MAILAM INDIA LIMITED PONDICHERRY FCAW MODERN TOOL FOR COST CONTROL ??? R.D.PENNATHUR,Head-Tech.

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The present emphasis in Fabrication Industry is on Productivity & Quality at most economical cost. The process reliability in combination with easy availability of required facility plays a very important role in selection of process .The liberalization of economy has ensured that whole world has become a Global Village. Thus no Industry is insulated from Global Trends & it is essential to keep updating technology to meet International Standards. Hence need for adopting welding techniques, which will give higher productivity & still meet stringent Quality requirements. FCAW has emerged as clear winner under this scenario. 1.0 INTRODUCTION: Industrialization & Globalization has made fabrication Industry highly competitive business. The fabrication engineer has much wider choice in selection of process in view of improvement in availability of Equipments as well as consumables. However each process has its own advantages & limitations. The continuous upgrading of Materials as well as critical design parameter keeps Welding Engineer to develop newer of consumables to suit Fabrication requirements. Thus Fabrication Engineers adopts Process & Consumable, which can give higher Productivity & Consistent Quality. In this context FCAW has important role to play. 2.0 CRITERIA FOR SELECTION: For a given specific application, the Consumable selection with compatible Process is to be done taking following factors into consideration. Metallurgical Mechanical Process

2.1 METALLURGICAL Factors to be considered are, 1.

1. 2. 3. 4. 5. 6.

Base Materials Mechanical Properties Chemical composition Corrosion requirements Physical properties Soundness & Structural Stability Heat treatment

2.2 MECHANICAL 1. Thickness of Material 2. Dimension & No. of components 2.3 PROCESS 1. Available forms of consumables 2. Adaptability for the job 3. Welding process selected 2.1.1 BASE MATERIAL The single important factor determining the selection of filler metal and process is base material specification being joined. The base materials are classified as per ASTM specification. In general the base metals are broadly classified as Carbon Steel, LAS, SS and High Alloy Steels. In addition there are other steels for low temperature application, Q & T Steels etc., for specific application. 2.1.2 MECHNICAL PROPERTIES Mechanical property of weld metal basically covers the aspect of, 1. Soundness 2. Strength 3. Toughness The welding consumable should be so designed, so as to be compatible metallurgically with base material and produce sound weld to give radiographic quality deposits. As the weld metal has a cast structure as compared to the rolled structure of the base metal and weld zone is likely to contain defects like porosity and slag, the weld metal tensile strength is required to be higher than base material. The Weld metal should also have adequate toughness at specified design temperature taking in to account fabrication practices. 2

2.1.3 CHEMICAL COMPOSITION: The Weld Metal chemistry in general matches the composition of base metal for similar metal joining. In case of dissimilar base metals are being welded, due care should be taken to see that diluted weld metal will not result in formation of brittle intermetallic compounds. The design of weld metal chemistry is to be based on diluted weld metal chemistry & its compatibility. The chemical composition of weld metal can be entirely different as compared base metal for overlay / hard facing application. 2.1.4 CORROSION PROPERTIES: The Weld Metal corrosion properties are to be equal or superior to that of base metal. This is to avoid preferential attacks on the weld joint. 2.1.5 PHYSICAL PROPERTIES: The Physical properties of weld metal should be compatible with that of the base metal. These include properties like the thermal expansion co-efficient, thermal and electrical conductivities, magnetic permeability etc. 2.1.6 SOUNDNESS AND STRUCTURAL STABILITY: The Weld Metal should be capable of resisting some amount of dilution of the base metal without forming a crack sensitive weld metal and the weld micro structure should be stable under the expected service conditions. 2.1.7. HEAT TREATMENT: The Consumables selected for joining should be capable of giving the desired test results in as welded condition as well as heat-treated condition. When heat treatment is not specified in design/code, it is very essential to identify various heat-treatment stages during fabrication and ensure that consumable selected does meet these requirements. The general heat-treatment cycles encountered during fabrication are normalizing and stress relieving. 2.2.1. THICKNESS OF MATERIAL: For selection of proper consumable and process, thickness of material plays a vital role. The selection of semi-automatic and automatic process comes into picture only if base metal thickness normally exceeds 10mm and joint configurations are adaptable for automation. 2.2.2. DIMENSION & NO. OF COMPONENTS: While thickness in principle decide the selection of process, the dimension of job and number of components to be welded also play an important role. In case of heavy sub-assembles even though length of the joint may be too small for automation, if the operation is repetitive in nature, the same can be considered 3

for automation. The automation not only reduces the cost but also improves the quality of jobs.

2.3.1. AVAILABLE FORMS OF CONSUMABLES: As you will all agree, this is single most important factor for selection of process. Once the technical details are worked out and suitable consumable specifications are identified, it is essential to find out whether consumables are readily available for SMAW, GMAW, FCAW &/or SAW before process selection could be started. At present, thanks to technological development, in general for all common materials SMAW, SAW & FCAW consumables are readily available. 2.3.2. ADAPTABILTY FOR THE JOB: Before finalization of the type of consumable to be used, it is essential to study whether the job is being done in the workshop, site or sub-contractors premises, so as to ascertain availability of suitable equipment and also take into consideration environmental condition. 2.3.3. SELECTION OF PROCESS: The process selection of course is based on availability of suitable consumables in addition to taking into consideration thickness of components, dimensions, number of components also adaptability of the process for the job. We will now look at various process options available such as SMAW, SAW, GMAW & FCAW Advantages & Limitation of each of above. 2.3.3.1. SHIELDED METAL ARC WELDING (SMAW): Advantages: a) Variety of electrodes with different features: As flux coating makes it possible to control weld metal chemistry, most wide range of consumables manufactured Most versatile in use-all-position joints/joints with limited access This is due to all position capability of consumables, ease of operation & also availability of qualified personnels & equipments. a) Suitable for most alloys This is extension of availability of suitable consumables. b) Equipment simple, inexpensive & portable. Disadvantages: a) Finite length Consumables are manufactured in fixed lengths of 450/350-mm. Hence process inbuilt with repeated stops, which results in lower productivity. b) High dependence on welder skill 4

Training of welder is most critical aspect for successful application c) Not amenable to automation Due to finite length of consumables, it is essentially labour intensive process 2.3.3.2 GAS METAL ARC WELDING (GMAW): Advantages: a) Continuous electrode Development toward automation wherein consumable is supplied continuously b) Higher current possible Even though the consumable diameter is smaller i.e. 1.2/1.6 mm higher current can be used due to higher speed of welding (Wire feed rate) c) Highly amenable to automation In view of continuous wire feed, can be automated based on specific application Disadvantages: a) Special Equipment required which is marginally costlier their SMAW b) Welder skill dependence still high, especially for out-of-position welding c) Not amenable to customization As weld metal chemistry will be same as wire chemistry 2.3.3.3 SUBMERGED ARC WELDING (SAW): Advantages: a) Highest deposition rate Being automatic process the currents can be set at 300 to 1000 amps depending on size of wire, application & hence high deposition rates. b) Most suited for automation As process, it is most suited for joints having symmetrical geometrical contours such as Longitudinal & circumferential joints c) Consumables can be customized As flux used in process can be utilized for addition of alloying elements, the combination wire/flux can be designed to give desired weld metal chemistry. d) Lowest operator fatigue Due automation the operator role is confined to supervision. Disadvantages: a) Not versatile no positional capability Not suitable for positional welding particularly for Vertical & Overhead positions. b) Generally not used for thin sections Recommended for thickness beyond 8 mm c) Joint fit up very critical In view of higher currents being used, mismatch & excessive gap will result in Burn through. d) Arc not visible. Hence joint or seam tracking may be necessary 5

Exact welding location is not visible due to flux covering. Hence external guidance to follow joint contour recommended achieving Quality Welds. 2.3.3.4. FLUX CORED ARC WELDING FCAW, which is also known as Inside-Out as compared to SMAW, has emerged as most versatile tool in the hands of Welding Engineer due to following reasons. a) High Productivity of Continuous Wire Welding. As compared to SMAW process, FCAW is a continuous wire type process giving higher productivity. b) Metallurgical benefit of the Flux-Tailor made Chemistry In addition to being continuous wire welding process, addition of flux makes it possible to produce wire giving weld metal chemistry to various Specifications using same type of strip. Higher Current than Solid Wire The FCAW can use higher current than solid wires as flux Shielding gives lesser heat dissipation & also lower spatter level. c)High Quality Radiography Weld Deposits The capability to use Higher Currents coupled with small diameter of wire makes it possible to achieve better sidewall fusions even in Narrow Grooves. This also helps in selecting superior joint design to reduce overall Weld metal deposition thus reduction in cost of fabrication. d)Versatile Use-All Positional, Wide Thickness Range The most important factor decisively in favor of FCAW is its positional capability as compared to GMAW even when typical specification of GMAW wire is available. Also availability of FCAW in 1.2mm, 1.6 mm & 2.0mm makes it possible apply the process to wide range of Thickness as compared to SAW. e)Visible Arc -Easy to Use In FCAW as compared to SAW, the arc is visible & hence results in Welder Comfort/ease of operation. Disadvantages: a) Special Equipment required which is marginally costlier their SMAW b) FCAW wires more expensive on weight basis but compensated by higher productivity. Even though wire cost is much higher on Kg basis, taking into consideration Productivity. FCAW becomes economical for Industries having higher Fixed Cost 3.0 ANALYSIS: Taking into consideration various process advantages & limitations, following points can be highlighted. For welding of CS/LAS & SS in most cases as all the process consumable are readily available; the process limitation is finally dictated by following criteria.

Dep. Rates Geo. Symmentry Positional Weld Field Joints Difficult Field Joint

SMAW 4 4 2 2 1

SAW 1 1 -

GMAW 3 3 -

FCAW 2 2 1 1 2

Code: (1) Very Good (2) Good (3) Satisfactory (4) Low For welding of alloy steels & special composition high strength steel only SMAW, SAW & FCAW consumables are readily available. FCAW consumables can also be designed to be used with flux for SAW application. The use of FCAW for Fabrication of Carbon Steel, Alloy steel, Q&T high Tensile Steels & Stainless Steel will not only results in faster Productivity but also yields quality welds which do not require any further work like grinding &finishing of Weld Joint. The operational ease, which is characteristic of FCAW process, ensures use of higher currents while welding. 4.0 TYPES OF CORED WIRES: a) Gasless (Self Shielded): Types of consumables available in this grade include Fabrication Wires for out door application, Stainless Wires & also R&M Alloys. The Gasless types of wires are normally available in 1.6mm to 2.4 mm. b)Gas Shielded : In this type of wires in addition to shielding provided by FCAW in form of slag cover & process gases generated, external gas like CO2 or mixed gas cover is used. These types of wires are mostly used for fabrication application. The additional gas cover ensures cleaner welds of radiographic quality. c) Composite Submerged Arc : These types of wires are extremely popular for specific wire chemistry required in smaller lots. Mostly used in combination with Fused or Neutral flux to get desired weld chemistry. d) Metal Cored : Newer generation of wires especially designed for Robotic application. The product yields very less or no slag cover, which avoids one cleaning operation in Robotic application. Also popular in closed environment welding due to high deposition efficiency & low level of smoke All the above types of Wires are readily available indigenously & being used on regular basis by Indian Welding Industries. 7

5.0 THE PRESENT TREND The success in todays competitive business is Productivity & two ways to improve Productivity are, a) Reducing Labor Cost b) Increasing Production Speed FCAW wires are capable of achieving the same in all position & also maintain good quality. In Indian scenario more than 80 % of welding is still being done with SMAW (Stick) & about 8 % by automatic process i.e. SAW. The share of FCAW &GMAW Process is about 10% leaving 2% to other processes. As compared to this, the global scenario regarding application of Process is indicated here below. SMAW GTAW SAW GMAW/FCAW JAPAN 20% 2% 8% 70% EUROPE 30% 2% 8% 60% USA 35% 2% 8% 55% INDIA 70% 2% 8% 20%

In India the Future trend is expected to be as indicated below: - Steady increase in solid &cored wire consumption - Covered Electrode consumption will decline &stabilize around 50% - In developed countries the CO2 welding accounts for more than 50% & India will also follow this trend to catch with International Productivity norms. 6.0 COSTING: In any Fabrication, the cost of a fabrication is divided into the following heads:a) * * * * * * Fixed Cost like Joint Preparation Fixturing Tacking Pre-Heating Clean-Up Inspection

The variable costs involved based on Process being selected are, a) Equipment Cost b) Electrode Cost c) Labor &Overhead Cost

The Equipment & Electrode Cost constitutes around 4-5 % & 8-10% of variable cost respectively whereas Labor &Overhead cost constitutes 80-85 %. As fixed cost remains same for all processes, the reduction in Labor &Overhead cost must bring in overall economy of any fabrication cost. In Table 1 & 2, Current Density of various processes & also cost comparison between SMAW, GMAW & FCAW at overhead cost of Rs.300 per hour is highlighted. It is clear from figures that FCAW becomes economical process even though per Kg. Cost of FCAW is highest. Also Table. 1 clearly indicates that even though same current settings are used for all processes i.e250 amps. The Current Density is much higher for FCAW i.e. 340 amps/sq.mm & hence higher deposition rates. 7.0 Application FCAW process application finds wide range of Industrial Usages wherein positional applications are involved. Ready availability of different types of consumables to varied specification coupled with ease of application makes FCAW first choice of Fabrication Engineer. Here below, some of the typical applications are highlighted. a) Fabrication Industries b) Corrosion resistance overlays c) Hard facing / Repair & Maintenance 7.1 Fabrication Industries The term Fabrication Industries includes the Boiler & Pressure Vessels required for Chemical, Fertilizer, Off shore, Shipbuild, Raw Materials, Transportation & Other heavy structural fabrication activities. All such industries needs classified wires of CS, LAS & High alloy Steels conforming to AWS. As FCAW consumables are available readily to meet full range of specification the same can be used for joining of, - Similar steels - Dismilar steel 7.2 Corrosion Resistance Overlay The development of technology & manufacturing process has made it possible to have corrosion resistance overlay using FCAW process not only for SS but also for but also for application involving Nickel, Monel, Cupro Nickel & Inconel. The easy availability of consumables is required quantity makes adoption of FCAW process advantageous. 7.3 Hard Facing / Repair & Maintenance

This is newer fieldwhere in FCAW has made tremendous progress. This application has two distinct categories. HF for OEM application HF for Repair & Maintenance

7.3.1 HF for OEM application This segment involves HF application on OEM segments like Shovels, Dozers & Shearing blades as well as valve seating surfaces. This basic concept is to avoid high cost Alloy Steel materials, which involves Heat treatment cycle for achieving desired hardness. Instead some OEM manufacturers in earth moving section are selecting Carbon Steel materials to be hard faced with suitable FCAW consumables insitu. This not only results in economical alternative solution but also helps to avoid distortiom problems associated with HT cycle. In other area of specilisation the valve seats are being stellited using FCAW wire. The results are said to be encouraging as overall thickness of overlay has been reduced with better homogeneous microstructure. Thus ability of FCAW to give required Chemistry of weld metal is being fully utilised for Industrial application. 7.3.2 Hardfacing for Repair and Maintenance For various Industrial segments like Sugar, Cement & Coal mines etc, the components used for crushing & sizing the raw material under go regular wear & need to be rebuilt. With available technical know how & also utilization data available the R & M is developing into fire science. The R & M of components which are normally high Carbon / Chrome material gives metallurgical challenge for rebuilding which has to be planned taking in to considieration. Base metal composition Type of wear Surface condition

For application HF on such components it is required to consider following aspects. - Type of Raw material being ground - Abrasive characteristics - Impact load behaviour Taking in to consideration above, suitable types of consumables are to be finalised for build-up. In many cases combination of consumables are used to compact erosion & impact load requirements. It is most common to use 2.4 Dia / 2.8 Dia Open arc FCAW HF consumable for R & M application where in 6 8 Kg weld metal per hour is deposited. The re10

building operation in In-situ requires innovative concepts to be adopted to achieve desired results in shortest possible time. 8.0 CONCLUSION: Based on the present industrial scenario following points can be highlighted. Industries are adopting FCAW, as productive process, which can give, desired quality. The availability of CS, LAS, SS & HF consumable in India has improved in last 5 years & being adopted in Fabrication & Repair & Maintenance Industries. The present process share of GMAW + FCAW which is at 10% is witnessing steady increase & expected to reach 20% by year 2005. As the Industrial application of SAW has already reached 100% utilization level, the FCAW application will have rapid growth. This will also be helped by lower capital equipment investment cost. The ready availability of products to international standards as well as custom built products will ensure adoption of FCAW as process where in productivity & consistent quality are basic requirement.

Table 1 - PROCESS COMPARISON Consumable Dia. (mm) Current Setting :Amps Current Density Amps/Sqmm SMAW 4.0 250 20 GMAW 1.2 250 220 FCAW 1.2 250 340

TABLE 2 - COST COMPARISON - TECHNICAL DATA Labour & Overhead Electrode Cost Rs/Kg Dep.Rate Kg/Hr Dep.Efficiency Operating Factor FCAW COMPANY 150 5.0 0.87 0.45 SMAW SPECI 60 2.0 0.65 0.30 GMAW FIC @ 50 3.0 0.89 0.45 11

Gas Flow Rate LPM Gas Cost Rs/Ltr Power Cost Rs/KWH Volts Amps Rework % Weld Metal Cost /Kg @OH of Rs.300 TABLE IV

FCAW 16 0.04 4 28 300 3 400

SMAW NA NA 4 28 250 8 1,350

GMAW 16 0.04 4 28 250 5 600

WELD METAL COST FORMULAS

1. LABOR & OVERHEAD = LABOUR & OVERHEAD COST / HR DEPOSITION X OPERATING RATE (KG/HR) FACTOR ELECTRODE COST/KG DEPOSITION EFFICIENCY GAS FLOW RATE X GAS COST (LITRE/MIN) PER LITRE DEPOSITION RATE (KG/HR) FLUX COST / KG X 1.4 DEPOSITION EFFICIENCY COST/KWH X VOLTS X AMPS 1000 X DEPOSITION RATE TOTAL COST PER KG OF DEPOSITED WELD METAL = SUM OF 1 5 ABOVE

2. ELECTRODE 3. GAS

= =

4. FLUX 5. POWER

= =

@@@ 1.8: Application FCAW process application finds wide range of Industrial Usages wherein positional applications are involved. Ready availability of different types of consumables to varied specification coupled with ease of application makes FCAW first choice of Fabrication Engineer. Here below, some of the typical applications are highlighted. Process Industries Boiler &Pressure Vessel Industries Heavy Structural Fabrication Off Shore Fabrication Rail &Road Bridges Ship Building Road Tankers Rail Wagon Transportation Repair & Maintenance 12

1.9: Conclusion: The FCAW process has established its presence in Indian Industry. The process share will grow very fast in coming decade in view of higher productivity & ease of application. It may not be out of context to point out that in advance Countries the process share is above 50% as compared to 10% in India. The consumable Manufacturers have already geared-up to expected demand & are in a position to meet Industrial requirements. The quality of FCAW products produced indigenously are of International Standard & are being exported to Gulf Countries on regular basis. Hence the coming decade will see growth of FCAW as Process is capable
of providing higher Productivity, Quality, Consistent Chemistry, Positional Capability & Ease of Application

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