FILARC welder guide

book No. 2
Welder Guide Book No. 2
PZ6113 all-position rutile flux-
cored wire and related types

Index page 1

Back to catalogue

FILARC PZ6113
all-position rutile flux-cored
wire and related types

All-position rutile cored wires

with excellent weldability and high productivity
FILARC welder guide
book No. 2 Due to its policy of continual improvements
in its welding consumables, FILARC reserves
the right to change data in this guide without notice.
PZ6113 all-position rutile flux-
cored wire and related types FILARC Welder Guide Books provide practical information on
the use of specific FILARC flux and metal-cored wires. The
content will assist welders to apply correct welding parame-
ters and use the FILARC cored wire effectively, to achieve op-
timum productivity and avoid faults. The information provided
will be helpful to welders both qualified or still to qualify for
Previous page cored wire welding. There is also helpful information for weld-
ing engineers establishing appropriate welding procedures, for
training instructors and for welding foremen. Overall the guides
will enhance results from the FILARC flux or metal-cored wires
Next page described.
This guide provides practical information on the use of FILARC
PZ6113 and related types with identical welding performance,
listed below. Refer to the FILARC flux and metal-cored weld-
ing wires catalog for detailed information on individual wire
types.
Introduction
FILARC PZ 6113 represents a range of all-position rutile flux-
cored wires with excellent weldability, a high productivity and
a very nice weld appearance. Spray arc droplet transfer in all
welding positions and smooth weld metal wash make these
wires very popular with welders. Welds are flat with smooth tie-
in, ensuring a high fatigue resistance.
Productivity is especially high in positional welding; deposition
rates amount to 3.5kg/h in 3G-up position. All types allow very
productive welding of high quality root runs on ceramic weld
metal support, in the downhand, horizontal-vertical and verti-
cal positions. Weld metal hydrogen contents are below HDM5.
This Guide Book provides all the information you need to en-
sure fully satisfactory use and to obtain high quality welds.

Back to catalogue FILARC Type Size mm AWS New AWS EN

Non-alloyed steels A5.20-79 A5.20-95 758 Index
FILARC PZ 6113 1.2, 1.4, 1.6 E71T-1 E71T-1 H4* T 42 2 P C 1 H5*
E71T-1M H8** T 46 2 P M 1 H10** Correct use of equipment..........................................Page 2
FILARC PZ 6113S 1.2, 1.6 E71T-1 E71T-9 H4 T 46 3 P C 2 H5 Torch, liners and cable assembly ...........................................2
FILARC PZ 6114 1.2, 1.4 E71T-1 E71T-1MJ H4 T 46 4 P M 1 H5
FILARC PZ 6114S 1.2, 1.4, 1.6 E71T-1 E71T-1J H4 T 46 4 P C 1 H5 Wire drive unit.........................................................................2
Low-temperature steels A5.29-80 Gas regulation ........................................................................2
FILARC PZ 6115 1.2, 1.6 E81T1-Ni2 T 50 6 2Ni P M 2 H5
FILARC PZ 6116S 1.2, 1.6 E81T1-K2 T 46 6 1.5Ni P C 1 H5 Gas cup and contact tip combination ....................................4
FILARC PZ 6138 1.2, 1.6 E81T1-Ni1 T 46 5 1Ni P M 1 H5
Correct stickout length ...........................................................4
Weatherproof steels A5.29-80
FILARC PZ 6112 1.2, 1.6 E71T1-G Gas cup sizes .........................................................................4
0.5% Mo creep resistant steels A5.29-80 Positive polarity ......................................................................4
FILARC PZ 6222 1.2, 1.6 E81T1-A1
FILARC PZ 6225 1.2, 1.4 E81T1-B2 Choke .....................................................................................4
* for CO2
** for Ar/20CO2
Welding parameter setting......................................................6
Characteristic features Choice of wire size .................................................................8
FILARC type Shielding gas Cv toughness Recommended average parameter settings ........................10
Back to catalogue/ PZ6112
PZ6113
CO2 or Ar/20CO2
CO2 or Ar/20CO2
20C
20C
ASME and EN welding positions..........................................13

product page PZ6113S CO2 30C Welding advice .....................................................................14

PZ6114 Ar/20CO2 40C
Torch positions for positional welding ..................................16
PZ6114S CO2 40C
PZ6115 Ar/20CO2 50C Weaving technique ...............................................................20
PZ6116S CO2 40C (CTOD tested)
PZ6138 Ar/20CO2 40C (CTOD tested) Grinding ................................................................................22
PZ6222 Ar/20CO2 + 20C Trouble shooting/process faults ...........................................24
PZ6225 Ar/20CO2 + 20C
Trouble shooting /weld defects.............................................25

1
FILARC welder guide
book No. 2
PZ6113 all-position rutile flux-
cored wire and related types
Previous page
Next page
Back to index page 1
Back to catalogue
Replace worn contact tip.
Correct use of equipment
FILARC PZ 6113 and other cored wires will always perform
well when welding sets are used correctly and maintained ac-
cording to the makers instructions. concentric hole worn hole
Following are some simple guidelines for preventive inspection
and maintenance. When carried out regularly, the most com-
mon causes of malfunctioning are avoided.
Torch, liners and cable assembly Inspect torch connec-
Ensure that the contact tip has the right size and is mounted
tions and clean liner
weekly.
tight. Ideally, contact tips are checked for wear upon wire
spool change and replaced when necessary.
Check gas cups for spatter built-up and clean if necessary. Im-
peded gas flow from clogged cups may cause porosity.
Blowing-out the liner into the direction of wire delivery should
be a regularly recurring routine. Check liners for damage at Exit to torch
least weekly, and replace when necessary. Spiral steel liners
are recommended.
Check gas and water connections for leaks. When fitted, en-
sure water cooler is filled and pump operates satisfactorily.
Correct location of wire guide tubes. Minimal space between
guide tubes and rollers. Proper alignment is essential.
Wire drive unit
Wire guide tubes must be as close to the rollers as possible to
prevent kinking of a cored wire. Proper alignment is essential
to avoid unnecessary friction. A substantial amount of fine
metallic swarf underneath the drive wheels indicates misalign-
ment (or excessively worn drive wheels). Exit to torch
Use drive wheels with a V-groove and, by preference, flat pres-
sure wheels. Check that the groove of the drive wheel is cor-
rectly selected for the wire diameter, and that the pressure
wheel is correctly tensioned. Too much pressure may flatten
the cored wire, giving increased wear of liner and contact tip. Excessive space between wire guide tubes and rollers can
Insufficient pressure may result in slip, causing erratic wire cause kinking of wire. Misalignment, also in the plane per-
feed and burn-back. pendicular to the one shown here, causes friction.
Limit the use of knurled wheels to situations where friction in
the liner causes wheels with a V-groove to slip. This is only like-
ly to happen with long, extremely curved cable assemblies,
and/or with units with one set of rolls. Knurled wheels cause in-
creased wear of liner and contact tip. Test wire delivery at the Check gas pressure
torch; this must be regular. and flow rate.
Gas regulation
Check that the appropriate gas is used (see inside cover page).
Adjust the flow rate between 15 and 20 l/min to suit wire and
joint configuration. Outdoors, use 20l. Make a short test run to
assure no porosity arises from incorrect gas flow.
Always check gas flow with a flow meter which fits on the nozzle,
to be sure that the required gas flow is available.
2 3
FILARC welder guide
book No. 2
Gas cup and contact tip combination
PZ6113 all-position rutile flux- 2mm 10mm

cored wire and related types
Previous page
It is essential to mount the gas cup and contact tip at the right
distance relative to each other. The ideal 2mm distance is
shown right. A larger distance will force the welder to use too
long a stickout length, which may lead to lack of fusion defects
and slag traps, mainly in narrow joints. Contact tips extending
beyond the gas cup can cause insufficient shielding gas pro-
tection.
Correct positioning Incorrect. Left: increased stickout caus-
of contact tip. es slag traps and fusion faults, mainly in
narrow joints. Right: contact tip ex-
tends beyond gas cup. Risk of insuffi-
cient shielding gas protection.

Correct stickout length

Next page The stand-off, here and in other FILARC sales literature referred
to as stickout, is the distance between the tip of the contact tip
and the workpiece. It must be held constant at 15 to 20mm for
Back to index page 1 PZ 6113 and related types in all sizes.
Correct, constant stickout must be maintained, as far as joint
preparation will allow. PZ 6113 and related types have a wide Ideal stickout length for all wire sizes.
parameter box, allowing the stickout variations that welders in- 15
-2
tentionally apply, but very large arc fluctuations will cause weld- 0m
m
ing defects.
Too long a stickout results in larger droplets, a "flagging" arc
and spatter, so poor weldability. Also reduced gas protection
Back to catalogue can bring weld porosity.
With extremely short stickout, the weld pool will become
warmer, which may present a problem, for instance, when
welding root runs. Also, it takes away the welders sight of the
weld pool.

Gas cup sizes 15m

Various cup diameters must be available to allow satisfactory m 25m
m
access to the joint, to maintain above recommended stickout
length, and to ensure proper shielding gas protection. Correct. Smaller gas cup Incorrect. Standard gas cup
Small diameter gas cups are used for first layers only. Revert diameter for 1st layers of diameter restricts access to
to the standard gas cup diameter when access to the weld joints with limited access. narrow joints, resulting in too
joint allows this, so full gas protection can be assured. long stickout length.
Check gas flow after a change of gas cup size.

Positive polarity
For PZ 6113 and related types use: Correct gas cup for
filling ensures good
+ POSITIVE POLARITY gas protection and
correct stickout.
Choke
FILARC PZ 6113 and related types operate in the spray arc
mode at all welding currents, so no choke is needed. Switch- Incorrect. Too small a
off the choke or select minimum setting if the choke can not be gas cup diameter for
disconnected. filling reduces gas
protection and brings
porosity.
4 5
FILARC welder guide
book No. 2
Welding parameter setting
PZ6113 all-position rutile flux-
A given welding current requires a specific arc voltage for op- Correct arc length.
cored wire and related types Concentrated arc with
timum weldability. The welding current is established by the
wire feed speed adjustment on the wire drive unit. The arc volt- quiet spray arc droplet
age is regulated by the OCV setting of the power source. transfer.

Advice. Pages 10 to 12 give average parameters for several

Previous page wire sizes and welding positions. These are to be regarded as
a starting point for the welder.
After disconnecting the choke or selecting the minimum cho-
ke value, set the required current value/wire feed speed.
Next page Start welding with the lowest value of the given arc voltage
range. This may result in stubbing (see right), but burn-back of
the wire in the contact tip is avoided.
Back to index page 1 The optimal setting, giving smooth spray arc droplet transfer,
can now be arrived at, as follows.

Increase the arc voltage in steps of 1 or 2V, until the arc

behaviour is satisfactory.

To optimise results or to re-establish the required welding cur-

rent, it may now be needed to:
Back to catalogue Arc length too short.
Slightly adjust the wire feed speed. Stubbing. Wire dips into
weldpool, caused by
At correct settings, there will be a smooth and quiet spray arc too high a wire speed
droplet transfer, a concentrated arc with good wetting proper- or too low an arc voltage.
ties, at a correct stickout length.
If the arc voltage is too high, the arc will spread too much and
may become unstable, wetting properties become worse and
the welder may feel inclined to increase the stickout length to
avoid burn-back. This requires readjustment of the arc voltage
or wire feed speed.

NOTE: Irregular wire feeding can result from incorrect adjust-

ment of wire drive wheels and guide tubes, a damaged torch
cable liner, or a worn contact tip. Check these if weldability
fluctuates; adjustment of welding parameters will not over-
come these equipment faults.

Arc voltage and welding current meters

Usually fitted to power sources, these are helpful for training or
monitoring purposes. They are not a substitute for correct ad-
justment of welding parameters and good judgement by the
welder.

Arc length too long.

Arc spreads. Wire speed
too low, or arc voltage
too high.

6 7
FILARC welder guide
book No. 2
Choice of wire size Wire 1.2mm 1.4mm 1.6mm

Welding Suitability for average application

PZ6113 all-position rutile flux- position
cored wire and related types FILARC PZ 6113 and related types are all available in 1.2 and
1.6mm diameters, allowing optimal productivity for various Root 1G/PA on backing1 on backing1 not recomm.
combinations of plate thicknesses and welding positions. Fill 1G/PA yes2 yes yes
Some types also come in 1.4mm size, providing a useful com-
promise between productivity and the use of a single diameter Root 2G/PC on backing on backing not recomm.
wire for all welding. The chart opposite shows recommended Fill 2G/PC yes yes yes
Previous page use.
Root 3G/PF on backing on backing3 not recomm.
For welding in 3F position the uphill technique is recommend- Fill 3G/PF yes yes possible3
ed. PZ 6113 and related types allow the deposition of a=4 fillet
Next page welds at 18cm/min, without weaving. Root 4G/PE not recomm. not recomm. not recomm.
Downhill welding is possible, but it may require more beads to Fill 4G/PE yes yes3 not recomm.
arrive at the specified a-size. Thin layers and small penetration,
Back to index page 1 moreover, give increased risk of cracking in rigid constructions.
It is not recommended above 5mm plate thickness.
Root 5G/PF
H-L000
not recomm. not recomm. not recomm.

Fill 5G/PF yes yes3 not recomm.

All-position rutile cored wires like FILARC PZ 6113 and related H-L000
types are not advised for one-sided root run welding in butt
joints without grinding and sealing the reverse side. Root 6G/PG not recomm. not recomm. not recomm.
In many applications, however, high quality one-sided root runs HL045
in V-joints can be produced very economically on ceramic Fill 6G/PG yes yes not recomm.
Back to catalogue backing materials, as indicated by chart opposite. HL045

Chart recommendations are for average situations. There will 1F/PA yes2 yes yes
be exceptions for plate size, application area etc., where the
versatility of PZ 6113 will still provide excellent results. 2F/PB yes2 yes yes
For additional advice, contact your FILARC agent or ESAB
sales organisation. 3F /PF yes yes yes
3F /PF yes4 yes4 not recomm.

4F/PD yes yes yes

1 One-sided root pass on ceramic backing, V-joint.
Centerline cracking may occur at welding currents over 200A;
a problem encountered with all rutile welding consumables
(also see page 28)
2 1.4 and 1.6mm sizes will improve productivity
3 1.2mm size is preferred
4 not recommended above 5mm plate thickness

8 9
FILARC welder guide
book No. 2
PZ6113 all-position rutile flux-
cored wire and related types
Recommended average
parameter settings
FILARC PZ 6113, 1.2mm , positive (+) polarity. Increase arc FILARC PZ 6113, 1.4mm , positive (+) polarity. Increase arc
voltage by 1-2V for CO2. voltage by 1-2V for CO2.

1G/PA Root* : 180-200A /6.0-8.0m/min 1G/PA Root* : 180-210A /4.0-4.5m/min

23-26V 23-26V
Fill : 180-280A/6.0-12.0m/min Fill : 190-340A/4.5-10.5m/min
Previous page 25-30V 24-32V

2G/PC Root* : 180-210A /6.0-8.5m/min 2G/PC Root* : 180-210A /4.0-5.0m /min

Next page 23-26V
Fill
23-27V
: 190-300A /4.5-8.5m/min
Fill : 180-260A /6.0-10.0m/min
25-29V 24-30V

Back to index page 1

3G/PF Root* : 180-260A /6.0-12.0m/min 3G/PF Root* : 180-270A /4.5-9.5m/min
23-32V 23-28V
Fill : 180-280A/6.0-12.0m/min Fill : 190-290A /4.5-10.0m/min
24-30V 24-30V

Back to catalogue 4G/PE Root : not recommended 4G/PE Root : not recommended
Fill : 180-260A /6.0-10.0m/min Fill : 190-240A /4.5-6.0m/min
24-28V 24-28V

5G+6G/PF/ Root : not recommended 5G/6G/PF/H-L000/H-L045 use same parameters as 4G.

H-L000+H-L045 Fill : 180-240A /6.0-9.0m/min
24-28V
3F/PG Fill : 190-230A /4.5-6.0m/min
24-28V
Not recommended above 5mm
plate thickness.

3F/PG Fill : 180-220A /6.0-9.0m/min 1F/2F/PA/PB 3F/4F/PF/PD

23-26V
Not recommended above 5mm 190-340A 190-290A
plate thickness. 4.5-10.5m/min 4.5-10.0m/min
24-32V 24-30V

1F/2F/PA /PB 3F/4F/PF/PD * One-sided root pass on ceramic backing, V-joint.

Use ceramic strip with rectangular groove.
180-300A 180-260A
6.0-14.0m/min 6.0-12.0m/min
24-31V 23-32V
* One-sided root pass on ceramic backing, V-joint.
Use ceramic strip with rectangular groove.

10 11
FILARC welder guide
book No. 2
ASME and EN Welding Positions
PZ6113 all-position rutile flux-
cored wire and related types FILARC PZ 6113, 1.6mm , positive (+) polarity. Increase arc
voltage by 1-2V for CO2.
1G/PA Root : not recommended
Fill : 210-400A /4.5-10.5m/min
25-35V
Previous page
1G /PA 2G /PC
2G/PC Root : not recommended
Fill : 210-320A /4.5-8.0m/min
Next page 25-33V

Back to index page 1

3G/PF Root : not recommended
Fill : 220-280A /5.0-7.0m/min
24-30V
3G / PF & PG 4G /PE

Back to catalogue 1F/2F/PA/PB 200-400A /4.0-10.5m/min

25-35V

3F/4F/PF/PD 3F: 220-280A /5.0-7.0m/min

24-30V
5G / PF & PG-H-L000 6G/ H-L045
4F 220-250A /5.0-6.5m/min
24-28V

1F/ PA 2F/ PB

3F/ PF & PG 4F / PD

12 13
FILARC welder guide
book No. 2
Welding advice
direction of travel
PZ6113 all-position rutile flux- 70-90
cored wire and related types Positive penetration
To ensure positive penetration, and avoid slag traps and lack
of fusion:

Always weld backhand (trailing)

Previous page It is easier to ensure good penetration and to prevent slag run- Figure A
ning ahead of the weldpool. See figure A. Correct backhand welding (trailing) with torch at 70 -90.
Forehand welding can deliver a reasonable weld appearance,
but penetration is often poor. There is also a chance of slag
Next page overflowing the weldpool, causing slag traps and lack of fu-
sion, see figure B.

Back to index page 1 Correct torch angle is 70-90 as shown figure A. At lower an-
gles, see figure C, insufficient penetration and lack of fusion
can be expected.

direction of travel

Back to catalogue

Figure B
Forehand welding (pushing). Risk of insufficient penetration, lack
of fusion and slag traps.

direction of travel

Figure C
Backhand welding with too small a torch angle, causing insuf-
ficient penetration and lack of fusion.

14 15
FILARC welder guide
book No. 2 C. Third layer builds
Torch positions for positional welding up weld thickness.

PZ6113 all-position rutile flux-

cored wire and related types FILARC PZ 6113 and related types are developed for all-posi-
tion welding.
Following are typical situations where correct torch positioning
plays an important role in avoiding weld defects.
10
2G/PC
Previous page Torch position depends on plate thickness and bevel angle of
the joint. If the torch positions shown cannot be used, it is re-
commended that the bevel angle is enlarged. D. Fourth layer creates
Always maintain the torch angle of 70-90 relative to the weld favourable angle
Next page bead and direction of travel as advised on page 15. for following pass.
Maintain a steady travel speed to achieve a regular bead thick-
ness, without sagging. See page 20 for further guidance.
Back to index page 1
A. Root pass.
Without backing: grind opposite side. 45
With backing: use round ceramic. Avoid overthick bead.

Back to catalogue
E. Fifth layer. Note
how layers are al-
ways built up from
bottom side of
10 joint as weld thick-
ness increases.

10

B. Second layer, using flatter bead.

Avoid sagging
Slag traps and fusion faults arise from sagging (rollover), typi-
cally caused by:

Too low a travel speed.

Incorrect torch angle.
Too high a welding current.
Wrong weld bead sequence.
45
Sagging requires grinding to
avoid defects when welding
subsequent passes.
Sagging can be avoided by
keeping weld beads as flat as
possible, as shown by dia-
grams above. wrong right

16 17
FILARC welder guide
book No. 2
PZ6113 all-position rutile flux-
cored wire and related types
Torch positions, continued 4G/PE
Use a basic electrode for the root run and fill with FILARC
3G / 3F / PF PZ 6113 or related types.
Note the torch positions shown below for root run and filling Figures A and B give ideal torch positioning.
layers.
Joint bevelling must allow good access to the root area. If nec-
essary use a narrower gas cup. A B

Previous page ceramic backing

90
80-90
Next page
2F/PB
Back to index page 1 10
Figures A and B show the ideal torch positions, using the back-
hand method recommended.

A B 45

Back to catalogue 70 - 90
Root pass

Trouble shooting
Figures C and D show possible undercut and sagging faults,
and possible causes.

C D

10

C.Undercut:
Welding current too high.
Arc voltage too high.
Travel speed too high.
Filling layers Arc too close to vertical
plane.
Torch angle () too small.
18
D. Sagging:
Welding current too high.
Arc voltage too high.
Torch angle () too big.
Layer too thick.
Travel speed too low.
19
FILARC welder guide
book No. 2
PZ6113 all-position rutile flux-
cored wire and related types
Previous page
Next page
Back to index page 1
Back to catalogue
Weaving technique 2G / PC Position
A. Correct
Torch pointed onto
horizontal plate.
Weaving is well applicable with PZ 6113 and related types, but Correct weaving width.
too high a heat input (thick layers) will go at the expense of the Good wetting onto plate
weld metal toughness. The fast freezing slag supports the edges and weld.
weld pool and allows high deposition rates, especially in 3F
and 3G position. The technique described below, is suited for
all situations where weaving is gen-
erally applied.
travel direction
B. Incorrect
Weaving technique Torch not pointed onto
Cross the weld pool from edge to horizontal plate.
edge in a straight line and gradu- Excessive weaving.
ally move into the travel direction.
3G / PF Position
Limited weaving and a correct technique are very important
when welding PZ 6138 and other low-temperature types in the
3G position. Start with stringer beads or split-weave tech-
Following advises on the welding techniques to be used to ob- nique, as soon as the joint geometry allows this. Dwell at the
tain good low-temperature weld metal toughness; often re- plate edges for approx. 2 seconds to allow weld metal to so-
quired for applications of PZ 6138, PZ 6116S, PZ 6115, lidify. Always ensure satisfactory side plate wetting, as shown
PZ 6114 and PZ 6114S. Here fully weaving is avoided as much figure A. FILARC PZ 6113S provides an exception.
as possible. Best weld metal toughness is obtained with the This wire has been developed to obtain good weld toughness
stringer bead or split weave techniques, because individual at 30C, while fully weaving.
beads are thinner.
1G /PA Position
Restrict weaving width; try to weld stringer beads as soon as
possible. A. Correct B. Incorrect
For K joints, correct torch position shown is important. The arc Stringer beads. Weaving across
must point into the corner between plate material and weld as No or minimal weaving. full width of joint.
illustrated below. Thick layers.
A. Correct
Apply stringer beads.
Correct torch position.
Weave as little as possible.
Backhand welding.
B. Incorrect
Excessive weaving.
Wrong torch position.
Forehand welding.
20 21
FILARC welder guide
book No. 2
PZ6113 all-position rutile flux-
cored wire and related types
Grinding Sealing runs
Grind before welding, as shown figure D, to create a smooth,
slightly concave groove, giving easy access to the welding
torch.
Grinding may become necessary to correct weld metal sag-
ging. Always grind starts and stops. Remove only the most ob- D. Correct.
vious irregularities and avoid making sharp edges. They can
lead to slag traps and lack of fusion when filling.

Previous page A. Correct. B. Incorrect.

Next page

Back to index page 1

E. Incorrect.
Grinding wheel
pushed into root,
resulting in a
Back to catalogue deep groove.
The narrow joint
is almost
inaccessible to
the torch.
C. Always grind starts and stops.

22 23
FILARC welder guide
book No. 2
PZ6113 all-position rutile flux-
cored wire and related types
Previous page
Next page
Back to index page 1
Back to catalogue
Trouble shooting/process faults
Although good equipment maintenance and proper welder
training will help preventing process faults and weld defects,
they can never be avoided completely. In such cases, under-
standing of the most common causes will lead the welder to
quickly solving the problem encountered.
Listed below are the most common process faults and their
likely causes. For faults that result from incorrect setting or
wrong welding techniques, we refer to previous chapters where
correct handling of FILARC PZ 6113 and related types is des-
cribed in detail. Weld defects and their origins are discussed
on next pages.
Process faults Likely causes
1. wire stubbing - parameter settings
2. wire burn-back - wire reel brake too tight
- parameter settings
- damaged/worn contact tip
- burn-back time too long
3. spatter - parameter settings
- wrong shielding gas/gas flow rate
too high, too low or irregular
- irregular wire feed
- worn contact tip
- paint, rust or dirt in joint area
4. irregular wire feed/ - roll pressure too low
unstable arc/ - damaged/worn contact tip
wire jam - wrong contact tip size
- overheated contact tip
- damaged/worn/bent liner
- dirty or rusty wire/wire kinks
- misalignment of rolls and
guide tubes/worn rolls
- wire reel brake too tight
- wire crossed on reel
(brake too loose)
- irregular gas flow
24
Trouble shooting/weld defects
Lack of fusion defects. There are several types of lack of fu-
sion defects, but all share the same feature that weld metal and
parent metal have not fused at one or more places.
Below, typical forms of lack of fusion are shown in a V-butt
weld. They can equally occur in other butt-weld types. Also
shown is a typical defect in fillet welds, where the weld metal
fails to fuse with, normally, the standing leg.
cold lap
lack of interrun fusion
lack of side wall fusion
lack of root fusion
lack of fusion
Possible causes Remedies
General
travel speed too high - reduce travel speed/allow
more dwell time at edges
wrong parameter setting - adjust parameters
forehand welding - backhand welding, 70-90
torch angle
Lack of root fusion*
root gap too small - enlarge gap
Fillet: lack of fusion at standing leg
torch too much pointed - change torch orientation
at horizontal leg
* Rutile cored wires are less suited for welding high quality root runs by
nature, unless used in combination with ceramic backing strips. Use
ceramic strips with rectangular groove to accommodate slag. Limit the
welding current to approx. 200A to avoid centerline cracking.
25
FILARC welder guide
book No. 2
PZ6113 all-position rutile flux-
cored wire and related types
Previous page
Next page
Back to index page 1
Back to catalogue
Lack of weld penetration Important
Lack of penetration occurs when the weld metal fails to extend A defect likely to occur with any all-position rutile cored wire,
into the complete root of a joint. is slag inclusions in 2G position. Here small joint angles pro-
Shown below are three typical cases. mote the formation of slag tracks at the upper plate edge, of-
ten associated with lack of fusion.
Rutile wires are more prone to this, because their arc is less
forceful by nature. Also, rutile weld metal has a tendency to
sagging, especially in 2G position, so that convex beads easi-
ly develop. A first step to prevent this can be done in the de-
sign stage, by enlarging the joint included angle by also bevel-
ling the bottom plate edge. This gives the welder more freedom
to avoid the sharp corners where slag gets trapped. Welders
must take care to use the correct stickout length and to main-
Examples of lack of root penetration tain a short arc so that the penetrating force is optimal. Travel
speed must be high enough to avoid sagging and slag running
ahead of the weld pool. See pages 16 and 17 for torch posi-
tions and bead sequence.
Possible causes
General
Remedies
Porosity.
welding current too low - increase wire feed/arc voltage Possible causes Remedies
arc voltage too high - reduce arc voltage draught/wind - close doors or windows/
travel speed too high - reduce travel speed place wind screens
travel speed too low - increase travel speed; avoid paint, grease or dirt - clean plates
slag running ahead of weld pool in the weld area
forehand welding - backhand welding gas cup clogged - clean/replace
torch angle too small - use 70-90 torch angle; aim gas cup distorted - replace
the arc at the leading edge of gas cup too small - replace with one suiting the
the pool or too big joint geometry
gas flow too high - adjust flow rate
Butt welds or too low
root gap too small/ - increase gap/reduce face gas leaks in system - check by blocking gas cup;
face too big aspirate air continued gas flow indicates
joint included angle - increase angle leaks
water leaks in cooled guns - check connections
Slag inclusions gas cup to workpiece - check positioning of contact tip
Slag inclusions occur when molten slag is not allowed to es- distance too long relative to gas cup;
cape to the surface of the weld pool, when the weld pool over- readjust parameters
rides slag running ahead of it, or when slag remainders at the
toe of beads are not sufficiently remolten. Undercutting

Possible causes Remedies

welding current too low - increase wire feed/arc voltage

travel speed too low - increase travel speed; avoid
slag running ahead of weld pool
forehand welding - backhand welding
torch angle too small - use 70-90 torch angle; keep
slag behind arc
convex beads - increase arc voltage
too much weaving - reduce travel speed; when
possible use split-weave
technique, otherwise reduce
weaving width.
Avoid thick layers.
Undercutting is generally caused by an excessive welding cur-
rent or arc voltage, or may be the result of a too high travel
speed. To avoid it, lower wire feed speed and /or travel speed
until satisfactory bead appearance is obtained.
If undercutting appears at one leg of a fillet weld, the torch po-
sition may be wrong; try increasing the angle between torch
and opposite leg.

26 27
FILARC welder guide
book No. 2
PZ6113 all-position rutile flux-
cored wire and related types
Previous page
Next page
Back to index page 1
Back to catalogue
Centerline cracking on ceramic backing strips Notes
When welding root runs on ceramic backing strips, centerline
cracking may occur at high heat inputs. Like the formation of
slag traps in 2G position, this is a characteristic aspect of ru-
tile cored wires.
The concave bead shape promotes an unfavourable solidifica-
tion, making the weld prone to hot cracking, especially when
shrinkage forces are high. For crack free welding, following
guidelines should be observed.
Apply a joint angle of 45-60 and approx. 5mm root opening.
Use ceramic strips with a rectangular groove to accomo-
date slag. The groove width must be around 15mm.
Use welding currents below 200A (1.2mm). This gives a
more or less oval weld pool, instead of the unfavourable ar-
row shape.
Minimize weaving to avoid excessive bead thickness, while
keeping the arc in front of the weld pool to obtain sufficient
penetration.
28 29
FILARC welder guide
book No. 2
PZ6113 all-position rutile flux-
cored wire and related types
Previous page
Back to index page 1
Back to catalogue
FILARC Welding Industries B.V.
P.O. Box 8086
NL-3503 RB Utrecht
The Netherlands
Tel : + 31 30 248 59 11
Fax : + 31 30 241 15 35
FILARC Welding Sales Organisations
Belgium & Luxembourg
S.A. Esab N.V.
Avenue Jules Bordetlaan 15
B-1140 Brussels
Tel : +32 2 726 84 00
Fax : +32 2 726 80 05
Czech Republic
ESAB VAMBERK a.s.
Smetanovo nbrez 334
517 54 Vamberk
Tel : +42 445 50 11 11
Fax : +45 445 50 14 64
Denmark
V. Lwener
Smedeland 2, P.O. Box 1330
DK-2600 Glostrup
Tel : +45 43 20 03 00
Fax : +45 43 43 03 59
Finland
FILARC Hitsaustuotteet
Yliopistonkatu 37C
SF-20100 Turku
Tel : +358 2 251 3880
Fax : +358 2 251 3940
France
Esab France S.A.
Rue du Petit Albi
ZAC du Moulin Vent
Batiment D, Porte 402
F-95800 Cergy St. Christophe
Tel : 33 1 30 75 55 00
Fax : 33 1 30 75 55 25
Germany
Esab GmbH
Beethovenstrasse 135
Postfach 100763
D-42648 Solingen
Tel : +49 212 298 0
Fax : +49 212 298 415
Great Britain
Esab Group (UK) Ltd
Hertford Road, Waltham Cross
Hertfordshire EN8 7RP
Tel : +44 1992 76 85 15
Fax : +44 1992 71 58 03
Italy
Esab Saldatura SpA
Via E Mattei 24, I-20010 Mesero (MI)
Tel : +39 297 96 81
Fax : +39 297 289 300
The Netherlands
FILARC Lastechniek B.V.
Kernkade 8, P.O. Box 8035
NL-3503 RA Utrecht
Tel : +31 30 248 59 11
Fax : +31 30 241 15 34
Member of The Esab Group
Norway
AS Esab
Frankendalsvn 97, P.O.Box 2050
N-3255 Larvik
Tel : + 47 331 210 00
Fax : + 47 331 152 03
Poland
Esab Sp. z o.o.
ul. St. Augusta 75, lok. 47
03-846 Warszawa
Tel : + 48 22 612 59 61
Fax : + 48 22 612 59 57
Portugal
Esab LdA
Av. Infante D.Henrique
Lote 332 - 2 Esq.
P-1800 Lisbon
Tel : +35 118 371 527
Fax : +35 118 591 277
Slovakia
Esab Slovakia s.r.o.
Rybnicn 40
835 54 Bratislava - Vajnory
Tel : + 42 728 87 41
Fax : + 42 728 87 41
Spain
Esab Ibrica SA
Calle Aragoneses, 17
E-28100 Alcobendas (Madrid)
Z.I. de Alcobendas
Tel : +34 1 661 55 80
Fax : +34 1 661 71 36
Sweden
Esab Sverige AB
Marknad Tillsatsmaterial
Herkulesgatan 72
P.O. Box 8004
S-402 77 Gteborg
Tel : +46 31 50 95 00
Fax : +46 31 50 92 22
Switzerland
Hulftegger & AG
Bahnhofstrasse 52
CH-8712 Stfa
Tel : +41 1 928 81 11
Fax : +41 1 926 67 55
For countries not listed here:
FILARC Lastechniek B.V.
International Division
Utrecht, The Netherlands
Printed in The Netherlands
CW-WG2-9607/ 01