
c) If welding a buffer layer is necessary
OK 67.70, OK 67.71
2. Conditions for welding
4. Environment
a) Is preheating possible or not?
a) Corrosive or non-corrosive?
If it is not possible, hardenable welding alloys
can only be used to a very limited extent. b) The temperature, high or low?
For steel and cast iron weldments: c) To resist wear in a corrosive environment, the
weld metal must be resistant to both corrosion
austenitic or non-ferrous alloys are preferable: and wear. So, depending on the severity of the
OK 67.45, OK 67.75 - austenitic corrosion attacks, an alloy with some degree of
corrosion resistance is required.
185
Reclamation Consumables
Reclamation Consumables
Conventional Hardfacing Alloys
BUFFERING
Buffer layers are used as intermediate deposits between
the base material and the actual hardfacing weldmetal
so that the following aspects are taken care of:
l Good bonding with the base material
l Spalling in subsequent hard layers is avoided In case of hardfacing with very hard and brittle alloys like
l Prevention of cracks or relief checks from the the ones containing chromium carbides or with cobalt
hardfaced layers running into the base material based alloys, there should be a buffering by an austen
itic consumable for one or two layers. The compression
stresses generated in the subsequent hard layers dur
Reclamation Consumables
ing cooling are thus accommodated, reducing the risk of
cracks in the hard weld metal.
The “relief checks” present in many hardfacing depos
its can propagate into the base metal under heavy im
pact or flexing. High strength steels are most prone to
such crack propagation. This is prevented by applying a
tough buffer layer.
BUILD-UP LAYERS
In case of heavy wear, the component has to be built-
up to its original dimensions. But hardfacing layers are
Generally, austenitic consumables are widely used as limited to 2-3 layers. In that case, a similar type of alloy
ductile buffer layers in hardfacing applications. The can be used to build it up before applying the hardfacing
choice of consumables depends on the base material deposit. Otherwise, alternate layers of hard and ductile
and the type of hardfacing alloy given the wear factors. deposits can be made finishing off with the hard layer.
The hardfacing layer tends to sink under high load con E.g. hammers, crushers, cold shearing tools, and exca
ditions if the base material is a soft one like mild steel. vator teeth.
This can result in the hardfacing layer spalling off. A
tough and strong buffer layer is applied to prevent this
occurence.
189
DUROID 250 tion of all worn out carbon steel parts requiring subse
quent matching. Other applications are pump housing,
Machinable Build-up Prior to Hardfacing rail ends (medium Mn steel) for railways and tramways,
A smooth running rutile coated general-purpose harcl forging dies, wheels, axles, and couplings.
facing electrode, depositing a tough air-hardening al Suitable for use as a supporting buffer between a top
loy weld metal, suitable for resisting moderate friction, layer of harder weld metal and a soft mild steel base.
abrasion and impact. Recommended for hardfacing components and ma
ALLOY BASE chine parts, which must be easily machinable after
hardfacing.
Fe, Cr, Mn
PROPERTIES
SPECIAL FEATURES
Hardness : 24-27 HRC
l Smooth arc with low spatter.
190
DUROID 650B l Smooth arc with low spatter.
l It is very ea$y to use in all positions. · Excellent weld
No-Problem Abrasion Resistance even for Thicker bead appearance.
Plates APPLICATIONS
A high alloyed basic hardfacing electrode depositing Coal cutter blades, rock drills, drill bits, oil expeller
a nonmachinable air-hardening weld metal. The weld worms, cane & bamboo cutting knives, excavator teeth,
deposit is resistant to severe abrasion and moderate hot & cold punching dies, bucket lips, dipper teeth,
impact between metal to mineral wearing stresses. It impellers, muller ploughs, chutes, conveyors, shears &
also resists scaling upto temperatures around 300°C croppers, pulping knives, ploughshares, road graders,
and also moderate corrosion. crusher hammers, caterpillar treads & shoes, etc. This
Apart from applications on mild and medium carbon electrode is specially recommended for applications
steels Duroid 650B, being basic coated, can also be involving metal to mineral wear.
used over high carbon and alloy steel base metals and PROPERTIES
on jobs of thicker cross-section. Requirement of pre-
heat can be lowered or avoided altogether to obtain weld Hardness : 57-59 HRC
deposit free from cracks, porosity and slag inclusions CURRENT RANGE : (AC 70, DC+/-)
Reclamation Consumables
when normal welding practice for basic coated electrode Size Length Current Range
is followed. (mm) (mm) (Amp)
ALLOY BASE
3.15 450 100-140
Fe, Cr, Mn, Mo, V 4.00 450 120-180
SPECIAL FEATURES 5.00 450 160-250
l Can be used on thicker sections without the need of
buffering.
DUROMANGAN steels.
ALLOY BASE
Work Hardening for Extreme Impact and Abrasion Fe, Mn, Ni, Cr
A basic coated electrode depositing an austenitic SPECIAL FEATURES
manganese steel weld metal. The deposit is highly
l Build-up is free from cracks (with proper welding
resistant to heavy impact and abrasion. The deposit is
work hardenable. The electrode is recommended for procedure).
surfacing of worn-out austenitic manganese steel parts.
It can also be used to give impact protection on carbon (Contd...)
191
l Superior arc stability than available grades of Mn l 14% Mn steel should never be preheated for
Steel electrodes. welding.
l It is very easy to use in all positions. l Welding should be done in stringer beads directing
APPLICATIONS the arc towards the weld pool keeping the heat input
to the base metal minimum. Skip welding/back step
Austenitic manganese steel components, crusher jaws,
welding can also be adopted.
crusher hammers, crusher mantles, dredger bucket
teeth, cement grinder rings, manganese steel railway l The weld bead can be peened with ball pen hammer
points & crossings, manganese steel components used immediately after welding.
in the mining industry. l Quenching has no adverse effect on welding and
192
Low Heat hardfacing Alloys
HARDFACING non-metallic particles. Abrasion may be
classified into three types:
Hardfacing involves protecting parts exposed to different a) Gouging abrasion: This class of
types of wear in order to obtain a certain specific wear abrasion involves the removal of
resistance. sizable particles from a metallic surface
Hardfacing is primarily used to restore worn out parts by the action of a coarse material.
back to usable condition in order to extend their The high pressure and impact cause
service life but it can be successfully employed in new the particles to cut into the surface
component manufacture as well. This technique will help and produce large gouge marks and
in manufacturing a component from cheaper material scratches. Eg. shovel diggers, chute
with a wear resistant overlay providing the surface impact areas, pulveriser mills.
properties. b) Low stress abrasion: This form of wear
A higher hardness level does not necessarily imply results from the sliding action of free
improved wear resistance or longer life. The effectiveness moving hard particles along a surface.
of any hardfacing alloy depends of its suitability in the Material is removed by scratching or
Reclamation Consumables
operating conditions. micro-machining process. Eg. chutes,
mineral conveyors.
So the appropriate hardfacing alloy has to be selected
considering the following aspects: c) High stress abrasion: It occurs where
abrasive particles are forced between
l the wear factors
two metal parts and crushed under
l the base material of the component heavy loads. The wear involves
surface damage accompanied by
l the surface finish required
plastic deformation. Eg. rock drills,
l the process to be used scraper blades, ball mills.
WEAR FACTORS Erosion This wear is similar to abrasion but the
particles are carried by a fluid stream like
Wear factors are the action of different agents on
water, steam, etc., generally at a higher
the metallic surface leading to degeneration and
velocity compared to low-stress abrasion.
disintegration of the metal. A number of wear factors
Eg. slurry transport systems, shot blasting
exist, which act individually or in combination. The weld
equipment.
metals have to be selected properly to counter these
factors effectively. Cavitation When a liquid is subjected to rapid changes
of pressure, vapour or gas bubbles form in
The major types of wear factors are as follows:
the lower pressure regions of the liquid.
Friction Wear from metal parts that roll or slide Entering high pressure areas at any metal/
against each other. It accounts for 15% of liquid interface, these bubbles collapse and
the total spectrum of industrial wear. This the immense force causes cyclic stress
type of wear is likely to be most severe and fatigue on the metal surface. E.g. ship
when parts rub together under load with propellers, pump impellers.
little or no lubrication. Generally, contact
Heat When metals are exposed to high
between surface materials of the same
temperature for long periods, they lose
hardness will result in excessive wear. E.g.
their durability mainly due to thermal fatigue
shafts against bearing surfaces, chain links
cracking. Moreover, the metals tend to
against a roll, sprockets, steel mill rolls.
lose their strength and hardness at higher
Impact The sudden action of a very large force temperatures. These factors add up to
for a very short time period gives rise to wear. Eg. hot forging dies, extrusion dies,
wear after some time. The mechanism stamping dies, sinter crushing equipment.
is attributed to fatigue failure that has an
Corrosion It involves reaction between a metallic
incubation period prior to the appearance of
surface and a corrosive environment
surface damage. E.g. crusher rolls, impact
whence the former is dissolved away
hammers, railway points and crossings.
leading to wear. In the presence of
Abrasion About 50% of all industrial wear is abrasion any mechanical force, the corrosion
in different forms. The wear takes place products may be removed leading to
when metal is removed from a surface virgin surface coming in contact with the
by the cutting or gouging action of hard
(Contd...)
193
corrosive environment again causing checks”, which are formed across the bead as the bead
continued wear. E.g. valves, seating rings, releases the stress generated while the hard weld metal
screw conveyors. cools. These relief checks are not harmful to the deposit
but may propagate into the base metal if the component
Oxidation In an oxidizing atmosphere, possibly
is subjected to heavy impact or flexing.
aided by high temperatures, the metal
surface builds .uP an oxide layer, which So, the issues of acceptability of relief checks and fin
is mostly brittle in nature. This may break ishing requirements should be addressed to when the
due to expansion and the entire oxidation hardfacing deposit is decided.
operation is repeated. E.g. blast furnace WELDING PROCESSES
parts, exhaust valves of internal combustion Shielded Metal Arc Welding : Covers the widest range
engines, hot working shears. of weld metals
BASE MATERIAL is a versatile process for
The two main groups of base materials for hardfacing on - site repairs and out-
are: of-position work
l Carbon or low-alloy steels: These steels require is inexpensive
Reclamation Consumables
preheating, post-weld heat treatment, slow cooling Flux - Cored Arc Welding : the same range of alloys
for hardfacing according to the chemical composition available as in case of
and the section thickness. The general guidelines coated electrodes
for preheating are given at the end of this section. on-site use is possible
l Austenitic manganese steels: These steels should self-shielded wires do
be welded without any preheating or post-weld heat not require any additional
treatment at all. The interpass temperature should shielding gas
be kept as low as possible.
high deposition rate
SURFACE FINISH
Submerged Arc Welding : high deposition rate
The surface finish requirements must be kept in mind
no spatter loss
while selecting the hardfacing alloy as they cover the
entire range from easily machinable to non-machinable. product range limited
Additionally, many of these deposits will contain “relief positional welding not
possible
194
RECOMMENDED PREHEATING TEMPERATURES IN OC
This chart is given as an indicative guide
Base Plate Steel Low alloy Tool steel Cr-steel Cr-steel Stainless 14% Mn
Material thickness 5-12% Cr >12% Cr steel steel
Filler (mm) <90 HRB 95 HRB- 30-43 HRC 32-51 HRC 95 HRB- -96 HRB 25-51
material 30 HRC 30 HRC HRC
Low-alloy Steel 20 N 100 150 150 100 N N
Reclamation Consumables
20-60 N 150 200 250 200 N N
Stainless Steel 20 N N N N N N N
Mn Steel 20 N N N X X N N
20-60 N N *100 X X N N
20 HRC 60 N N *100 X X N N
N = Not necessary
L = Preheating when large areas are surfaced
X = This combination is not used
195
ASTRÄ HTB l Oxidation resistance retained upto 1100OC.
APPLICATIONS
Resistance to Corrosion, Cavitation and Erosion Joining and surfacing of hydel turbine blades, valve seats,
Astra HTB is the only machinable alloy that resists pump casings, gates, key-ways, machine components
corrosion, cavitation alongwith erosion by suspended exposed to corrosive atmosphere, matching parts
particles on the strength of the unique recipe of this for which shape retention in service is of paramount
electrode. The alloy also shows great resistance to importance.
deform in service and hence maintains shape and PROPERTIES
angularity of the original machined component at room
temperature and also upto 700°C. UTS : 85-90 kg/mm2
Astra HTB endures in high temperature service as Elongation : 18-24%
well. It offers best combination of machinability, friction Hardness : 42-45 HRC
and fatigue resistance, and shape retention at high CURRENT RANGE : (AC 70, DC+/-)
temperature. Size Length Current Range
ALLOY BASE (mm) (mm) (Amp)
Reclamation Consumables
196
OK SELECTRODE 83.40 l Smoothest running electrode of its class.
l Low tendency to moisture absorption.
Infinite Fissure-Free Build-up for Impact Loading l Marginal work hardening.
A smooth running touch welding low heat input electrode APPLICATIONS
depositing a tough air hardening machinable multi-al
loyed weld metal for low stress abrasion and good im Hammers, wobblers, railway equalizer beams, crane
pact. wheels, excavators, sprockets, rollers, pump shafts, gear
teeth, concrete mixer blades, rims, carbon-alloyed rails,
The deposit is free from surface micro-cracks even for dies, striking tools and other machine parts subjected to
higher build-up. It has high endurance limit and is suit heavy shock loading and pounding in service.
able for compressive and fatigue loading.
It is the right consumable to use for providing buffer
Special additives in electrode coating make it smooth layers where impact and abrasion occur together.
running and easily maneuverable. Superior bead finish
is obtained independent of welder skill. PROPERTIES
The flux is devoid of hygroscopic elements, making it Hardness : 28-33 HRC
ideal for site conditions.
CURRENT RANGE : (AC 50, DC+/-)
Reclamation Consumables
ALLOY BASE
Size Length Current Range
Fe, Mn, Cr, Ni (mm) (mm) (Amp)
SPECIAL FEATURES
3.15 450 90-130
l Micro-crack free surface even for higher build-up. 4.00 450 120-170
l Very good resistance to metal-to-metal wear and 5.00 450 150-220
fatigue.
197
OK SELECTRODE 84.78 APPLICATIONS
Highly recommended for earthmoving, construction,
Maximum Abrasion Resistance cement and agriculture industries.
OK Selectrode 84.78 gives an alloy rich deposit, which Road rippers, earth moving parts, excavator blades,
offers best resistance to high-pressure abrasion by gritty crushing mills, edge runners, chutes, mixer blades,
particles. screw conveyors, asphalt phasing screws, coal mill
The stainless bead is temper resistant upto 600°C. The exhauster fan blades, plough shares, tampers, scrapers,
deposit resists corrosion and oxidation even at elevated feeding screws, grader blades, pug mill knife etc.
temperature. PROPERTIES
Relief cracks, transverse to the weld bead, are Hardness : 57-60 HRC
desirable.
CURRENT RANGE : (AC 70, DC+/-)
ALLOY BASE
Size Length Current Range
Fe,C,Cr (mm) (mm) (Amp)
SPECIAL FEATURES
3.15 450 110-160
Reclamation Consumables
198
ESAB 550 APPLICATIONS
Highest metal-to-metal wear resistance in upto 500°C
Super Hot Hardness and Edge Retention along with good impact resistance. To be used where
A basic coated hardfacing electrode giving a weld deposit cutting, shaving, and piercing proprieties are required to
suitable for rebuilding of hot working tools, forging tools be maintained.
etc. Intended for hardfacing of hot trimming blades, hot Typical applications are shear blades, roll face repairs,
bar shears etc. Resistance to scaling and tempering is tools for hot trimming and cold punching, lifting tongs for
upto 600°C. billets, high-speed steel dies and tools.
The weld-metal gives extremely good spalling PROPERTIES
resistance, hot hardness due to grain boundary pinning Hardness : As deposited : 49-52 HRC
by fine carbides.
After tempering at
ALLOY BASE 600°C for 1 hr. : 53-56 HRC
Fe, Cr, Mn, W, V, Mo, Co
SPECIAL FEATURES CURRENT RANGE : (AC 70, DC+/-)
Size Length Current Range
l Weld metal is resistant to scaling upto 600°C.
Reclamation Consumables
(mm) (mm) (Amp)
l The weld deposit gives extremely high secondary
hardening. 3.15 350 80-120
4.00 350 120-170
l An excellent edge-retention property for repairing
5.00 350 170-230
cutting and shearing tools.
199
DUROBELL APPLICATIONS
Seat area of blast furnace bells & hoppers, tong-pins,
Blast Furnace Bell Reclamation hot shears, furnace rollers, knives, valve seat, idler
Durobell is a hardfacing electrode which deposits an rollers of hot strip mills etc.
alloy steel deposit that is both impact and abrasion PROPERTIES
resistant. The electrode is the only one for blast furnace Hardness : As deposited : 53-55 HRC
bell repair as it gives rise to good resistance to abrasion
at those temperatures. At 500°C : 46-50 HRC
ALLOY BASE CURRENT RANGE : (AC 70, DC+/-)
Fe, C, Ni, Mo Size Length Current Range
SPECIAL FEATURES (mm) (mm) (Amp)
TERROWELD MN PROPERTIES
Hardness : As deposited : 22-24 HRC
Low Heat Build-up on Manganese Steel Work hardened : 42-45 HRC
This is a low heat input electrode suitable for surfacing, WELDING PROCEDURE
building up and joining of austenitic manganese
l 14% Mn steel should never be preheated for
steels of plain & alloy types. The austenitic deposit
is more resistant to cracking, deformation and heat welding.
embrittlement. The deposit is tough to witbstand metal l Welding should be done in stringer beads directing
to metal impact. It resists wear under rolling abrasion at the towards the weld pool.
high contact pressures. l Heat input to the base metal should be kept minimum,
ALLOY BASE if required skip welding/back step welding can be
Fe, C, Mn, Ni adopted.
l The weld bead must be peened with ball pen hammer
SPECIAL FEATURES
immediately after welding.
l Graphite free coating avoids carbon pick-up.
l Quenching has no adverse effect on welding and
l Deposit gives high strength, combined with excellent
should be adopted whenever possible after slag
resistance against impact. removal and peening. If possible the Mn steel job
l Smooth are, fine ripples and a fluid but controlled can be submerged in water during welding.
slag, which is easily detachable.
APPLICATIONS CURRENT RANGE : (AC 70, DC+/-)
Manganese steel shovel bucket teeth & lips, pulverizing Size Length Current Range
(mm) (mm) (Amp)
hammers, beaters, grinding ring & rollers, gyratory
crusher mantle and liners, cone and ring, jaw crusher 3.15 450 80-100
plates etc. 4.00 450 110-160
5.00 450 180-225
(Contd...)
200
TYPICAL APPLICATIONS PROPERTIES
Hardness : As deposited : 56-58 HRC
Blast furnace parts, railway tampers, pump casing & At 600OC : 46-48 HRC
impellers, ore breaker teeth, rolling mill guides, furnace
parts, sinter plant disintegrators, screw conveyors cold CURRENT RANGE : (AC 70, DC+/-)
forming dies, chain saw, coal burner nozzles, mechanical Size Length Current Range
stackers, steam valve flanges etc. (mm) (mm) (Amp)
TERROWELD 35 APPLICATIONS
Hardfacing of rollers, tractor idler wheels, brake shoes,
Low Heat Deposit for Impact and Pressure mine car wheels, drive sprockets, conveyor parts, gear
A hardfacing electrode for operation at low heat teeth, briquette press, crane wheels, concrete mixer
input depositing a tough air hardening alloy, giving a blades, mill pinions, knife edges etc.
Reclamation Consumables
combination of moderate abrasion and good impact PROPERTIES
resistance as encountered in rolling, reciprocating and Hardness : 33-36 HRC
sliding systems.
ALLOY BASE CURRENT RANGE : (AC 50, DC+/-)
Fe, Cr, Mn Size Length Current Range
(mm) (mm) (Amp)
SPECIAL FEATURES
l Low heat formulation. 3.15 450 75-110
4.00 450 110-160
l Tough machinable deposit.
5.00 450 140-185
201
OK 84.80 TYPICAL APPLICATIONS
Blast furnace bell & Hopper, BLT chutes, sinter crusher,
DIN 8555 E-10-65-GZ crushing mills, edge runners, chutes, mixer blades,
l Maximum abrasion resistance. screw conveyors, asphalt phasing screws, scrapers,
l Zero dilution convex bead.
coal mill exhauster fan blades, feeding screws, grader
blades, ploughshares, tampers pug mill knives, etc.
Deposits a high carbon high chromium alloy, which
offers best resistance to hih - pressure abrasion by gritty CHEMICAL COMP.: C - 50, Si-2.0, Mn-0.7, Cr-23.0,
particles. Mo-7.0, Nb-7.0, W-2.0, V-1.0.
The stainless bead is temper resistant up to 700OC. HARDNESS: 62-65 HRC
It resists corrosion and oxidation even at elevated HIGH TEMP WEAR RESISTANCE - Very good.
temperature. CORROSION RESISTANCE - Excellent.
Relief cracks transverse to the weld bead are allowed.
SPECIAL FEATURES
l Weld bead is convex and dilution is negligible.
Reclamation Consumables
202
Cast Iron Electrodes
WELDING CAST IRON PREPARATION FOR WELDING
The following steps should be kept in mind before com
Cast iron is an alloy of iron with a carbon content of 2- mencing the welding of cast iron:
5%, silicon content of 1-3% and upto 1 % manganese. l Joint angles should be wider than for mild steel.
The major types of cast iron are: l All sharp edges should be rounded off.
l grey cast iron
l Preferably use U-grooves.
l nodular cast iron
l For repairing cracks, either gouge/grind the entire
l malleable cast iron crack or drill small holes at each end of the crack.
l white cast iron l The welding should start from the centre of the crack
Cast iron has very low ductility, low strength and is very and proceed in both directions.
brittle. It is generally alloyed or heat-treated for improv l The absorbed oil and liquid should be removed be
ing these properties. fore welding. If that is not possible, use an electrode
The high carbon content adversely affects the weld giving a spray transfer for an anchoring buffer layer.
ability of cast iron. Out of the grades mentioned above, l In critical welds, buttering by a ductile layer helps in
Reclamation Consumables
white cast iron is considered unweldable for all practical absorption of the contractional stresses, thus saving
purposes. The other types can be welded successfully the crack-susceptible HAZ.
with the consumables available.
203
FERROLOID 1 APPLICATIONS
Repairing of cracks and for depositing buffer layer
Excellent colour match with all cast irons prior to building up with nickel-copper types of weld
Ferroloid 1 is a monel-cored electrode depositing metal, rebuilding of broken, cracked, worn-out cast iron
a weldmetal, which bonds easily and matches in castings, gear teeth, pumpimpellers, pump casing etc.
colour with cast iron. Weld deposit is soft, ductile and Pipes, especially with heavy wall thickness, can be
machinable. It is very effective for defect correction in welded in circumferential positions without cracks.
foundries. It is excellent for joining cast iron to steel. PROPERTIES
ALLOY BASE UTS : 35-40 kg/mm2
Ni, Cu, Fe
SPECIAL FEATURES CURRENT RANGE : (AC 50, DC+/-)
l Smooth and stable arc with low spatter. · Excellent
Size Length Current Range
(mm) (mm) (Amp)
colour match.
l Good machinability. 3.15 350 75-95
4.00 350 100-130
Reclamation Consumables
204
PROPERTIES CURRENT RANGE & PACKING DATA
UTS : 28-31 kglmm2 Size Length Current Range
(mm) (mm) (Amp)
Reclamation Consumables
UTS : 55-60 kglmm2
is suitable for non-critical welding in cast iron with high
preheat. Hardness : 42-45 HRC
It is also suitable for welding in deep holes and tight cor WELDING PROCEDURE
ners for all types of sections giving good colour match l Preheat the job uniformly to 250°-350°C.
ing as the deposit oxidizes in a similar fashion. l Stringer bead to be used.
ALLOY BASE
Fe, Mn, Si CURRENT RANGE : (AC 70, DC+/-)
Size Length Current Range
SPECIAL FEATURES
(mm) (mm) (Amp)
l Spray type deposit insensitive to contamination.
3.15 450 100-130
l Good colour match.
4.00 450 130-170
l Can be used in final layer to give hardness and wear 5.00 450 160-200
resistance.
Ni,Si, Fe, Conforms to AWS A5.15 ENi-Cl 200°C will keep the weld more ductile.
l Reinforcing studs should be used when the volume
SPECIAL FEATURES
of weld metal required is more.
l Superb slag detachability.
l Light peening of the weld metal is advisable at hot
l Excellent weld bead appearance.
stage to minimize shrinkage stresses.
l Preheat is seldom necessary.
205
OK SELECTRODE 92.58 cast iron dies, etc. Other applications are cast iron gears
and pulleys, sliding tables for machine tools, cylinder
Strength Welding for all Cast Irons blocks.
OK Selectrode 92.58 is a new generation alloy electrode PROPERTIES
for welding and repairing of malleable and grey cast UTS : 44-47 kg/mm2
irons, and difficult-to-weld cast irons viz. S.G. iron. WELDING PROCEDURE
The weldmetal is machinable, possesses high strength l Clean the weld area of all scales, grease and dirt.
coupled with good toughness, thus making it suitable
l The smallest possible electrode diameter and the
for joining cast iron to steels and filling-up cavities in
castings. lowest possible current should be used.
l Skip welding sequence may be used to limit the
ALLOY BASE
heating of the base metal.
Ni, Fe, Mn, Si Conforms to AWSA5.15 ENi - Fe CI
l Although mostly preheating is not required, when
SPECIAL FEATURES welding thick sections and malleable irons, preheat
l Smooth bead consists of fine ripples. ing to about 250-300°C is advisable to minimize the
shrinkage stresses and cracking.
Reclamation Consumables
l Barium Free l Just after welding the joint can be lightly peened and
The weld deposit produced has exceptional strength for big jobs use sufficient current for proper base
over those created by run-of-the-mill cast iron electrodes. metal fusion and bonding.
For repairing thick joints in cast iron it provides fail-proof l One may use skip welding sequp.nce to limit the
performance and prolonged service life. heating of the base metal.
It can also be used for radiographic quality joints between l Although preheating is not required in most cases,
cast iron and stainless steel/mild steel/manganese steel/ when welding complicated castings preheat to about
Inconel alloys. 250-300OC to minimize the shrinkage stresses gen
ALLOY BASE erated in the base metal.
l Just after welding peen the joint lightly with ball pen
Ni, Fe, Mn
SPECIAL FEATURES hammer and cool slowly.
l High quality joints in any critical cast iron repairs.
CURRENT RANGE : (AC 50, DC+/-)
Size Length Current Range
l Nitrogenous slag gives clean inclusion-free joint.
(mm) (mm) (Amp)
l Barium Free.
206
ESAB 801 KG SPECIAL FEATURES
l Very good wetting property for thin sections and
Nickel Base Ductile Electrode for Cast Iron Welding filling up cavities.
A nickel-cored electrode depositing an almost pure l Carbon dissolving capacity is high.
nickel weld metal suitable for joining and repairing gray SPECIFICATION: AWS 5.15: E Ni-CI
cast irons giving a perfectly machinable deposit.
APPLICATIONS
The electrode performs well even in areas that are
difficult to reach. While rebuilding machine components, Reclamation of castings and machine parts, filling-in of
ESAB 801 KG does not overheat the job. blow holes in castings, joining cast iron to steel etc.
For welding thicker sections and bigger jobs, should be PROPERTIES
used with peening for best result. This makes sure the UTS : 29-32 kg/mm2
weld bead remains ductile and tough. CURRENT RANGE : (AC 50, DC+/-)
ALLOY BASE Size Length Current Range
Ni,Si (mm) (mm) (Amp)
Reclamation Consumables
3.15 350 65-95
4.00 350 80-130
207
CURRENT RANGE : (AC 50, DC+/-)
Size Length Current Range
(mm) (mm) (Amp)
TERROWELD CF PROPERTIES
UTS : 36-39 kg/mm2
Low Heat Input Strength Joints WELDING PROCEDURE
A nickel-alloyed electrode for welding and repairing l Clean the weld area of all scales, grease and dirt.
of cast irons, e.g. S.G.lron, malleable and grey iron
l The smallest possible electrode diameter and the
castings etc.
lowest possible current should be used to restrict the
The electrode deposits a high strength weld metal
Reclamation Consumables
208
Steel and Dissimilar Joining Alloys
The welding is almost always carried out with over- l wear-resistant steels
alloyed stainless consumables i.e. having higher alloy Steels of unknown composition are also treated as
content than the base metal. Two different methods having limited weldability so that the weld does not fail
are employed for this type of welding. The entire weld in any respect.
groove can be filled up with the over-alloyed stainless Welding theory says that all these steels can be
steel or any nickel based consumable. Otherwise, the welded with matching ferritic consumables with proper
lower alloyed surface can be buttered with an over- preheating and post-weld heat treatment (PWHT).
alloyed stainless weld metal and then the groove can be
Reclamation Consumables
But repair welding, by nature, does not always allow
filled up with a consumable matching with the stainless preheating or PWHT. Therefore, the safest way is to weld
side. The welding can usually be performed without with austenitic stainless or nickel-based consumables.
preheating. However, if there is any recommendation The risk of cracking due presence of hydrogen is
for that particular grade of steel, then that has to be neutralized by the greater solubility of hydrogen in
followed. austenite and also by the higher ductility of the weld
WELDING MANGANESE STEELS metal. For welding steels of unknown composition,
Manganese steel typically contains 11-14% manganese the best choice is a ferritic-austenitic duplex type of
and 1.0-1.4% carbon. Some other grades can have consumable.
other minor alloying elements. This steel has an ability WELDING TOOL STEELS
to workharden e.g. under high impact and/or high Tool steels have a higher carbon content along with
surface pressure. These steels have to be reconditioned chromium, nickel, molybdenum, vanadium and are
by repairing cracks or breakages, rebuilding worn out generally heat-treated to achieve certain specific
portions and hardfacing to extend service life. properties.
Weldability of manganese steel is governed by the fact The repair welding of tool steels without changing
that it tends to become brittle when reheated and slow their inherent properties is very difficult. This calls
cooled. Consequently, the interpass temperature should for use of consumables producing a weld metal with
not exceed 200°C. As a result, during welding of these matching composition, microstructure and properties.
steels, the following matters should be noted : But practically, this is very difficult as it involves scaling
l the heat input should be as low as possible change of dimension and time.
l stringer beads should be used The welding is simplified by using specific consumables
l simultaneous working with several components developed for tool steels:
should be done, as far as practicable Shock resistance, toughness, Straight chrome
l the component can be cooled by putting it in cold abrasion resistance martensitic deposit
water Hot strength, abrasion Fine carbides in
Welding manganese steel involves anyone of the fol resistance at high temperature martensitic matrix
lowing cases: Edge retention at high High speed
l joining manganese steel to itself or to unalloyed, low temperature, impact toughness steel deposit
alloy steel The welding is done by preheating the job to 200-500°C
l rebuilding worn out surfaces (as per the type of steel) and maintaining it during the
For joining manganese steels and manganese steels to course of the welding. The preheating and PWHT to be
carbon steels, austenitic stainless consumables have to followed can be found in different international standards
be used to obtain a tough and strong joint. like SAE/AISI.
Prior to surfacing also it is advisable to add a buffer
layer of austenitic stainless consumables. On top of
that regular 13% manganese type deposit is put as the
surfacing layer.
209
TERROWELD DMS l Self-lifting slag ensures no slag cleaning for the
welder. · Runs on low OCV transformers.
High Speed Touch Welding Electrode for X-ray APPLICATIONS
Quality Joining thin sheets at high speed, welding boiler quality
Auto-run Terroweld DMS is characterized by ‘Push-arc’ steels, ship plates, and general repair and maintenance
that speeds up the output even for unskilled welders. The operation of containers, air conditioning units, ducts,
low heat electrode is preferred to any similar electrode tanks, bus bodies, for great finish and shiny bead
due to its very high speed of welding and ability to appearance.
weld thin sheets without burn-through. Terroweld DMS PROPERTIES
is suitable for touch welding in all positions, so even
unskilled welders can give X-ray quality welds. UTS : 47-52 kg/mm2
No slag cleaning is required by the welder since Elongation : 24-28%
the nonsynthetic slag detaches itself from the bead CURRENT RANGE : (AC 50, DC+/-)
automatically. Size Length Current Range
ALLOY BASE (mm) (mm) (Amp)
Reclamation Consumables
ESAB 116 steel, and chemical plant parts where Ni-Cr-Mo steels
are used. It is suitable for build-up and repair of forge
Low heat electrode for very high tensile strength dies. The maintenance of strength upto 538°C renders
joining it usable on steam turbine rotors that operate upto this
A medium-to-heavy coated electrode, Esab 116 gives temperature.
a hydrogen-controlled deposit for welding high-tensile MECHANICAL PROPERTIES:
low-alloy steels. The deposit has excellent resistance UTS : 95 – 106 kg/mm2
to creep and has a high corrosion resistance. It is used Elongation : 15 - 18%
regularly for repairs of hot dies.
CURRENT RANGE (AC 70, DC+/-):
SPECIAL FEATURES
l Resists annealing Size Length Current Range
l Stupendous weld strength (mm) (mm) (Amp)
l Weld deposit is insensitive to hot cracking 2.50 350 60-90
TYPICAL APPLICATIONS 3.15 450 100-140
Recommended for joining and repair of machine parts 4.00 450 130-180
fabricated out of high tensile steels. It is also suitable 5.00 450 170-230
for automotive parts, specific grades of armour plate
OK 53.18 holes and building up worn out shafts and other ma
chine parts that are not exposed to excessive wear.
For welding galvanising baths MECHANICAL PROPERTIES
Esab 53.18 is a special purpose electrode which gives UTS : 44-48 Kg/mm2
a deposit that is almost pure iron that makes it the ab Elongation (l = 4d) : 28-32%
solute choice for welding galvanising baths. The low
impurity content, especially silicon, ensures excellent WELDING CURRENT: AC 50, DC+
resistance to molten zinc corrosion.
The weld metal is fairly strong and ductile. The weld CURRENT RANGE
beads are smooth and shiny with easy slag detachabil Size Length Current Range
ity. The electrode gives very low spatter for a pleasing (mm) (mm) (Amp)
welding experience. 2.50 350 60-100
TYPICAL APPLICATIONS 3.25 350 80-130
4.00 350 125-180
Special formulation for welding and repairing hot dip
5.00 350 170-250
galvanising baths. Other applications include filling up
210
TERROWELD DBL Perfect in welding steels like free-cutting steels, where
sulphur and other alloys are added.
Super Ductile Joining and Buffering PROPERTIES
Terroweld DBL deposits a high strength low alloy weld UTS : 52-55 kg/mm2
metal recommended for building up and joining of low, Elongation : 28-32%
medium carbon and low alloy steels. It is also suitable
for giving buffer layers on medium and high carbon CURRENT RANGE : (AC 50, DC+/-)
steels prior to hard surfacing. Size Length Current Range
The weld deposit is extremely ductile and crack resistant. (mm) (mm) (Amp)
Produces excellent result in highly constrained heavy
machinery joining. 3.15 450 90-135
4.00 450 140-165
Low heat formulation suitable for joining thin section 5.00 450 170-220
without risk of burn-through.
ALLOY BASE
Fe, Mn, Si, Ni
Reclamation Consumables
SPECIAL FEATURES
l Super-ductile weld.
APPLICATIONS
Joining and build-up of medium tensile steels, joining
dissimilar sections, restrained joints, giving buffer layers
on pipes, flanges, pressure vessels, cross members,
gun plates, steel castings, heavy machine components,
etc.
APPLICATIONS
Joining & build-up of medium tensile steels, restrained
joints, steel castings, heavy machine components,
etc., dragline bucket and chains, dipper stick,
repairing cranks and undercarriage, dozer blades
repair, chassis of earthmoving equipment like dumper,
shovel, dragline etc. and repairing pulleys of dragline.
211
DUROCHROME Joining and surfacing of high carbon, low and high alloy
steels, tool steels, spring steels, manganese steels,
Low Heat Dissimilar Steel Strength Joining case hardening steels, etc.
Esab Durochrome is an electrode for welding complex PROPERTIES
dissimilar alloys and high strength steels with low heat UTS : 77-82 kg/mm2
input giving sound joints, free from any cracks and Elongation : 30-35%
fissures. The electrode is also suitable for depositing
buffer layers prior to hard surfacing on high strength and CURRENT RANGE : (AC 70, DC+/-)
high alloy steels.
Size Length Current Range
The deposit is corrosion resistant and resists high (mm) (mm) (Amp)
temperature oxidation. It provides excellent metal to
metal frictional resistance. 2.50 350 40-65
3.15 350 55-95
ALLOY BASE 4.00 350 85-135
Fe, Cr, Ni, Mn 5.00 350 110-165
SPECIAL FEATURES
Reclamation Consumables
TERROWELD DS2 high strength high alloy steels giving a high strength
joint. It gives a good combination of impact, heat, and
High Strength Dissimilar Joining Applications corrosion resistant properties.
Terroweld DS2 is a low heat input electrode depositing It can be used to join fatigued and dirty cast steel
super stainless weld metal recommended for joining of components.
carbon steels and alloy steels to themselves or to other (Contd...)
212
ALLOY BASE of manganese steel components, salvaging of broken
Fe, Cr, Ni, Mo rolling mill spindles, hydel turbine blades, trash beams,
etc.
SPECIAL FEATURES
PROPERTIES
l Superior bonding with all steels.
UTS : 72-80 kg/mm2
l Crack-less joint.
Elongation : 29-34%
l Very good strength and impact toughness.
Reclamation Consumables
TERROWELD DS3 l Smooth arc and fine ripples.
APPLICATIONS
Strength Joining for Dissimilar and Unknown Joining, surfacing and rebuilding shafts, spindle, gears,
Steels pinions, springs, bull gears and sprockets, pump, gear
Terroweld DS3 deposits a high ferrite stainless steel de box casing, rolling stock couplings, universal coupling,
posit suitable for joining, building up and buffering ap chassis frames, shovel booms, wobblers, kiln tyres,
plications. The specially designed microstructure of the hammer shafts etc.
weld deposit ensures superior resistance to crack, cor Also used as a buffer layer before hard surfacing of min
rosion and oxidation. The electrode is suitable for join ing and earth-moving machinery.
ing dissimilar, unknown and difficult to weld steels. It is
suitable for welding thick sections with deep groove in PROPERTIES
all positions. Weld deposit is of excellent quality ensur UTS : 80-86 kg/mm2
ing fail-safe performance. Elongation : 30-34%
ALLOY BASE CURRENT RANGE : (AC 70, DC+/-)
Fe, Cr, Ni, Mn, Si Size Length Current Range
SPECIAL FEATURES (mm) (mm) (Amp)
l Deposit gives high strength, combined with excellent 3.15 350 70-100
resistance against impact, friction. 4.00 350 100-130
l Heat and corrosion resistant surfacing. 5.00 350 110-140
l Easy slag peel off revealing shining bead. 3.15 350 70-100
4.00 350 80-130
l Thick bead facilitating smooth surfacing.
5.00 350 110-140
213
TERROWELD DS6 points and crossings. This electrode obviates the need
for separate electrodes for joining the points & cross
Single Electrode for Railway Points and Crossings ings and hardfacing.
Terroweld DS6 is a heavy-coated basic electrode for PROPERTIES
applications, which demand resistance to high abra UTS : 59-65 kg/mm2
sion coupled with heavy to moderate impact. It is a very Elongation : 18-22%
smooth running electrode having very good slag de Hardness : As deposited : 22-26 HRC
tachability and bead appearance.
Work hardened : 40-44 HRC
The weld deposit consists of fine austenite grains with
about 5% carbide precipitated at the grain boundaries. WELDING PROCEDURE
l Welding is recommended to be done by stringer
ALLOY BASE
beads.
Fe, Cr, Ni, Mn, Mo
l All precautions, as necessary for welding manganese
SPECIAL FEATURES steel parts, should be taken.
l Beautiful bead appearance.
l Peening at hot condition has beneficial effect.
Reclamation Consumables
214
l Suitable for all position welding. WELDING PROCEDURE
l Finely rippled bead with minimum spatter and easy l The weld area should be cleaned of all dirt, grease
detachability of slag. and oil.
APPLICATIONS l Stringer beads are preferable, maintaining a short
Reclamation Consumables
TERROWELD S3 APPLICATIONS
Terroweld S3 is recommended for welding all austen
Stainless Steel Electrode for Oxidation Resistance itic stainless steels for heat & oxidation resistance upto
Terroweld S3 is an all-purpose high alloy stainless steel 1100°C in dairy, chemical & distillery equipment for ap
electrode having high corrosion and heat resistance, plications like valves, heat exchangers etc.
which can be operated at low heat input. This electrode PROPERTIES
is specially recommended for repairing and joining of
heat resistant stainless steel plates and pipes for pro UTS : 56-58 kg/mm2
tection against oxidation and corrosion. It is also suit Elongation : 30-35%
able for joining dissimilar metals and overlays. WELDING PROCEDURE
ALLOY BASE l The weld area should be cleaned of all dirt, grease
Fe, Cr, Ni and oil.
SPECIAL FEATURES l Stringer bead welds are preferable, maintaining a
l Suitable for all position welding. CURRENT RANGE : (AC 70, DC+/-)
l Finely rippled bead with minimum spatter and easy Size Length Current Range
detachability of slag. (mm) (mm) (Amp)
215
WELDING PROCEDURE l If required the Mn steel job may be submerged in
l 14% Mn steel should never be preheated for water during welding.
welding. CURRENT RANGE : (AC 70, DC+/-)
l Heat input to the base metal should be kept Size Length Current Range
minimum. (mm) (mm) (Amp)
l The weld bead may be peened with ball pen hammer 3.15 350 100-150
just after welding. 4.00 350 150-200
l Quenching has no adverse effect on welding and 5.00 350 200-250
should be adopted whenever possible after slag
removal and peening.
OK 68.53
Mechanical Properties
Classifications : EN 1600 E 25 9 4 N L R 3 2 YS 700 MPa
Werkstoff Nr. (1.4410)
UTS 850 MPa
EL 30%
OK 68.53 is a coated electrode for welding austenitic
Charpy V
ferritic steels of Super Duplex types, e.g. SAF 2507 and
Zeron 100. OK 68.53 has good welding characteristics Test temp OC +20, -40
in all positions and the slag is easily detachable. Impact Values, J 50, 35
APPROVALS : VdTŰV Ferrite content FN 35-50
WELDING CURRENT : DC+, AC OCV 60 V
TYPICAL WIRE COMPOSITION (%) CURRENT RANGE :
Size Length Current Range
C Si Mn Cr Ni Mo N
(mm) (mm) (Amp)
0.03 0.6 0.7 25.5 10.0 4.0 0.25
2.50 300 55-85
3.25 350 70-110
4.00 350 110-150
216
OK 69.33 Classification
DIN 8556: E 20 25 5 L Cu R
A fully austenitic rutile - basic 20.25.4, 5 weld metal Typical weld metal composition%
with better corrossion resistance to sulphuric acid
than lower alloyed weld metals of AISI 316L and C Si Mn Cr Ni Mo Cu
317L type. <0.030 0.5 1 20.5 25 5 1.5
Description and applications Typical mechanical properties All weld metal speci-
OK 69.33 is designed for welding of stainless steel mens
with corresponding composition. This type of steel has 0.2% proof stress 400 N/mm2
better resistance to sulphuric acids than lower alloyed Tensile strength 575 N/mm2
stainless steels. OK 69.33 is recommended for swed Elongation 4xD 35%
ish Standard Standard steel SS 2562, Avesta 254 SLX
Butt weld test
UHB 904L, Sandvik 2 RK 65, 2R N65.
Test temp CVN impact values.
Welding current: DC+, AC > 65V
+20 C
O
80J
Diameter Length Current Arc Volts
Reclamation Consumables
mm mm Amps Approx -140 C
O
45J
2.5 300 60-90 25 Ferrite Number : 0
3.25 350 85-130 26 Approvals
4.0 350 120-180 28 TUV eignungsgeprüft
Redrying: 250OC 2h
ASTRÄ ZF CLASSIFICATION:
AWS 5.4: E 385-16
Super resistance to sulphuric acid corrosion CHEMICAL COMPOSITION
Asträ ZF is a high performance electrode with excel C Mn Si Cr Ni Mo Cu
lent corrosion resistance to acids than the standard AISI <0.030 1.4-1.8 0.4-0.6 20.0-22.0 23.5-25.0 4.5-5.2 1.3-1.9
316L or 317L types where the alloy content is lower.
FERRITE: 0
A rutile based electrode, Asträ ZF is characterized by
smooth running and a selfpeeling slag. MECHANICAL PROPERTIES
SPECIAL FEATURES: UTS : 56-58 kg/mm2
l Stunning resistance to sulphuric, phosphoric, acetic Elongation (l=4d) : 33-35%
acids WELDING CURRENT: DC+, AC 65
l Smooth arc, a ripple free bead and a slag that re WELDING PARAMETERS AND PACKING DATA
moves itself Size Length Current Net Wt. of Net Wt. of
TYPICAL APPLICATIONS (mm) (mm) (Amps) Electrodes Electrodes
The electrode is designed for welding stainless steels in a in a
of corresponding composition viz. Carpenter 20, SS Carton Case
2562, Avesta 254 SLX UHB 904L, Sandvik 2RK65, (Kg) (Kg)
2RN65, etc. The weld deposit is resistant to sulphuric, 2.50 350 90-110 2 10
phosphoric, acetic, oxalic, formic and other acids like 3.15 350 120-140 2 10
fatty acids. The electrode can be successfully applied 4.00 350 150-185 2 10
in pipeline and storage applications handling the above 5.00 350 170-250 2 10
chemicals.
217
Non-Ferrous Alloys
WELDING NON-FERROUS can be applied on either the copper or the steel side.
The groove has to be filled up a stainless or a bronze
ALLOYS type of deposit.
The preheating should be 300-500°C when buttering
NICKEL AND NICKEL ALLOYS
copper or bronze whereas the preheating temperature
Nickel and nickel based alloys are used in industrial has to be chosen according to the base material if the
applications for: buttering is done on the steel side.
l corrosion resistance
ALUMINIUM AND ALUMINIUM ALLOYS
l heat resistance and high temperature properties
The characteristics of aluminium and its alloys that
l cryogenic properties make them amenable to fabrication are enlisted below.
Preheating is not normally required unless there is a risk These are:
of porosity from moisture condensation. PWHT is not l light weight
usually needed to restore corrosion resistance. l good corrosion resistance
Inconel type of deposit is used for obtaining high The filler metals used for welding aluminium alloys are
temperature, high strength joints designed to perform selected considering the following aspects:
Reclamation Consumables
218
ESAB CN1 G APPLICATIONS
ESAB CN1 G is ideally suited for joining Inconel, Incoloy,
Excellent High Temperature and Corrosion etc. and their combination with stainless steels.
Resistance PROPERTIES
Esab CN1 G is an electrode designed to deposit weld UTS : 60-64kg/mm2
with excellent resistance to corrosion and oxidation.
It provides superior strength at temperatures above YS : 40-44 kg/mm2
650°C. Elongation : 30-40%
ALLOY BASE CURRENT RANGE : (AC 70, DC+)
Ni, Cr, Fe, Mn, Mo Size Length Current Range
(mm) (mm) (Amp)
SPECIAL FEATURES
l Smooth and stable arc with low spatter loss. 3.15 350 80-120
4.00 350 100-160
l Excellent resistance to acid corrosion.
5.00 350 140-190
l Superior strength at higher temperatures.
Reclamation Consumables
ESAB CN182 APPLICATIONS
Repair of rotary kiln tyres, heat treatment equipment
High Temperature Resistance Ultimate Bonding such as trays, tongs, cryogenic equipment, and fabri
Esab CN182 virtually bonds with everything like ferrous cation of nickel steels for corrosion resistant tanks and
metals, stainless steels, nickel steels, chromium steels, containers, heat exchangers, furnace components and
cobalt-based alloys, carbides. It is perfectly suitable for fittings, and low temperature applications.
re-buffering hardfaced layer and welding dissimilar al It is suitable for welding of nickel, inconel, monel, stain
loys. It can be used for welding 5% and 9% nickel steels, less steels, heat-resisting steels and difficult-to-weld
Inconel, Incoloy, etc. steels. This electrode is perfect for joining dissimilar
The weld metal is tough and ductile and can withstand metals and alloys like carbon steels, stainless steels,
severe thermal fluctuations. nickel and nickel alloys to each other.
ALLOY BASE PROPERTIES
Ni, Cr, Mn, Fe, Nb UTS : 60-64 kg/mm2
SPECIAL FEATURES Elongation : 42-48%
l Withstands stresses generated by thermal cycles. Impact (CVN) at -196°C : 45-55 J
l Tolerant to dilution and produces crack resistant CURRENT RANGE : (AC 70, DC+)
welds/clads, even in massive sections. Size Length Current Range
l Superior bonding properties. (mm) (mm) (Amp)
219
CURRENT RANGE : ( DC+)
Size Length Current Range
(mm) (mm) (Amp)
OK SELECTRODE 93.60 seats, hot forging tools, dies, hot shear blades. OKS
93.60 is suitable for hardfacing of components such as
DESCRIPTION grates, trays, radient tube supports and parts in contact
OK Selectrode 93.60 electrode of Stellite Gr. 250 type with molten slags and molten coppor.
which is cobalt-chromium-iron heat resistant alloy with MECHANICAL PROPERTIES
excellent resistance to thermal shock, impact, hot cor Hardness : 35-45 HRC
rosion and oxidation and also abrasion at high tempera Tensile Strength : 551 MPa
tures from flue gas, slags. The alloy has good sliding
properties. The alloy resists galling and corrosion to Elongation :8
splendid levels.
SPECIAL FEATURES CURRENT RANGE : (AC 70, DC+)
l Smooth and stable are with low spatter. Size Length Current Range
(mm) (mm) (Amp)
l Slag is easily detachable.
220
OK SELECTRODE 93.62 PROPERTIES
Hardness : at 20°C : 42-49 HRC
Excellent Wear resistance upto 600OC at 300OC : 42-49 HRC
The weld metal has excellent resistance to friction, abra at 600°C : 30-35 HRC
sion, impact, corrosion & oxidation and abrasion at high
temperature. The alloy resists spalling due to thermal
cycling is exceptional. And is characterized by its spat
terless smooth arc and easy slag detachability. CURRENT RANGE : (AC 70, DC+)
WELDING CURRENT: DC+, AC Size Length Current Range
(mm) (mm) (Amp)
TYPICAL APPLICATIONS
Hardfacing of parts subject to wear at elevated temper 3.20 350 70-100
atures, also in corrosive environment. Surfacing of hot 4.00 350 110-160
rolls, kneading rolls, press screws, band screws, skid
buttons, dies, valves, buner nozzles, drawing valves,
seats, steam ends etc.
Reclamation Consumables
WELDING PROCEDURE
l Clean weld area for oil, grease and other impurities.
OK SELECTRODE 93.66 tongs, hot punches, knives, chemical valve seats, steam
ends, pump sleeves, wear pads, screw conveyors, etc.
High Temperature Chemical Inertness in chemical, petroleum and sugar industries and also in
OK Selectrode 93.66 deposits a highly crack resistant steel plants.
weld metal of Stellite Gr. 6 type. The electrode is char WELDING PROCEDURE
acterized by its spatterless smooth arc and easy slag l Clean weld area for oil, grease and other impurities.
detachability. The weld metal has excellent resistance l Preheat job wherever possible.
to friction, abrasion, impact, corrosion and oxidation and
l Hold electrode perpendicular to work piece and weld
abrasion at high temperature. These features make it
suitable for combined wear conditions. The alloy resists in stringer beads.
spalling due to thermal cycling and has good sliding l Maintain interpass temperature 300°C or lower.
properties. l Cooling should be slow.
ALLOY BASE PROPERTIES
Cr, Co, C, W Hardness : At 20°C As deposited : 39-42 HRC
SPECIAL FEATURES Work Hardened : 43-46 HRC
l Retains about 40 HRC hardness at 750°C. At 750°C As deposited : 19-22 HRC
l Only solution to complex wear system. Work Hardened : 38-43 HRC
l Exceptional resistance to corrosion. CURRENT RANGE : (AC 70, DC+)
APPLICATIONS Size Length Current Range
Hardfacing of parts subject to wear at elevated temper (mm) (mm) (Amp)
atures and also in corrosive environment like hot forging 3.25 350 70-100
tools, hot shear blades and dies, cutting edges, grab 4.00 350 110-160
221
BRONZOID 1 APPLICATIONS
Welding and surfacing of copper brass and bronze,
Excellent Welding of Copper Alloys cracked engine jackets, cylinder heads, electrical fit
Bronzoid 1 is an electrode that provides an alloy suit tings, propeller blades, pump parts, bearing bushing,
able for welding brass, bronze, deoxidized copper, cast shaft, castings, stampings and valves. Filling cavities in
iron, steels and dissimilar metals. copper alloy castings, joining copper and bronze to cast
It has easy slag detachability and produces homoge iron overlays and steel.
neous and sound weld metal free from porosity and PROPERTIES
cracks. Excellent colour match on bronze. UTS : 28-36 kglmm2
ALLOY BASE Elongation : 18-26%
Cu, Sn, P CURRENT RANGE : ( DC+)
SPECIAL FEATURES Size Length Current Range
l Smooth and stable arc with almost no spatter loss. (mm) (mm) (Amp)
l The deposit can be machined to a smooth finish with 3.15 450 60-120
Reclamation Consumables
222
Cutting and Gouging Electrodes
CUTTING AND GOUGING For gouging normally AC or DC- should be used, where
as for cutting and piercing DC+ is recommended. The
The cutting, gouging and piercing by means of shielded arc is struck holding the electrode at 90° to the work
metal arc welding principles is a flexible and economic piece. Once the arc is ignited, the electrode has to be
method of removing metal. The process does not re pointed in the appropriate direction at 5-1 0° to the job
quire any compressed air, gas or any type of special surface and pushed in the forward direction. A to-and-
electrode holder as standard equipment can be used. fro motion has to be maintained to carryon with the cut
The coating on cutting and gouging electrodes develops ting or gouging action. For piercing, the arc has to be
a strong gas jet, which blows away the molten material. struck in a vertical position and the electrode pushed
These electrodes are excellent for preparation prior to down to penetrate through the material. The electrode is
repair of cast iron. The jet drives out and burns away manipulated with a sawing motion to enlarge the bore.
impurities and/or graphite on the surface and thus re
duces the risk of cracking and porosity when welding
later. Gouging of manganese steel can also be suitably
done.
Reclamation Consumables
223
TERROCUT APPLICATIONS
Cutting of mild steels, low carbon steels, manganese
Precision Cutting Electrode steels, cast iron, copper, manganese, aluminium, nickel
Specially designed electrode producing a highly forceful and their alloys, casting risers, gates, dressing for filling
and concentrated arc, which can be efficiently used for up, etc. Absolutely suitable for burning rivets, disman
cutting and piercing holes in carbon steels, cast irons tling work at site and for cutting out unwanted metal in
and manganese steels. castings.
Terrocut does not heat up the material excessively due CURRENT RANGE : (AC 70, DC+/-)
to ionizing additives in coating design. This results in
Size Length Current Range
lower heat affected zone. (mm) (mm) (Amp)
SPECIAL FEATURES
3.15 300 160-250
l High cellulose roaring arc.
4.00 350 220-300
l Low heat affected zone. 5.00 350 260-350
Reclamation Consumables
224
Cobalarc
Reclamation Consumables
because greater dilution will lower the hardness of weld pool.
the deposit. In this respect, Cobalarc gives a major l This outer coating has one more function. Since it
headway because only a thin walled tube has to be contains non-hygroscopic stabilizers the mild steel
melted instead of a solid wire. So the heat requirement tube is free from rusting giving these electrodes an
will be considerably less and automatically the heat indefinite shelf life. The rigid tube also protects the
input will really be low. preformed carbides from degeneration over time.
l The low heat input also reduces the heat-affected
zone in the base metal.
225
COBALARC 1M
Preformed Carbides to Resist High Stress Abrasion
Cobalarc 1 M is the ultimate in welding technology.
It has autogenous fume shielding over preformed
l Non-hygroscopic coating needs no storage
carbides in a tubular form, which gives the user genuine
precaution – infinite shelf life.
low heat input and infinite shelf life by dint of its non-
hygroscopic coating. APPLICATIONS
It deposits fine chromium carbides in tough austenitic I.D. fan blades, impeller casings, dredger bucket lips,
matrix and gives better abrasion resistance on mild crusher jaws, bulldozer cutting edges, muller tyres,
and low alloy steel bases where impact requirement is sizing screens, pulveriser and crusher hammers, ball
limited. This will ensure excellent wear resistance on mill liner plates, scraper blades, crane grab shovel,
12-14% manganese steel components. dragline bucket lips, points and cutting edges, teeth
augers, conveyor chains, rolling mill guides, agriculture
SPOT COLOUR: YELLOW
implements. The electrode is suitable for 12-14%
ALLOY BASE manganese steel parts and also for carbon steel
Reclamation Consumables
226
COBALARC 4 l Low spatter level.
l Unmatched deposition rates - high integrity
Preformed Tungsten Carbides for High Pressure deposits.
Abrasion l Compared to solid cored electrodes, the current
Cobalarc 4 is the ultimate in welding technology. requirement is low so the dilution by parent metal is
It has autogenous fume shielding over preformed contained to a minimum.
carbides in a tubular form, which gives the user genuine l Non-hygroscopic coating needs no storage
low heat input and infinite shelf life by dint of its non- precaution – infinite shelf life.
hygroscopic coating. APPLICATIONS
The electrode deposits fine tungsten carbide embedded Rock drill bits, oil well drills, churn drills, sand gravel
in a hard and tough martensitic-austenitic matrix, which chutes, coal cutter bits and picks, bulldozer end plates,
is suitable for extreme abrasion with low to moderate grader end bits, feed screens, scraper for sand and
impact. It resists all forms of abrasion and wear. refractory materials, fan and pump impellers, pug mill
Deposition efficiency is very high when compared with augers and knives, choppers, post hole auger teeth,
coated electrode. feed screws, mixer blades/paddles etc.
Reclamation Consumables
SPOT COLOUR: PINK PROPERTIES
ALLOY BASE Hardness : 57-63 HRC
Fe, W, C, Co
CURRENT RANGE : (AC 70, DC+/-)
SPECIAL FEATURES
Size Length Current Range
l Exceptional resistance to severe abrasion and (mm) (mm) (Amp)
moderate to heavy impact at low to medium
temperatures. 5.0 400 90-120
6.3 400 120-140
227
Flux Cored Wires
OKTUBROD 14.17 APPLICATIONS
Field equipment maintenance and repair, joining of MS
All Position Self-Shielded Basic FluxCored Wire and carbon manganese steels and cast and forged
OK Tubrod 14.17 is a self-shielded flux cored wire for steel components as well as site welding of general and
the single and multi-pass welding of mild and medium/ structural steel work.
high tensile steels in all positions including vertical up Also suitable for buffering in difficult positions at high
and overhead. The deposit is suitable as a buffer under deposition rate prior to hardfacing.
neath higher hardness deposits. PROPERTIES
It is ideally suited for on site welding and can run in or UTS : 58-62 kg/mm2
dinary MIG machines as well as constant current flux
cored arc welding wire feeders. Elongation : 22-27%
ALLOY BASE CURRENT RANGE : (DC-)
Fe, C, Mn Size Welding Current Voltage
(mm) position (Amps) (Volts)
SPECIAL FEATURES
l No shielding gas is required. 1.2 F.H.V.O 100-280 24-26
Reclamation Consumables
l Self-shielded wire - does not require costly shielding 2.4 F.H 350-450 27-32
gas.
l Excellent ductility.
228
CURRENT RANGE :
Diameter Welding Polarity Current Voltage
(mm) position (Amps) (Volts)
Reclamation Consumables
steels for better impact toughness. Elongation : 32-35%
ALLOY BASE Hardness : 20-22 HRC
Fe, C, Cr, Mn, Ni CURRENT RANGE :
SPECIAL FEATURES Diameter Welding Current Voltage
l Stainless steel wire - no risk of rusting. (mm) position (Amps) (Volts)
229
OKTUBRODUR 15.52 APPLICATIONS
It is used widely for cost effective surfacing of earthmoving
Flux-Cored Wire Imparting Abrasion Resistance equipment, agricultural implements and other material
OK Tubrodur 15.52 is an open-arc/gas-shielded/self handling applications like augers, mixer blades and
shielded flux-cored wire, which deposits a martensitic vessels, scraper blades, cement mill crushers, and
weld metal containing some grain boundary carbides. quarrying components. It is specifically designed for
It works excellent for combined wear of low-pressure hardfacing of feed screws and ring grooves on diesel
abrasion and impact. The weld metal can only be motor pistons.
machined by grinding. PROPERTIES
This can also be used safely for multilayer build-ups. Hardness : 56-60 HRC
ALLOY BASE CURRENT RANGE : (DC+)
Fe, C, Cr, Mn, Mo, Si Diameter Welding Current Voltage
SPECIAL FEATURES (mm) position (Amps) (Volts)
l Flexibility of operation - can be used with or without 1.6 F.H 150-300 22-28
shielding gas. 2.4 F.H 280-460 23-30
Reclamation Consumables
230
WELDING PROCEDURE FOR SUBMERGED ARC l When multi-pass welding is being done, the inter
WELDING pass temperature should preferably not fall below
l OK Tubrodur 15.73 should be deposited on DC (+/-). 300°C.
Negative polarity gives a higher deposition rate and CURRENT RANGE : (DC+/-)
less fusion of the base material and is recommend Diameter Welding Current Voltage
ed when the minimum possible dilution of the weld (mm) position (Amps) (Volts)
metal is desired.
1.6 F.H 150-300 24-30
l Except at the start, preheat is not required while 2.4 F.H 280-460 24-32
hardfacing solid carbon steel shafts having diameter 3.0 F 300-450 25-33
upto about 200 mm. 4.0 F 400-600 30-36
Reclamation Consumables
sion
APPLICATIONS
A self-shielded flux-cored wire, OK Tubrodur 15.80,
deposits a martensitic weld metal containing a high This continuous flux-cored wire is used for items sub
volume of patented light carbides. This wire has been jected to a high degree of abrasive wear by fine grained
developed for maximum resistance to abrasive wear materials under pressure like augers, mixer blades,
under load arising out of fine and lumpy particles along scraper blades and cement mill crushers as well as
with moderate impact. The deposit is normally crack- many earth moving and quarrying components.
free and maintains very good hot hardness. PROPERTIES
The weld metal can only be machined by grinding and Hardness : 56-60 HRC
for best results restrict to one or two layers. CURRENT RANGE : (DC+)
ALLOY BASE Diameter Welding Current Voltage
Fe, C, Cr, Mn, Ti, Mo (mm) position (Amps) (Volts)
APPLICATIONS
Cored Wire for All Wear Factors It can be used for regular hardfacing of parts subjected
OKTubrodur 15.86 is a gas-shielded metal-cored wire to complex and combined wear patterns at elevated
that deposits an alloy weld metal which can provide ex temperatures and also in corrosive environments. Typi
cellent resistance to all wear factors and patterns. Thus cal applications are hot forging tools, hot shear blades &
it can be used for wide spectrum of surfacing applica dies, hot punches, valve seats, steam ends etc.
tions. The wire gives maximum resistance to erosion, PROPERTIES
abrasion, high temperature, corrosion, impact and fric
tion. The deposit is crack-free and perfectly machin Hardness : At room temperature : 40-43 HRC
able. At 750°C : 20-23 HRC
ALLOY BASE CURRENT RANGE : (DC+)
Fe, C, Cr, W, Co, Ni, Si, Mn Diameter Welding Current Voltage
(mm) position (Amps) (Volts)
SPECIAL FEATURES
l Only continuous welding solution to complex wear 1.2 F.H 120-240 22-32
system.
231
Gas Brazing Alloys
232
RUPATAM 2 engineering for joints in motor windings, wires and
cables, braided conductor, system and other conductor
Brazing of Copper and Copper Alloys assemblies where any risk of corrosion by flux must be
SPECIAL FEATURES avoided.
l Strong clean ductile joints in copper and copper
FLUX
alloys without flux. No flux for brazing of copper. In other cases use
l Flame should be slightly oxidizing on copper and
Rupatam A.
neutral on alloys. PROPERTIES
APPLICATIONS Melting Range 638 - 694OC
Extensive employment of the alloy in electrical Available D/A - (mm) - 1.6, 2.5, 3.15
Reclamation Consumables
APPLICATION
Brazing of Brass, Bronze, Molybdenum and Silver Extensive employment of the alloy in electrical engineering
SPECIAL FEATURES for joints in motor windings, wires and cables, braided
l Rupatam 14 is used for obtaining strong, clean, and conductor and other conductor assemblies where any
high tensile brazed joints in brasses, bronzes. It also risk of corrosion by flux constituents must be avoided.
effectively joins silver and molybdenum. FLUX
l It is not recommended for ferrous metals or alloys No flux for brazing of Cu. In other cases use Rupatam
of high nickel content due to the possibility brittle A.
phosphide formation. PROPERTIES
l Flame should be slightly oxidizing on Cu and neutral
Melting Range : 643-802oC
on Cu alloys.
Electrical conductivity : 8% I.A.C.S.
Available D/A - (mm) - 1.6, 2.5, 3.15
RUPATAM 35 APPLICATION
It is an alloy suitable for general purpose work on
Brazing Joints having Non-uniform Clearances engineering metals with excellent capillary flow with
SPECIAL FEATURES better ductility for filling gaps.
l It can be used in operations requiring a slightly FLUX
higher brazing temperature. Rupatam A
l The alloy is a free-flowing one with melting range for PROPERTIES
ensuring a good joint for joints where clearances are Melting Range : 607-702°C
not even uniform.
Available D/A - (mm) - 1.6, 2.5, 3.15
RUPATAM 43 APPLICATION
Rupatam 43 can be used in brazing steel, copper,
Single Brazing Alloy for a Range of Applications brass, gunmetal, tin bronzes, aluminium and magne
SPECIAL FEATURES sium bronzes, copper nickel alloys and nickel silver of
l This alloy can be used in brazing operation requiring
all varieties.
a low temperature giving a quick and complete FLUX
penetration. Rupatam A
l It produces neat joints of very high strength that PROPERTIES
need little or no finishing. Melting Range : 608-617°C
l It is essentially for use on joints that are closely
Available D/A - (mm) - 1.6, 2.5, 3.15
fitted.
233
RUPATAM 50 APPLICATION
This alloy is ideally suited and used extensively for braz
Brazing Tungsten Carbide Tips ing carbide tool tips to tool shanks as it wets the tip beau
SPECIAL FEATURES tifully. It is also suitable for brazing stainless steels.
l This alloy has a wide wetting range, hence the solid FLUX
and the liquid portions do not separate. Rupatam A
l Good corrosion resistance - brazing stainless PROPERTIES
steels. Melting Range : 632-688OC
l Rupatam 50 is ideal for bridging gaps.
Available D/A - (mm) - 1.6, 2.5, 3.15
RUPATAM 60 APPLICATION
This alloy is ideally suited and used extensively for braz
Brazing Alloy for Joints Requiring High Electrical ing electrical components requiring high electrical con
Conductivity
ductivity.
SPECIAL FEATURES
FLUX : Rupatam A
Reclamation Consumables
234
CRYSTALLOY 60 APPLICATIONS
Resurfacing and hardfacing of parts subjected to wear
TIG filler for resistance to combined complex wear at elevated temperatures and in corrosive environment.
Crystalloy 60 is an alloy that exhibits excellent resis Valves, valve seats, hot forging tools, hot shear blades
tance to friction, abrasion, impact, corrosion & oxidation & dies, hot punches, steam ends, pump sleeves, wear
and abrasion at high temperature. Resistance to spall pads, screw conveyors, etc. in chemical, petroleum,
ing due to thermal cycling is exceptional. The alloy has sugar and steel plants.
good sliding properties. PROPERTIES
Good resistance to abrasion, impact and oxidation, fric Hardness As deposited Work Hardened
tion makes it suitable for combined wear. At 20°C: 39-42 HRC 43-46 HRC
Conforms to AWS : RCo Cr A At 750°C: 19-22HRC 38-43 HRC
SPECIAL FEATURES AVAILABLE DIA. (MM)
l Retains 40 HRC hardness at 750°C
0.8, 1.2, 1.6, 2.4, 3.2
l Only solution to complex wear system
CRYSTALLOY 61
Reclamation Consumables
paper, plastic and carpets. Refacing and hardfacing of
parts subjected to wear at elevated temperatures and in
TIG filler for resistance to heat and corrosion corrosive environment.
Crystalloy 61 is an alloy that exhibits excellent resistance PROPERTIES
to impact, corrosion & oxidation and also abrasion at high Hardness
temperature. The alloy has good sliding properties. The At 20°C: 52-57 HRC
alloy resists galling and corrosion to splendid levels.
At 600°C: 41-46 HRC
Exceptional resistance to impact friction, and oxidation
makes it suitable for combined wear. At 800°C: 32-37 HRC
Conforms to AWS : R CoCr C Typical chemical composition
SPECIAL FEATURES C 2.2
Cr 30.0
l Gives 25 HRC hardness at 750°C
W 12.5
APPLICATIONS Fe 3.0
Valves, valve seats, hot forging tools, hot shear blades Co Rest
& dies, hot punches, steam ends, pump sleeves, wear
AVAILABLE DIA. (MM)
pads, screw conveyors, cutting edges of knives for wood,
1.6, 2.4, 3.2, 4.0
CRYSTALLOY 62 Surfacing hot rolls, kneading rolls, press screws, band
saws, feeder screws, wood-working tools, valves, valve
TIG filler for resistance to high temperature wear seats, hot forging tools, hot shear blades & dies, hot
Crystalloy 62 is an alloy that exhibits excellent resis punches, steam ends, etc.
tance to friction, abrasion, impact, corrosion, & oxidation PROPERTIES
at high temperature. The alloy has good sliding proper Hardness As deposited
ties giving rise to exceptional abrasion resistance. At 20°C: 44-49 HRC
Good resistance to abrasion, impact and oxidation, fric At 600°C: 36-41 HRC
tion makes it suitable for combined wear.
Typical chemical composition:
Conforms to AWS : R Co Cr B
C 1.4
SPECIAL FEATURES Cr 28.0
l Retains 40 HRC hardness at 600°C W 8.5
Fe 3.0
l Machinable by cemented carbide tools
Co Rest
APPLICATIONS AVAILABLE DIA. (MM)
1.6, 2.4, 3.2, 4.0
CRYSTALLOY 80 monel alloy used in petroleum and ammonium sulphate
industry. This alloy is also used by power plants and any
Filler Wire for Corrosion Resistant Monel Coating plant that handles seawater.
Crystalloy 80 gives a ductile and crack resistant weld Conforms to AWS : ER Ni Cu 7
deposit that meets rigid requirements on corrosion ALLOY BASE
resistance against seawater. It joins corrosion resistant Ni,Cu,Ti (Contd...)
235
TIG Filler Wires
SPECIAL FEATURES APPLICATIONS
l Welding of ASTM 8127 and 8164 can be done Seawater corrosion resistant overlay, joining monel
successfully. metal.
l It also welds DIN Werkstoff Nr. 2.4360. PROPERTIES
l Exceptional resistance to reducing and oxidizing UTS : 50-56 kg/mm2
acids. Elongation : 42-48%
CRYSTALLOY 81 CLASSIFICATION: AWS SFA 5.14: ER Ni - 1
C 0.15 max
Filler wire for joining nickel Mn 1.0 max
Crystalloy 81 is used extensively for joining nickel and Fe 1.0 max
nickel alloys. The weld deposit other than being highly Si 0.75 max
ductile is resistant to most common acids. Cu 0.25 max
Al 1.5 max
SPECIAL FEATURES: Ti 2.0-3.5
l Corrosion resistance Ni 93.0 min
Reclamation Consumables
236
Hot Metal Spray Powders
POWDER WELDING The flow of powder and spreading on base metal
depends primarily on two characteristics: Powder
The powder welding process basically uses a simple particle shape and size. The mesh size determines
oxy-acetylene torch where finely divided powder is fed the acceptability of the powder to be used by hot metal
into the flame from a hopper attached to the torch. The spray process. Usual range is between 15-160 microns.
powder melts to give a dense coating and forms a strong The shape of powder is very important for the welder
bond with the base material by surface alloying and as it solely determines the ease of flow of the powder
diffusion. Fluxing elements such as boron and silicon through the nozzle of hot spray gun. The powder shape
are necessary in the powders for good metallurgical is dependent on the method of manufacture of the
bond. This process is typically used for deposits having powders. Gas atomized powder have spherical particles
thickness between 0.2-12 mm, in particular for smaller resulting in a smooth flow through the nozzle and higher
parts or repairs. The process is applicable only in iron- deposition rate. Ground powders have irregular shape
base, nickel-base or copper-base material. and the flow characteristics are poor.
Hot metal powder alloys are mostly nickel-based. Nickel Advantages of powder spray:
when added with boron gives hardness due to formation l Thin layer can be given with hardness upto 65 HRC
of borides. The percentage of boron can be monitored (upto 0.15 mm thickness).
Reclamation Consumables
to achieve a particular hardness range. Boron also l Coating is uniform; hardly any post-machining
brings down the melting point of nickel and helps the required.
powder to fuse much below melting point of steel.
l No heat treatment is required.
For enhanced protection against wear and increased
corrosion resistance, silicon along with other special l Self-fluxing: no slag cleaning required.
alloys is added. Some cobalt-based powders are also l For machine parts, life obtained is much higher.
available but are not as costeffective as nickel-based The limitations are:
powders. Tungsten carbide is added to a nickel boride
l Not economic for thicker build-up on big jobs.
matrix to combat highpressure abrasion.
l Not applicable for aluminium, magnesium
components.
l For big jobs furnace preheating and melting is
required.
237
CASTCOAT 20 ALLOY BASE
Ni, B, Si, Fe
Buffer for Coating Machinable Build-up SPECIAL FEATURES
Cast Irons on Steels l Machinable deposit.
CastCoat 20 extends the benefit of powder coating to l Good resistance to corrosion and oxidation.
cast irons. It has excellent machinability and can be used
l Allowable build-up: 20 mm.
for original or worn out components. For higher hardness
requirements, it can be used as buffer layer to be coated l Coverage for a 1 mm thick layer: 650 cm2/500 gm.
by harder alloy grades. This CastCoat technology saves APPLICATIONS
castings from being scraped and abraded. The wettability This powder is used for casting defect repairs, brazing
and fluidity adds to the advantage of being used for and joining cast iron components, building up funnels
brazing and joining. The inertness of the base alloy can or moulds in the glass industry, cast iron cylinder
be utilized with much success to counter corrosion and heads, engine blocks, housings, manifolds, and vessels
oxidation related problems in the industry. handling acetic acid.
The powder can also be used as a superbly machinable PROPERTIES
Reclamation Consumables
238
TUNGSTRENGTH 70 l Economic repair in case of chronic abrasion related
jobs.
Ultimate Abrasion Protection Technology l Non-machinable deposit - can only be ground by sili
A protective coating by TungStrength 70 can effectively con carbide or diamond wheel. · Allowable build-up:
enhance component life and reduce spares inventory 1.2 mm.
holding. As it retains its hardness upto 450°C, it can l Coverage for a 1 mm thick layer: 460 cm2/500 gm.
solve regular abrasion problems faced by maintenance APPLICATIONS
engineers. TungStrength 70 exhibits a slag free deposit
and better surface coverage. The composite alloy sys TungStrength 70 provides a hard deposit for prolonged
tem based on tungsten carbide ensures better micro life on machine parts viz. shear blades, die frames, wire
structural properties and ease of bonding with any fer drawing rolls, pulleys & capstans, wear rings, crusher
rous and nickel based material. teeth, guide rolls, conveyors, chains, mixer blades and
paddles.
ALLOY BASE
PROPERTIES
Ni, B, W, C, Cr, Si, Fe
Hardness : As-welded : 62-64 HRC
SPECIAL FEATURES
Retained upto : 450OC
Reclamation Consumables
l Optimum matrix-carbide ratio prevents distortion
during spraying. Melting Point : 1100°C
Chrome - C Complex carbides in a tough matrix for c, 55-58 Crusher parts, bucket
resistance to severe abrasion and moderate Cr, lips, conveyor screws
impact loads Mn,
Mb
Micro - C Dense micro carbides in a hard martensitic C, 58-62 Mixer biades, scrapers,
matrix resisting severe coarse and fine Mn, mill parts, pipes
particles abrasion. Cr,
Mo,
Ti
Therm - C High temperature carbides in an austenitic C, 62 - 65 Sinter plant parts, chutes,
matrix to resist complex wear at elevated Cr, boiler flue gas ducts
temperatures. Retains hardness upto Mn,
800OC. Mo,
Nb,
V
239
Applications in Industry Sectors
Power Wagon tipplers, excavators, chutes, primary and secondary crushers, coal pipes, bunkers,
apron feeders, mill vane wheel segments, boiler flue gas ducts, ash pipelines, screw
conveyors
Cement ID fan blades, chtes, coal pipes, crushers, earth moving equipment, Y-ducts, clinker
chutes, cyclones
Steel Sinter screen decks, hot discharge chutes, downcomer pipes, burden liners, discharge
chutes, vibratory feeders, rolling mill guides
Mining Chute liners, shovel buckets, dragline buckets, dumper bodies, dozer blades, crusher
parts, apron feeders, conveyor systems,
Chemical Crushers, mixing blades, slurry pipes, blowers, deflector plates
Sizes available
Plate dimensions: Plates are available as per drawing and / or customers’ requirements.
Thickness:
Reclamation Consumables
Base Layer (mm) Hardfacing Layer (mm) The plates may be supplied in bent forms in accordance
with the drawing. The minimum bending diameter is 300
6 4 mm for the hardfaced layer inside. For joining the plates,
8 4 countersunk holes can be provided for subsequent
10 4 attachment. These features are optional and shall be
charged extra.
12 4
Otherwise, basic coated mild steel electrodes may be
16 4
used to weld the plates to the components Wear Strips/
8 5 Wear pads.
10 5 Esab India also supplies wear strips / pads with all the
8 6 same featuresw as those of wear plates for ease of
10 6 attachment. These are available in different sizes as per
requirement of he end - user. These strips / pads can
12 6 be used on earthmoving equipment and preparation
of convering system in differnt industries. They give
economical and fast repairs with very quick inter -
changeabillty.
240
l Hardness : 477-534 BHN APPLICATIONS
l Fabrication : The ETH Plates can be easily joined l Dragline buckets, Loader Buckets, Dumper Bodies,
by using ESAB Terroweld DBL electrodes. Agricultural Equipments
l Cutting : Both oxy - acetylene flame cutting and l Conveyors, Screw Conveyors, Mixers, Moulds
plasma - cutting processes can be employed to cut l Side Wedges of Jaw Crusher, Screws Feeder Table
these plates to the requisite shapes and sizes. of Crusher Lining
l Drilling & Counter - Sinking Holes : By using re l Chutes, Hoppers, Ducts
placeable carbide insert tools.
l Rail Cars - Sidewalls & bottom plates are subjectd to
l Available Thickness : 6, 8, 10, 12, 14, 16, 20, 25 - same wear as Dumber bodies.
100 mm
l Feed Hoppers, Feeders, Grating, Protection Plates.
Reclamation Consumables
Multiply
ALS
To Convert from To
by All the given values are correct for these elements
Mass kg Ib 2.205 in their pure form
metric tonne ton 1.102
Name Symbol Melting Sp. Gravity
Force N kgf 0.102
Point (OC)
Ibf 224.8
Aluminium AI 658 2.58
Stress MPa kgf/mm2 0.102
Boron B 2300 2.5
ksi 0.145
kgf/mm2 psi 1421.57 Cadmium Cd 320 8.64
bar Pa 1 x 105
Chromium Cr 1510 6.5
atm 0.987
Energy J ft-Ib 0.7376 Cobalt Co 1490 8.6
241
COMPARATIVE HARDNESS SCALES
This chart is given as an indicative guide
242
Metal Selection Guide
ESAB CONSUMABLES FOR DIFFERENT REPAIR WORK
Hard Facing
Reclamation Consumables
High OK OK OK OK Cobalarc 1 M Cobalarc 9
strength Selectrode Selectrode Selectrode Select rode OK Tubrodur OK Tubrodur
32.03
Aluminium OK OK OK
(12% SI) Selectrode Selectrode Selectrode
243
SELECTION OF HARD FACING CONSUMABLES
Low Resistance against Abrasion High
Low
OK Selectrode 84.78
Astra HTB OK Tubrodur 15.73 Terroweld SHR OK Selectrode 84.80
Heat
Esab 116 Ni Cobalarc 1M
OK Tubrodur 14.70
and
Corrosion
Resistance
Esab 550
Terroweld DS4* Esab CSA* OK Selectrode 68.82 Terroweld EWR
Terroweld DS1* Cobalarc 9
OK Tubrodur 14.71* Cobalarc MX
Ni-based* Co-based
Esab CN182* OK Selectrode 92.35* OK Selectrode 93.66
Esab CN1G* OK Tubrodur 15.86
High
244
ESAB CONSUMABLES FOR JOINING OF DISSIMILAR METALS
Material Mild Steel Stainless 14% Ni-Cr-Alloys Ni-Cr-Alloys Bronzes Cast Iron
Stainless Esab CSA Esab CSA Esab CN182 Esab Monel Bronzoid1 OK
Cr-Ni Steel OK Tubrodur OK Tubrodur Selectrode
Reclamation Consumables
14.71 14.71 92.58
OK Tubrodur
15.66
245
METAL IDENTIFICATION CHART
Magnet File Surface Colour Grinding sparks Metal type Welding tips
Soft
Magnetic
Dark grey Long Yellowish- High carbon steel Pre-heat heavy
white lines with Low alloy steel sections to
starts 150°C
Hard
Shiny grey Yellowish-red 13% Cr steel Can be
Non-Magnetic
Shiny Very light No visible Aluminium alloys Pre-heat coarse
sparks materials to
150-200°C
Hard sparks
246
Arc Equipment
Arc Equipment
Welding and Cutting
Equipment
1
MMA Transformers
Arc Equipment
l Ideal for TIG welding with optional TIG attach-
Technical Data Transweld 400
ments.
Mains supply, V/Ph, Hz 415 / 2 Lines of 3, 50
Technical Data THH 630
Open circuit voltage, VAC (Max) 80
Mains supply, V/Ph, Hz 415 / 2 Lines of 3, 50
Welding current range, A 50 - 400
Open circuit voltage, VAC (Max) 73 - 80
Output at 60% duty cycle, A 300
Welding current range, A 90 - 630
Class of insulation H
Output at 60% duty cycle, A 500
Type of cooling Natural Air
Class of insulation H
Dimensions, l x w x h, mm 600 x 410 x 720
Type of cooling Forced Air
Weight, Kg 115
Dimensions, l x w x h, mm 820 x 675 x 1050
Weight, Kg 210
249
RS 400 EasyWeld SSR 400 / 600
The All Purpose Thyristorised MMA Welding Recti- Fully Thyristorised Heavy Duty Thyristorised MMA
fier Welding Rectifier
l Reliable and high performance tyristorised MMA l Heavy-duty thyristorised rectifiers for shop and site
welding rectifier for projects, construction and pipe use.
welding.
l Hex phase rectification ensures excellent welding
l Built-in Hot Start facility for easy arc striking. output.
l Burns all types of electrodes including cellulosic. l Hot Start, prevention against electrode freezing and
protection against HF interference.
l Suitable for long lead welding with any type of elec-
trode. l True vertical welding characteristics.
l Robust construction with large rubber wheels - ideal l Remote Control to adjust welding current during
Arc Equipment
l Remote Control to adjust welding current during l Ideal for TIG welding with optional TIG attach-
welding. ments.
Technical Data EasyWeld EasyWeld
l Ideal for TIG welding with optional TIG attach-
SSR 400 SSR 600
ments.
Mains supply, Ph x V, Hz 3 x 415±10%, 50 3 x 415±10%, 50
Technical Data RS 400
Open circuit voltage,
Mains supply, Ph x V, Hz 3 x 415 ± 10%, 50 VDC (Max) 100 100
Open circuit voltage, VDC (Max) 90 Welding current range, A 10 - 400 10 - 600
Welding current range, A 10 - 400 Output at 60% duty cycle, A 400 600
Class of insulation H Class of insulation H H
Type of cooling Forced Air Type of cooling Forced Air Forced Air
Dimensions, l x w x h, mm 825 x 695 x 1070 Dimensions, l x w x h, mm 675 x 350 x 690 675 x 455 x 850
Weight, Kg 195 Weight, Kg 130 155
250
LHJ 425 / 750 Origo Arc 150 / 200
Heavy Duty MMA Welding Rectifiers for Welding Single Phase Portable Inverters for MMA Welding
and Gouging
l Burns 2.5/3.15 mm electrodes of any class continu-
l Heavy-duty MMA welding rectifiers for MMA welding ously.
with electrodes of any class and arc gouging (LHJ
750). l Practical and rugged design - convenient to use.
l Stepless adjustment of welding current by hand l Can be used with longer input supply cable - pro-
crank. vides a larger area of operation.
l Fan cooled for optimum cooling of the power l Suitable for Scratch TIG.
source. Technical Data Origo Arc 150 Origo Arc 200
Arc Equipment
l Suitable for Scratch TIG. Welding current range, A 4 - 150 5 - 180
Technical Data LHJ 425 LHJ 750 Output at 60% duty cycle, A 110 140
Output at 60% duty cycle, A 300 600 Dimensions, l x w x h, mm 380 x 180 x 300 380 x 180 x 300
251
Origo Arc 4001i A22 / A24 Caddy Arc 251i A32 / A34
Heavy Duty Inverters for MMA Welding Portable inverter power sources for MMA Welding
l Burns up to 6.3 mm electrodes of any class. l Burns up to 4.0 mm electrodes of any class continu-
ously.
l Basic analog control Panel A22 and advanced con-
trol panel A24 with digital display and finer controls. l Rugged design - impact resistant polymer design.
l Adjustable arc-force and hot start options available. l Built-in PFC to eliminate harmonics, digital display,
Arc Plus II regulator common in A32 / A34 control
l Dust filter and laquered electronics - increased reli- panel.
ability.
l Adjustable arc force, hot start and 2 job memories
l Suitable for Scratch TIG. (A34).
Technical Data Arc 4001i
l Handles 100m long mains cable.
Mains supply, Ph x V, Hz 3 x 400±10%, 50
l LiveTIG Start for smooth and safe operation in TIG.
Arc Equipment
Fuse (slow), A 20
Technical Data Caddy Arc 251i
Open circuit voltage, VDC (Max) 91
Mains supply, 3 x 400 V, 50 Hz
Welding current range, A 16 - 400
Fuse (slow), A 16
MMA MIG / MAG 20 - 400
Open circuit voltage, VDC (Max) 78
TIG 4 - 400
Welding current range, A (TIG/MMA) 4 - 250 / 3 - 250
Output at 60% duty cycle, A 320
Output at 60% duty cycle, A 190
Type of cooling Forced Air
Enclosure class IP 23
Enclosure class IP 23
Application class S
Application class S
Standards of compliance IEC 60974 -1 / -10
Standards of compliance IEC/EN 60974 -1/-10
Dimensions, l x w x h, mm 418 x 188 x 208
Dimensions, l x w x h, mm 652 x 249 x 423
Weight, Kg 10.5
Weight, Kg 40
252
Origo Arc 410c / 650c / 810c 653 cvcc
Chopper Based DC Power Sources for MMAW / CAG Power Sources for MIG/MAG, SAW, MMA Welding
/ GTAW and Arc Gouging
l Robust construction to handle tough working condi- l Multi-process thyristorised welding power sources
tions. suitable for heavy duty welding applications.
l Built-in arc force, hot start and anti stick functions. l MIG/MAG welding of all metals with 0.6 - 2.4 mm
MS/Al/FC wire and suitable wire feeder.
l Burns electrodes of any class including cellulosic.
l Control PCBs are housed suitably to protect from
l Stepless welding current control and optional re- dust and dirt and permit longer operational life.
mote.
l Optional pulsing option available.
l Mains voltage compensation - stable welding.
l Wide choice of functionalities with wire feeders MIG
l Digital VA meter to display the welding parameters 4HD, Dura Drive 4-30 and Dura Drive 4-48.
(optional for Origo Arc 410c).
Arc Equipment
Technical Data 653 cvcc
Technical Data OrigoArc OrigoArc OrigoArc
410c 650c 810c
Mains supply, Ph x V, Hz 3 x 400±10%, 50
Mains supply,Ph x V, Hz 3 x 400±10%, 50 3 x 400±10%, 50 3 x 400±10%, 50
Open circuit voltage, VDC (Max) 59
Fuse (slow), A 25 50 63
Welding current range, A 50 - 750
Open circuit voltage, VDC 56 56 56
Output at 60% duty cycle, A 310 490 630 Output at 100% duty cycle, A 600
Type of cooling Forced Air Forced Air Forced Air Type of cooling Forced Air
Enclosure class IP 23 IP 23 IP 23
Dimensions, l x w x h, mm 819 x 483 x 622
Application class S S S
Weight, Kg 240
Standards of compliance EN 60974 -1/-10 EN 60974 -1/-10 EN 60974 -1/-10
Dimensions, l x w x h, mm 1310 x 800 x 780 1310 x 800 x 780 1310 x 800 x 780
253
EDW 350 / 400 / 500
Engine Driven Welder + Power Unit
254
Power Compact 255 Migmatic 250
Compact MIG / MAG Welding Package Power Source for MIG / MAG Welding
l Compact MIG/MAG packages with enclosed wire l Heavy-duty design for high quality of welding.
feeder.
l Digital V/A meters for display of welding parame-
l Spot, stitch and continuous welding operations. ters.
l Ideal for thin sheet fabrication and automotive indus- l Ideal for sheet metal and automotive industry.
try.
Technical Data Migmatic 250
Technical Data Power Compact 255
Power Source Migmatic 250
Power Source
Mains supply, Ph x V, Hz 3 x 415, 50
Mains supply, Ph x V, Hz 3 x 415, 50
Open circuit voltage, VDC (Max) / steps 16 - 34 / 10
Open circuit voltage, VDC (Max) / steps 16 - 37 / 10
Welding current range, A 30 - 250
Welding current range, A 30 - 250
Output at 60% duty cycle, A 250
Arc Equipment
Output at 60% duty cycle, A 190
Type of cooling Forced Air
No. of inductance outlets 2
Dimensions, l x w x h, mm 620 x 390 x 580
Spot / interval welding time, sec 0.2 - 2
Weight, Kg 78
Type of cooling Forced Air
Wire Feeder Migmatic
Dimensions, l x w x h, mm 840 x 375 x 736
Wire feed speed, m/min 1.5 - 22
Weight, Kg 90
Wire diameter, mm / type 0.8 - 1.2 / MS
Wire Feeder (Enclosed)
Weight, Kg 6
Wire feed speed, m/min 1.5 - 22
255
Smashweld 4000T LAB 4000
All Purpose Semi-Automatic Welding Equipment Heavy Duty Semi-Automatic MIG / MAG Welding
Equipment
l MIG/MAG welding on all metals including Al
and Cu. l MIG/MAG welding on all metals including Al and
Cu.
l Rubber wheels and gas cylinder base.
l Rubber wheels and gas cylinder base.
l Digital V/A Meter to display welding parameters.
l Digital V/A Meter to display welding parameters.
l Variable inductance to minimize spatter.
l Stepless adjustment of welding current.
Technical Data Smashweld 4000T
Output at 60% duty cycle, A 270 Open circuit voltage, VDC (Max)/steps 17 - 44 / stepless
Arc Equipment
Wire diameter, mm / type 0.6 - 1.2 / MS, Al, FC Wire Feeder Servo - III
Weight, Kg 11
256
Technical Data Auto K 400 Auto K 600
Power Source
Arc Equipment
welding output free from spatter.
257
Technical Data Auto K 400 Synergic Auto K 600 Synergic
Power Source
Adjustment of
welding current Stepless Stepless
Remote Current
Regulator type RCU-AUTO K 400 RCU AUTO K 600
Synergic Pendant
Auto K 400 Synergic Wire and gas combinations Wire Wire Dia Gas
mode.
Wire Feeder Servo - I Servo - 11
l Software based auto selection of parameters using Drive system DC motor DC motor
inputs of wire diameter, material and shielding gas.
Speed control Stepless Stepless
l User settable non-volatile and editable job Wire feed mechanism 2-roll quick changeover type 2-roll quick
memories. changeover type
l
Length of interconnection, 5 5
mtr
l LCD display for welding parameters.
Wire feed speed, m/min 1.5 - 19 m/min 1.5 - 19 m/min
l Mounted on rubberized wheels for better mobility Wire diameter, mm 0.8 - 1.2 0.8 - 1.6
along with gas cylinder base.
Wire type MS / Al / FC MS / AI / FC
Weight, Kg 7 5 Kg
258
Technical Data SCR 400(S)
Power Source
Weight, Kg 149
Weight, Kg 7
SCR 400(S)
MIG / MAG Welding units for Shipyard
Arc Equipment
l Wire feeder interconnection up to 50m possible
259
MIG C3000i MA6
MIG 3001i/4001i
•Lower power rating
•Higher rated current at 100% duty cycle
•Higher OCV
•Overload and single phase protection
•Ammeter
•Remote control option
260
Technical Data Mig 5000i
Power Source
Application class S
Weight, Kg 66 / 86*
Cooling Unit*
Aristo Mig 5000i
Cooling power, W** 2500*
Heavy-duty Multi-process Inverter Power Sources
for MIG/MAG (Pulse / Synergic / Non-Pulse), MMA Coolant 50% water and
Welding and Arc Gouging 50% glycol*
l Inverter power source for applications demanding Coolant quantity, ltr 5.5*
Arc Equipment
high level of performance.
Maximum water flow, ltr/min 2*
l Robust construction, body made of aluminium to
* Applies to water cooled models Aristo Mig 5000iw only
prevent corrosion and handle tough working envi-
ronments. ** At 40 Deg C temperature difference and flow rate 1.5 ltr/min
261
Technical Data Mig U4000i Mig U5000i
Power Source
Enclosure class IP 23 IP 23
Application class S S
Cooling Unit*
262
Technical Data Control Panel Control Panel
MA23 MA24
2/4 Stroke X X
Crater filling X
Creep start X
Memory 3 set X X
Arc Equipment
Mains supply, Ph x V, Hz 1 x 42, 50 3 x 400 ± 10%, 50
Wire type MS / Al / FC MS / Al / FC
* Applies to water cooled models Aristo Feed 3004w / 4804w only, which are
suitable for Aristo Mig 4000iw / 5000iw only
** With additional bobbin adapter
263
Technical Data Control Panel U6 Pendant U8#
2/4 Stroke X X
Crater filling X X
Creep start X X
Hot start X X
Inductance X X
Memory 10 set X
Pendant U8 # Can also be used with Aristo Mig 4000i / 5000i without TIG functionalities
Wire type MS / Al / FC MS / Al / FC
Weight, Kg 15 19
* Applies to water cooled models Aristo Feed 3004w/4804w only, which are
suitable for Aristo Mig 4000iw/5000iw only.
264
Technical Data PSF 250 PSF 305 PSF 405 PSF 505
Wire diameter, mm 0.6 - 1.0 0.8 - 1.2 0.8 - 1.6 1.0 - 2.4
MIG Torches - Air / Water Technical Data PSF 410w PSF 510w
Arc Equipment
l Conforms to international standard
IEC/EN 60974-7.
265
EasyWeld SSR400-T / 400T-Pluse Caddy Tig 1500i / 2200i TA33 /
Thyristorised Power Source for DC TIG and MMA TA34
l Robust and compact construction. Single Phase Portable Inverters for DC TIG / Pulse
TIG / MMA Welding
l Outstanding welding characteristics in TIG / MMA.
l Rugged design - impact resistant polymer design.
l Hex-phase rectification gives almost ripple free out-
put. l Built-in PFC to counter harmonics, Arc Plus II regu-
lator for smooth output, handles 100m long mains
l Suitable for all positional welding. cable.
l True vertical welding characteristics. l TIG - Start by HF/Lift Arc, up/down slope, pre/post
gas.
l Built-in HF for smooth start in TIG.
l TA33 - Auto set of parameters based on plate thick-
l Higher OCV for better arc striking. ness
l Heavy-duty design, suitable for manual well as l TA34 - Manually set pulse parameters in TIG.
Arc Equipment
Output at 60% duty cycle, A 400 Dimensions, l x w x h, mm 488 x 188 x 208 488 x 188 x 208
Class of insulation H
Weight, Kg 155
266
Technical Data Tig 3001i (TA24)
Application class S
Weight, Kg 33
Inverter Power Sources for DC TIG / Pulse TIG /
MMA Standards of compliance IEC/EN 60974 -
1/-3
• Inverter power sources for MMA, DC TIG (TA23)
IEC/EN 60974 -10
and also DC Pulse TIG (TA24) with excellent weld-
ing output. Control Panel TA24
Arc Equipment
Gas pre-flow, sec 0-5
• Burns MMA electrodes of any class of size up to
Gas post-flow, sec 5 - 25
5.0 mm.
Pulse/background current, A 4 - 300
• Trolley, remote hand / foot control optional.
Pulse/background time, sec 0.01 - 2.5
Weight (empty), Kg 19
267
Technical Data Tig 4000i (TA4) Tig 4000i (TA6)
Enclosure class IP 23 IP 23
Application class S S
l Heavy-duty power sources for MMA, DC TIG (TA4) Coolant type 50% water / 50% water /
and also DC Pulse TIG (TA6) with excellent welding 50% ethylene glycol 50% ethylene glycol
output.
Cooling power, W** 2500 2500
l Robust and compact construction. Coolant volume, ltr 5.5 5.5
268
Technical Data Heliarc 252 Heliarc 352
Heliarc 252 / 352 AC/DC Foot switch, TIG FC-5B EHD FC-5B EHD
l Heavy-duty power sources for MMA, AC/DC TIG Pulse control kit Optional Optional
and DC Pulse TIG. with high quality welding output. Slope control kit Optional Optional
l Robust construction and proven design. Power factor correction kit Optional Optional
l Square wave AC output gives superior welding with Cooling Unit WC-8C WC-8C
improved cleaning. Trolley with 2-cylinder rack TR-23A Truck Kit TR-23A Truck Kit
Arc Equipment
l Complete solid-state design with no mechanical con-
tactor, which eliminates output drift as well as lowers
maintenance and promotes long life.
269
Technical Data Tig 2200i AC/DC Tig 2200i AC/DC
(TA33 AC/DC) (TA34 AC/DC)
Enclosure class IP 23 IP 23
Application class S S
Weight, Kg 15 15
Caddy Tig 2200i AC/DC, TA33 / Standards of compliance IEC/EN 60974 -1/-3 IEC/EN 60974 -1/-3
TA34 AC/DC
IEC/EN 60974 -10 IEC/EN 60974 -10
l TA33 - parameters adjusted based on plate thick- Gas pre-flow, sec Preset Preset
ness. Gas post-flow, sec 0 - 10 5 - 25
l TA34 - manually adjust all parameters. Pulse frequency DC, sec -- 0.01 - 2.5
270
Technical Data Tig 3000i AC/DC, TA24 AC/DC
Application class S
Weight, Kg 42
Inverter Power Sources for AC/DC TIG / DC Pulse Slope up, sec 0 - 10
TIG / MMA
Slope down, sec 0 - 10
l Designed to weld any metal e.g. aluminium, copper,
Gas pre-flow, sec 0-5
stainless steel and its alloys with high performance.
Gas post-flow, sec 5 - 25
l Digital display, 2 job memories.
Pulse / background current, A 4 - 300
l QWave - High performance AC welding with low
Pulse / background time, sec 0.01 - 2.5
noise.
AC balance, % 50 - 98
l Electrode preheating - excellent arc start and
Arc Equipment
extended electrode life-time. AC frequency, Hz 10 - 152
l Burns MMA electrodes of any class of size up to 5.0 Coolant type 50% water / 50% ethylene glycol
mm.
Cooling power, W* 1700
l Trolley, remote hand / foot control optional. Coolant volume, ltr 4.2
Weight (empty), Kg 19
271
Technical Data Tig 4300iw AC/DC,
TA24 AC/DC
Enclosure class IP 23
Application class S
Weight, Kg 95
Origo Tig 4300iw AC/DC, TA24 TIG start mode HF / Lift Arc
AC frequency, Hz 10 - 152
l QWave - High performance AC welding with low
noise. Electrode preheating 1 - 100
l Energy save made - cooling fan and pump on Coolant volume, ltr 5.5
demand. Max flow, ltr/min 2
l Burns MMA electrodes of any class of size up to 6.3 * At 40 Deg C temperature difference and flow rate 1.0 ltr/min
mm.
272
Technical Data TXH 150 / TXH 200 /
TXH 150r / TXH 200r /
TXH 150V TXH 200V
Arc Equipment
l TXH 150r/200r/250wr/400wr/400wr HD TIG
torches available with remote control for
CAN-bus based TIG machines i.e. for Caddy Tig
2200i AC/DC, Origo Tig 3000i, Origo Tig 3000i AC/
DC, Aristo Tig 4000i and Origo Tig 4300iw AC/DC.
273
LPH 35 / 50 / 80 / 120
Rugged Power Sources for Air Plasma Cutting
l Faster and economical on Al, SS and CS below 20 PowerCut 650 / 900 / 1300 / 1600
mm. Inverter Power Sources for Air Plasma Cutting
l Cutting can be done from gauge thickness to thick l Inverter based power source, excellent cutting
plates. output.
l Very safe and convenient. l Robust and compact construction.
l No distortion even on sheets below 6 mm. l Cuts thin sheets of gauge thickness to thick plates.
l Light weight torches make cutting effortless. l Cutting packages with mechanized cutting torch
l Circle and profile cutting attachments available also available for PC1300 and PC1600.
optionally. l Circle and profile cutting attachments available
Technical Data LPH 35 LPH 50 LPH 80 LPH 120 optionally.
Mains supply, PhxV, Hz 3x415, 50 3x415, 50 3x415, 50 3x415, 50 Technical Data PC-650 PC-900 PC-1300*** PC-1600***
OCV, VDC (Max) 295 320 310 310 Mains supply, PhxV, Hz 1x230*, 50 3x400, 50 3x400, 50 3x400, 50
Arc Equipment
Output@% duty cycle, A -- -- -- OCV, VDC (Max) 290 275 278(typical) 278
Pressure, bar 3.5 - 7 4.5 - 7 4.5 - 7 4.5 - 7 Output@% duty cycle, A 40@40% 60@60% 70@100% 90@60%
Cutting capacity, mm 8/12* 12/15* 25/35* 35/45* Air supply, ltr/min / bar 118/5.5 150/5.2 165/5.5 165/5.5
Enclosure class IP23 IP23 IP23 IP23 Cutting capacity, mm 15.9/19** 22/32** 32/38** 38/45**
Type of cooling Forced Air Forced Air Forced Air Type of cooling Forced Air Forced Air Forced Air Forced Air
Dimensions, lxwxh, mm 610x255 680x325 760x390 760x390 Dimensions, lxwxh, mm 483x318 516x275 800x318 800x318
x515 x515 x845 x845 x416 x409 x419 x419
Torch/length, m PT-30KK/4 PT-27/7.6 PT-27/7.6 PT-25/7.6 Manual cutting torch PT-31XLPC AU PT 38 AU PT 38 AU PT-38
* Quality cut / sever capacity Torch length, m 7.6/15.2 7.6/15.2 7.6/15.2 7.6/15.2
274
Technical Data CPRA 800(S) CPRA 1200(S)
Power Source
l 4-step voltage control in coarse and fine mode. Speed range of tractor, m/min 0.15 - 15 0.15 - 15
l Mains voltage compensation ensures minimal Wheel center of tractor, mm 350 350
fluctuation in arc voltage. Dimensions, l x w x h, mm 1368x410x1145 1368x410x1145
Arc Equipment
275
Welding Automation
Thyristorised SAW Power Sourc-
es - DC
LAF 635 / 1000 / 1000M / 1250 / 1250M / 1600 /
1600M
LAF 635 LAF 1000 LAF 1000M LAF1250M LAF 1250M LAF 1600M LAF 1600M
Mains supply, V/Hz 400/50-60 400/50-60 400/50-60 400/50-60 400/50-60 400/50-60 400/50-60
Max output at 60% duly cycle, A 800/44 1000/44 1000/44 - - - -
Max output at 100% duty cycle, A 630/44 800/44 800/44 1250/44 1250/44 1600/44 1600/44
Setting range, A/V, MIG/MAG 50/17-630/44 50/17-1000/45 50/17-1000/45 60/17-1250/44 60/17-1250/44 - -
Setting range, A/V, SAW 30/21-800/44 40/22-1000/45 40/22-1000/45 40/22-1250/44 40/22-1250/44 40/22-1600/46 40/22-1600/46
Open circuit voltage, V 54 52 52 51 51 54 54
No load power, W 150 145 145 220 220 220 220
Efficiency at max current 0.84 0.84 0.84 0.87 0.87 0.86 0.86
Power factor at max current 0.90 0.95 0.95 0.92 0.92 0.87 0.87
Voltage, 3 ph 60 Hz, V 400/415 400/415/500 230/400/415/ 400/415/500 230/400/415/ 400/415/500 230/400/415/
500 500 500
Voltage, 3 ph 60 Hz, V 440 400/440/550 230/400/440/ 400/440/550 230/400/440/ 400/440/550 230/400/440/
550 550 550
Endosure class, protection IP 23 IP 23 IP 23 IP 23 IP 23 IP 23 IP 23
External dimensions, LxWxH, mm 670x490x1090 646x552x1090 646x552x1090 774x598x1428 774x598x1428 774x598x1428 774x598x1428
Weight, kg 260 330 330 490 490 585 585
Arc Equipment
l Excellent arc ignition characteristics and good weld- Enclosure class, protection IP 23
ing properties.
External dimensions, LxWxH, mm 355x210x164
l Ideal for SAW.
TAF 800 TAF 1250
Mains supply, V/Hz 42 (AC)/50-60
Max output at 100% doty cycle, A 800 1250
Weight, kg 5.5
Setting range, A/V 300/28- 400/28-
800/44 1250/44
Max power consumption, VA 900
Open circuit voltage, V 71 72
Efficiency at max current 0.86 0.86
Power factor at max current 0.75 0.76
Voltage, 1 ph 50 Hz, V 400/415/500 400/415/500
Voltage, 1 ph 60 Hz, V 400/440/550 400/440/550
Enclose class, protection IP 23 IP 23
External dimensions, LxWxH, mm 774x598x1228 74x598x1228
Weight kg 495 608
276
Orbital TIG Welding
A21 PRB/PRC/PRD 100/PRD 160/ POC 12-60, Aristo
Mech Tig 4000iw
Arc Equipment
arc voltage control, which produces higher productiv-
ity and better welding quality, particularly when welding
thick-walled tubes.
277
It is a small, compact, motor-operated trolley designed
for the mechanisation of GMAW, gas metal arc welding,
in particular. The permanent magnet built-in magnet,
which can be switched on/off, holds the tractor in the
correct position on the work-piece.
Weight, kg 8.5
Power, W 20
Weight, kg 7
Weight, kg 17
278
l Quick set-up and easy operation
l Quick assembly and easy operation Railtract FW1000, Flexi Weaver, for oscillated welding.
The Railtrac FW 1000 can be delivered in a “FW1000
l Programmable with five programs L” version if the welding process need to be done with a
lower welding speed than with FW1000.
l Calibrated setting values in cm, mm and sec
l Welds and outs in all positions on magnetic and
l Programmable “backfill” for crater filling
non-magnetic materials
Railtrac FR1000
Arc Equipment
Railtrac BV1000 / BVR1000
l Welds and cuts in all positions on magnetic and non-
magnetic materials Railtrac BV1000 and BVR1000 are two automatic units
for mechanising the repair and hardfacing of rail pro?les
l Quick set-up and easy operation
smoothly and efficiently. The equipment can be assem-
l Programmable with five programs bled, and controlled quickly and easily by one person.
Learning to use it is easy and extremely fast.
l Calibrated setting values in mm, cm and sec
Rail length, m 2
l Programmable “backfill” for crater filling Welding speed, m/min 0.1-1.5
Weaving range, mm 1-80
Weaving speed, mm/s 7-50
Max power consumption, W 80
Control voltage, V, AC 36-46
Crater fill duration, s 0-9.9
Zero-line shift, mm 25 (+-12.5)
Railtrac FWR1000 Programmable edge length, cm 6-99
Railtract FWR1000, Flexi Weaver Return, for oscillated Weight, kg 7
welding with automatic return.
The track for all the above models of Railtrac are made
l Welds in all positions on magnetic and non-magnetic of Aluminium and can be either extended or cut to get
materials the required length.
279
A2 Multitrac with
Weight, kg 47 47 43 43
Tractor Automats - Trippletrac /
Multitrac / Mastertac
A2 Trippletrac
A6 Mastertrac
280
Roller Beds Positioners
Esab offers a wide range of roller beds with capacity Esab offers a comprehensive range of positioners for
varying from 5 - 250 tons. The roller beds have mechan- automatic welding. These very versatile welding tools
ical adjustment for circular work-pieces and self-aligning enable welding to be carried out in the optimum posi-
roller beds, which automatically adapt o the roller bed tions to benefit the quality of the work. The positioners
diameter. These roller beds are designed to operate in can be integrated with A2/A6 automatic welding equip-
combination with A2/A6 automatic welding equipment ment.
and Esab’s columns and booms.
Arc Equipment
281
Friction Stir Welding Friction Stir Welding
Legio Friction Stir Welder Super Stir Friction Stir Welder
The LEGIO combines the latest technology with proven The SuperStir program includes a variety of machines
quality. The modular system makes it possible to as- developed from a standarized SuperStir base unit
semble welding stations to suit the most varied Friction having working ranges of 0.5x1.5m (19.7x59in) up to
Stir Welding applications. 10x20m (33x66 ft) within the same concept.
The LEGIO system consists of five basic designs in a This includes customized models of various designs for
series of seven sizes, covering a welding depth of 1.2 specific customer requirements in different production
mm (.045 in) to 60 mm (2.4 in). These basic types can areas.
be supplemented with different types of equipment to
suit the most varied production needs and give maxi- These different designs are used worldwide in R&D
mum flexibility to any production line. centers for joining of extrusions to panels, in production
of pressure vessels as well as small parts for the auto-
The versatile Legio family includes linear motion with motive and electronic industries.
Arc Equipment
282
Robotics for Arc Welding
Esab offers a wide range of automated welding solu-
tions using a range of robots from ABB. Robotics can
provide a cost-effective and modular solution for a va-
riety of welding applications with increased productivity.
The various advantages of using robotics are:
Pre-program Offline
Arc Equipment
gantries, columns with booms and elevators for heavy-
duty welding, allowing for a wide variety of working
range capabilities. Workpiece positioners with one or
two axis can also be added to this to increasing the flex-
ibility in positioning.
283
Range of Robots IRB 2400L
IRB 140 Slim yet robust arm-based, 6-axis robot. All the IRB
2400 industrial robots are ideal for arcwelding applica-
ABB’s fastest and smallest arm-based industrial robot. tions. Features unlimited axis 6. IRB 2400L load capac-
Highly flexible with slim wrist, 6-axis robot able to reach ity is 7 kg; reach 1.8 meters. IRB 2400/10 load capacity
into narrow, small spaces. Easy-to-mount equipment. is 10 kg; reach 1.5 meters. IRB 2400/16 load capacity;
Robust and compact. The standard IRB 140 can be 16 kg; reach: 1.5 meters.
mounted at any angle without modification for optimum
reach and efficiency. Load capacity: 5 kg; supplemen-
tary load is: 1.5 kg; reach: 0.81 meters.
Arc Equipment
IRB 4400
284
Accessories
ARMOUR HEAD SCREEN For sale comfortable, life long welding. They are de-
signed for use with intermittent welding currents up
l Ultra light weight (Lighter than fibre glass) Rugged, to 600 A. Suitable for manual Welding Electrodes 1.6
Flame retardant construction mm to 6.3 mm. The welding cable is connected to the
electrode holder by a slip proof mechanical fastening
l Extended Crown: For better protection of the arrangement.
head.
Welding Cable
l Lift up arrangement for the lens
Single core tough rubber sheathed copper cable and al-
Arc Equipment
l Height Adjustment: The facility to adjust the helmet uminium cable are available in the following sizes made
height with respect to the operator’s convenience exclusively for long life performance by ESAB.
provides operator ease.
400 amps. Aluminium and copper (70 sq. mm & 50 sq.
l Ratchet headgear: Ensures the fitting to any head mm respectively.)
size without slightest hesitation or problem.
600 amps. Aluminium and copper (120 sq. mm & 70 sq.
l 4 point contact adjustment: Ensures perfect fitting mm respectively.)
to any face size and eye level.
Conforming to IS-9857
l Rigid lower lib provided deflects welding spatter
from chest area.
l Accommodates
Standard 41/4”x 31/4” welding
lens.
285
ARMOUR RANGE OF ELEC- HANDYOVEN
TRODE HOLDERS Portable Electrode Drying Oven
EHOP 400/600 & EHJK 400/600 ESAB Electrode drying oven - Handyoven is designed to
make it portable and is ideal for redrying medium quantity of
Specially designed for heavyduty use where Safety, electrodes. Most of the welding electrodes, particularly the low
Ease of Use and Economy is highly appreciated. The Hydrogen Iron powder type electrodes may absorb moisture
from the atmosphere. If the moisture is excess than the rec-
fully insulated fibreglass reinforced moulded handles
ommended level consistent with the type of flux, they should
and Tip insulators are provided to make the product be redried before use at 130°C-230°C to drive away and ab-
shock proof, and resistant to Heat, Oil and light impacts. sorbed moisture from the flux coating.
Arc Equipment
286
CHOICE OF FUSION WELDING
METHOD
When choosing welding methods, you need to pay at-
tention to several factors:
Arc Equipment
1. Gas shield
10. Choice of welding method which gives the lowest
2. Tungsten electrode 3. Gas nozzle
costs. Calculation of consumables consumption.
4. Filter wire
11. Estimate of the accuracy of the joint preparation
5. Metal drops
which must match the welding method.
6. Molten pool
12. Please also compare table-key data for the most
common fusion welding methods.
Welding Methods
MMA-welding-manual Metal Arc Welding or Manual SAW-welding (submerged Arc Welding).
stick electrode welding.
1. Electrode from spool
1. Gas shield from the electrode coating
2. Electrode coating 2. Flux
3. Core Wire
4. Metal drops 3. Molten pool. Diagram shows the electrode surround-
5. Molten pool ed by flux and a cover of melted flux
287
288
Arc Equipment
MMA Manual Metal Arc Welding
Manual Metal Arc welding, also called hand welding, interfere through magnetic arc blow.
is still the best known and most common method of 5. Use a static welding converter (rectifier or inverter)
welding. for welding of heavy plates if the mains supply is
Manual Metal Arc welding is noted for: weak.
6. Use gravity welding for mass production of long
1. Low investment cost.
straight fillet welds.
2. Low cost of filler material in relation to kgs. weld
7. Weld vertical down instead of up whenever
deposit. 3. Filler material (stick electrodes) are easily
possible.
available in a wide range of types and dimensions.
4. Less strict demands on edge preparation and Equipment
purity of the parent material than by other welding The equipment consists of power source, welding cable,
methods. electrode holder and return cable. Below is a survey of
5. The same equipment can be used for all non-alloyed, the characteristics of different power sources.
low alloyed and stainless welding construction Welding transformers
steels. Also for cast iron, modular iron and weldable
They give alternating currency (AC) and are the least
non-ferrous metals.
expensive power sources. They have a high efficiency
6. Short set-up times, good at piece fabrication.
80-90% for the most commonly used transformers for
Arc Equipment
7. Can be used in all positions. Also in narrow spaces
welding. They are used for welding of unalloyed, low
with hard to get at welding points.
alloyed stainless steels and cast iron but not for e.g
8. Often gives a more machineable weld deposit than
aluminium.
Gas Metal Arc Welding.
9. Reasonable heat input to the parent material. Certain electrodes have better welding characteristics
This gives reasonable grain growth and thus a on alternating current (AC) than on direct current (DC).
transformation zone less exposed to brittle fracture Among these electrodes you find in particular the high
than other methods working with higher heat input. recovery types, and notably the larger dimensions.
The efficient and economical use of the Manual Metal Welding rectifiers
Arc welding method can be summed up in the following In this case a rectifier has been added to the transformer,
seven recommendations. thus supplying DC. It costs approximately twice as much
1. Weld in the horizontal position with high recovery as a transformer of corresponding size. For modern
stick electrodes whenever possible. This minimizes rectifiers, the efficiency is 60-80%.
both weld time and energy consumption. For both rectifiers and transformers, the efficiency is
The use of roller beds and positioners can often lower, the lower the used current is. Vice-versa a higher
contribute to a shorter weld time by making horizontal utilization of the capacity of the power source gives
welding possible. a higher efficiency. The rectifier may be used for all
2. Use sufficiently strong power sources to make weldable materials.
possible the use of fast welding high recovery Welding converters
electrodes. One electric motor (AC) is coupled to a generator (DC).
3. Save on electricity by using power sources with high Generally, a more expensive solution than a rectifier of
efficiency and low no load rating. corresponding size. The efficiency is 50-60%.
4. Use welding transformers for heavy plates,
framework and in other cases when DC welding will Its range of use is the same as that of the rectifier.
289
Engine driven generators For fillet welds with 4-5 mm effective throat thickness,
the maximum weld speed is 0.5 m/min when using OK
These normally provide DC. They are more expensive Femax high recovery electrodes.
than converters and as a rule heavier.
For gravity welding using 600-700 mm long electrodes,
The smaller types normally have 2-stroke petrol engines, you can reach a speed of up to 60m/manhour when
whereas larger ones have diesels. In both cases the welding straight fillet joints. For gravity welding, AC is
engine drives the DC generator. always used. The effective throat thickness may be
varied by using different electrode dimensions.
Welding inverters
Range of application-Material types
This is the most recent development within Manual
Metal Arc welding. Inverters produce DC or AC/DC. The Manual Metal Arc welding is used for all unalloyed, low
efficiency is high - 80-90%. The cost is somewhat higher alloyed and stainless common structural steels according
than that of a conventional thyristor regulated rectifier. to Swedish Standard (SS) and other comparable steels.
See also “Standards, Classification System and Codes”
The Inverter’s main components are:
in the ESAB Welding handbook-Filler Materials.
l A rectifier which turns the incoming 3-phase AC
These steels comprise:
(sometimes only 1-phase AC) into DC.
l Common structural steel.
l An inverter which changes this DC into HIGH
FREQUENCY AC. l Pressure vessel steel.
l A transformer which takes this current down to a l Ship plate.
lower voltage (20-50 V).
l Cast steel and machine steel.
l A rectifier which transforms the AC into DC suitable
for welding. Manual Metal Arc welding is also used for:
The inverter’s main features are low weight and volume. l Spherolitic cast iron.
Since both efficiency and power factors are high, smaller
mains cables and fuses may be used in comparison to l Malleable iron.
conventional rectifiers. l Weldable non-ferrous metals.
Productivity-Welding Speed
Arc Equipment
290
MIG/MAG Gas Metal Arc Welding
MAG WELDING
Gas metal arc welding with active gas Spray Arc welding IS tne best method for plate thickness
For this method it is significant that DC is used, and above 3 mm.
that the electrode is a wire which is automatically fed to Spray Arc welding is only used in horizontal and vertical
workpiece. The arc is surrounded by the shielding gas. butt position.
The negative pole of the power source is connected to Productivity-Welding speed
the workpiece. The welding speed of MAG welding is measured in kgs
MAG welding takes place in a shielding gas zone of weld deposit per hour. When welding horizontal fillet
consisting of Carbon Dioxide (C02) or a gas mixture weld in thick materials, MAG welding is slower than
consisting of 80% Ar!Jon and 20% Carbon Dioxide. Manual Metal Arc welding using high efficiency stick
The Argon/C02 mixture is costlier than pure C02’ But electrodes.
it gives a softer arc, smoother weld and less spatter. MAG welding is suitable for thin plates. You can also
The mixture also contributes to a higher strength and weld medium size plate, piece constructions and small
ductility of the weld metal. to medium sized crossbar jobs with good economy.
Arc Equipment
The Argon/C02 mixture is therefore generally preferred The advantages of MAG welding are:
for welding of thin plate and often for low alloyed steel. 1. No stoppages for change of stick electrodes (in com-
The electrodes are usually solid wires with diameters parison with Manual Metal Arc welding)
0.6, 0.8, 1.0, 1.2 or 1.6 mm, usually on spools of 5-15 2. Less distortion due to shrinking in comparison with
kgs, or flux cored wires with diameters 1.2, 1.4, 1.6, 2.0 Manual Metal Arc welding. The advantages are:
or 2.4 mm on spools of 15 and 25 kgs. l less straightening work after welding
Short Arc welding means a low arc voltage giving a l often simpler welding fixtures
short arc. Practically all metal transfer through the arc is l possibly a better bead appearance
completed by short-circuiting globules. 3. Smaller joint volumes when compared to Manual
Metal Arc welding because of the thinner electrode.
Spray Arc welding needs more than 200 A and 25 V. On
A 6.0 mm coated high recovery stick electrode may
the whole, the metal transfer is by free-flight globules
have an outside diameter of about 15 mm.
being forcefully propelled through the arc.
4. There is no de-slagging. A certain quantity of metal
Short Arc welding is the best method for: oxide is found as “slag isles” on the bead. The ori-
l Thin plate. gin is a chemical reaction between Mn, Si and C02’
l Thin pipes. They should be removed, if strict rules apply to the
l Root runs in butt joints with edge preparation. surface of the weld.
5. There is no risk of hydrogen brittleness in quenching
With Short Arc welding you weld in all positions. steels caused by moisture in a stick electrode coat-
Welding vertical down should be limited to thin plate. ing.
There is a risk of insufficient penetration which grows 6. The weld deposit quality may well be compared with
with a growing plate thickness. This is more apparent at what can be achieved with normal basic electrodes.
vertical down than in other welding positions.
291
Range of application - Materials - Plate thickness MIG WELDING
All unalloyed and low alloyed steels may be welded. Gas Metal Arc welding with Inert (non-active) Gas
Use Short Arc from about 0.8 to 3 mm and Spray Arc In MIG welding, as in MAG welding, you work with
from about 3 mm plate thickness. Short Arc as well as Spray Arc. The most common gas
is Argon, but mixtures of Argon and Helium are also
MAG welding with flux cored wires is done with plate used. When welding stainless steel, it is often difficult
thicknesses from about 8 mm for longer beads and up to achieve a good penetration. If some few per cents of
to 10 mm for shorter (less than 0.5 m). Oxygen are added to the mixture, this disadvantage is
overcome and the arc will be stabilized.
Helium-Argon mixtures give a “hotter” weld than pure
Argon. These mixtures are therefore often preferred for
thick copper and aluminium materials.
For aluminium welding of medium thickness, pure Ar-
gon is used.
Welding positions are: Short Arc-all positions, Spray
Arc-horizontal position.
The radius of action is 3-16 m from the wire reel, de-
pending on machine model.
The equipment is the same as for MAG welding.
The shielding gas Argon wth 2% C02 has given as good
results as Helium with Argon, when welding heavy stain-
less plate. Since Argon witn 2% C02 is less expensive
than Argon/Helium, the former gains in popularity for
stainless.
However, steels with extra low carbon content should
not be welded with Argon/Helium. Instead, Argon+2%
02 is used.
In any case, the quality of the weld deposit is the best,
provided parent material and the filler material are of
Arc Equipment
292
TIG (GTAW) Tungsten Inert Gas Welding
TIG is a welding method where the electric arc is created TIG is used both for manual and mechanized welding.
between a non-melting electrode and the workpiece in For manual welding, the welding consumable is fed by
an atmosphere of inert gas. That means that the gas hand, as for oxyacetylene welding. In equipment for
does not take part in any chemical reaction during mechanized welding, a feed unit is used for wire. The
welding. welding wire is on a spool and is automatically fed to the
welding torch.
The arc melts the parent metal and the welding
consumable, if any. The molten pool, as well as the TIG welding is used from 0.5 mm material thickness and
electrode, is protected from Oxygen and ‘Nitrogen in the up to 5-6 mm. For heavier material, TIG is often used for
air by the shielding gas. This gas is usually Argon, but root beads in order to make sure of a perfect root pass.
Helium or mixtures of Helium and Argon are also used. No other method equals TIG in this respect. Consecutive
beads are made with more productive methods and
TIG welding is done with DC or AC. DC negative pole filler materials such as Gas Metal Arc, Submerged Arc
is used for all metals which do not form oxides which or Manual Metal Arc with high recovery electrodes.
are difficult to weld, like e.g aluminium and magnesium.
They are instead welded with AC, the positive amplitude With plate thickness of less than 1 mm, you often use
of which has a good breakdown effect of the oxide. flange butt joints and edge joints. Butt joints are welded
up to 3-4 mm thickness. Above that, you use, V- or U-
The name of this method was taken from the first letters joints. Sometimes also x-joints. In this case the groove
of Tungsten Inert Gas. angle should be 60° and the unbevelled edge 1-1.5
Arc Equipment
mm.
Range of application
A general rule for selecting the welding current is:
The TIG process is noted for high weld quality, purity
Aluminium 45 A, copper 70 A, steel 50 A per mm
of weld material and an even surface. It is used where
thickness.
quality demands are high, e. g. within the nuclear and
process industries, but also for difficult-to-weld materials TIG is used in all positions.
such as titanium, monel, copper-nickel etc. The largest
range of application is for stainless steels and light Productivity-Welding speed
metals.
Manual TIG welding : about 30 cm/min
293
Range of application - plate thickness - edge prepa-
ration
294
Common Faults in Arc Welding
Weld faults are in most cases hidden deep under the has been put into the production before theoretical and
surface of the weld, and therefore difficult to detect. practical training have been carefully accomplished.
The most common and reliable methods of detection
presently used are ultrasonic and X-ray tests. These A common cause of incomplete penetration with Gas
methods permit quality control of the weld without Metal Arc welding is usually too low travel speed. This
changing or destroying it. You can expose most faults gives a molten pool too large for the arc to melt the joint
with respect to type, size and position. walls.
The X-ray test has also proven to be of great importance On the other hand, incomplete penetration is not rare
to the welder himself. It has been established that certain when thick stick electrodes are used in Manual Metal
faults, which the welder perhaps makes more or less Arc.
unconsciously, gradually disappear if he is shown X-ray
pictures and informed of what they reveal.
Incomplete penetration will occur if the welder strikes the
In other words, the X-ray picture is an excellent
arc against one of the fusion faces and lets the molten
educational means. It makes the weld so to speak
pool run down onto the other, cold face. It may also
‘’transparent” and shows it in full length. The welder can
occur if too low current is used on very thick material.
easily learn from the fault, since you can conclude how
Then the heat supply will not be sufficient to melt the
the fault arose from the nature and position them. In
parent material.
this way, the welder can steadily manage to eliminate
possible shortcomings and improve his craftmanship. Slag inclusions
The most common faults are pinholes, slag inclusion, On an X-ray picture, slag inclusions stand out as lines.
undercuts, root defects, incomplete penetration, and The picture below shows a cross section of the weld.
cracks. Here, the de-slagging has been incomplete between the
beads. When the top bead was welded, pieces of slag
Above all, incomplete penetration, slag inclusion,
from the previous bead were not melted. Instead, the
undercuts and root defects can be linked to lack of skill
top bead sealed them in.
and precision on behalf of the welder.
You will observe this on the X-ray picture as typical
Incomplete penetration that is incomplete fusion between
lines.
weld and parent material, may easily occur at Gas Metal
Arc welding if not done professionally. In most cases, The risk of creating this fault is greater if the underlaying
the cause is a too short training period. The welder bead is strongly convex. If, for some reason, a strongly
convex bead is welded, it is recommended to grind off
Arc Equipment
some of it. Then the risk of fault is eliminated.
295
Please pay special attention to multi-bead welds! check Undercut will always mean a weakening of the joint.
carefully that there exist no sharp angles between the Therefore please always weld so that undercut is avoid-
different beads. If so, it may be impossible to remove ed. If, in spite of all precautions, this cannot be achieved,
the slag or melt down slag deposits all the way to the then in most cases the undercut should be welded up.
bottom when laying the next bead.
In undercut, it is common to find slag deposits remain-
The pictures below shows a multi-bead weld which is ing inside the weld. But the X-ray film will reveal slag
incorrectly done. Narrow grooves have been created inclusions.
beween the beads. The same weld, but correctly done,
is shown further on. Root defects
Undercut
296
removed, the defect is closed-in by the backweld. It will in connection with the gouging of the root before the
then be revealed by the X-ray or ultrasonic inspection. back bead is welded.
In Submerged Arc welding, the penetration in the joint It should, however, also be noted that cracks may ap-
is an important factor. When root defects appear, the pear in the weld or the parent material which have noth-
penetration has been inefficient. ing to do with the welding procedure.
If, in the case of double-sided welding, the beads have Examples of this are hot cracks or solidification cracks
not met at the bottom, there could be several reasons which run along in the middle of the weld. These are
such as: common at fillet welds, where a difficult tension situation
is at hand.
l The joint had a too big unbevelled edge.
The reason for these cracks may be parent material.
l Too small groove angle. This could be difficult-to-weld steel, having too high
contents of Carbon, Sulphur and possibly Phosphorus.
l Possibly both these causes together.
These elements give certain segregation effects when
l Too low welding current. the molten pool solidifies.
l Too high or low welding speed. Acid electrodes are especially sensitive to impurities.
Rutile electrodes are less sensible and basic ones are
l The two beads are not exactly facing each other. practically nonsensitive.
Cracks Unlimited weldable steels have maximum proportions
of Carbon 0.20%, Sulphur 0.05% and Phosphorus
In most cases, cracks are not directly dependant on the
0.04%. If parent metals containing more of these are to
welder’s skill. But a weld can be done in such a way
be welded, basic electrodes should be used. Then you
that formation of cracks is promoted. If there are faults
will avoid hot tears also by high proportions of these
in the weld, of course the risk of cracks is.greater due to
elements.
tension or other influences than if the weld is completely
homogeneous. The same advice is given also for the use of basic elec-
trodes if you have to weld a material where the compo-
sition is unknown.
Hot tear
Arc Equipment
Welded joints is a pipe-formation combined with segre-
gation of Carbon and Sulphur.
297
pressure and the direction was oriented up through the
middle of the molten pool. This is the last portion to be-
come solidified.
Pinholes
298
Industrial Gas Equipment
Gas Equipments
Process Description
Gas Equipments
301
302
Gas Equipments
303
Gas Equipments
Single Stage Regulators
Gas Equipments
304
305
Gas Equipments
Double Stage Regulators
Gas Equipments
306
307
Gas Equipments
High Pressure Regulators
Gas Equipments
308
309
Gas Equipments
Pipe Line Regulators
Gas Equipments
310
Special Regulators
Gas Equipments
311
Cutting Blowpipes
Gas Equipments
312
313
Gas Equipments
Welding & Heating Blowpipe
Gas Equipments
314
315
Gas Equipments
Flashback Arrestors
Gas Equipments
316
317
Gas Equipments
Small Cutting Machine
Gas Equipments
318
319
Gas Equipments
Cutting Nozzles
Gas Equipments
320
321
Gas Equipments
Welding Tips
Gas Equipments
322
323
Gas Equipments
Accessories
Gas Equipments
324
325
Gas Equipments
326
Gas Equipments
PPF & Welding Accessories
Gas Equipments
327
328
Gas Equipments
329
Gas Equipments
HELMETS, MASKS & SCREENS
Gas Equipments
330
331
Gas Equipments
RESPIRATORY EQUIPMENT
Gas Equipments
332
333
Gas Equipments
SPECTACLES, GOGGLES & VISORS
Gas Equipments
334
335
Gas Equipments
WELDING CURTAINS
Gas Equipments
336
WELDING GLOVES
Gas Equipments
337
SAFETY FOOTWEAR
Gas Equipments
338
339
Gas Equipments
WELDING CABLES
Gas Equipments
340
ELECTRODE HOLDERS & CLAMPS
Gas Equipments
341
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