FUNCTION OF FLUX MATERIALS

Deoxidation of Scavengers- Helps to Purify The Weld Metal Slag Formers -Slag Protects Weld Puddle From Atmosphere During Solidification Arc Stabilisers - Produce a Smooth Arc & Help Reduce Spatter & Smoke Alloying Elements - Provide the Necessary mechanical Properties Gasifier - Provide a Shielding Gas

`TYPES OF CORED WIRES

CS/LAS SS Gasless (Self Shielded) A 5. 20 5.22 Gas Shielded Flux Cored A 5.20 5.22 Composite Submerged Arc Gas Shielded Metal Cored A5.18

GASLESS (SELF SHIELDED)

Generates its Own Protective Shielding Gas. Normally used in Flat & Horizontal Positions only . For CS most commonly used for Out Door Fabrication & also extensively used for Repair & Maintenance application For SS Mainly used for Joining & Overlay Welding Application

GAS SHIELDED FLUX CORED WIRES

For CS/LAS Currently Available in Two Types Positional Welding type - Rutile Slag Flat/ Horizontal type - Basic Slag Both Types Typically Run with Ar-25%Co2 or 100% CO2 Diameter Down to 0.9 mm Available For SS Positional Welding Type available in all grades suitable for CO2 Shielding

COMPOSIT SUBMERGED ARC

FCAW Consumables used mainly with Neutral Flux to give desired Weld metal Chemistry Typical Application include High Alloy Steel Compositions with special TDC Required in Small Quantity.(Tailor Made Product)

GAS SHIELDED METAL CORED

Composit or Metal Cored FCAW consumables most commonly used for robotic application in view of Higher Deposition Efficiency Bead on Bead Welding (NO Slag ) Better Wire Feeding.

CLASSIFICATION OF FCAW CONSUMABLES

For Metal Cored Wires as per AWS A 5.18

E 70 C X Y N HZ
For FCAW Wires as per AWS A 5.20

E XXT XMJ HZ
For SS FCAW Wires as per A 5.22

E XXX T X-X

FCAW -CORED WIRE

ADVANTAGES High productivity of Continuous Wire Welding Metallurgical Benefit of Flux Higher Current than Solid Wire Versatile Use-All Positional ,Wide Thickness Range Visible Arc -Easy to Use DISADVANTAGES Equipment more complex & Costlier than SMAW FCAW Wires more Expensive on Weight Basis but compensated by higher Productivity

COMMOMLY AVAILABLE FCAW PRODUCTS

FCAW Product for Positional Welding of CS / LAS With Gas Shielding. Self Shielded FCAW Product for CS Self Shielded for HF Products Gas Shielded SS Small Dia.Cored Wire Product for Fabrication Self shielded SS Cored Wire for SS Overlay /Cladding

SELECTION CRITERIA
Chemical & Mechanical Properties Commercial Availability of Product Suitability for Restraint Welds -Hydrogen Level in Weld Metal Type of Gas Shielding to be used Feasibility of Application Cost Factor

ACID vs BASIC vs METAL CORED vs RUTILE BASIC E70T-1 vs E70T-5 vs E70C-6M vs E70T-1
ACID UTS,Mpa YS Mpa %E 585 518 23 BASIC 535 450 28 METALCORED 575 517 27 RUTILE BASIC 585 497 27

IMPACT J -18 DeG C -29 Deg C

40-65 20-45

110-160 80-135

75-100 25-55 3-8 FLAT GOOD

80-125 65-100 2-5 FLAT VERY GOOD

HYDROGEN 5-10 2-5 Ml/100 GMS OPE.CHARAC. FLAT CONVEX BEAD SHAPE WETTING VERY GOOD FAIR

STORAGE & RECONDITIONING FOR SMAW /FCAW

SMAW Low Hydrogen Store 100-150 Deg C Recondition at 400 Deg C- 1Hr Stainless Recondition at 200 Deg C- 1Hr FCAW Plastic Recondition at 50 Deg C- 48Hr Min Coils Store 100-125 Deg C Recondition at 150 Deg C- 6-8Hrs Wire Spool Store 150 Deg C Basket Recondition at 250 Deg C- 2-3Hrs Higher Rebake Temperature , Faster Reconditioning

SHIELDING GASES

Arc Characteristics Penetration Profile Mode Of Transfer Spatter Level Alloy Recovery Material Types

SHIELDING GAS COMPARISON E 81T-1-Ni1 VERTICAL UP @21 KJ/CM

95Ar/5CO2 75Ar/25CO2 50Ar/50CO2 100CO2 TYPICAL CHEMICAL ANALYSIS TYPICAL MECH. PROP(Mpa) TYPICAL IMPACT PROP(J) BEAD SHAPE C Mn Si YS UTS 0 Deg C -40Deg C .059 1.29. .44 540 603 123 91 FLAT .055 1.29 .44 531 586 125 84 FLAT .042 1.24 .39 502 568 109 48 CONVEX .041 1.16 .31 457 565 104 40 CONVEX

IMPORTANT
Making a Gas Decision Deciding on a particular shielding gas should be based on the specific manufacturers recommendation. Failure to do so may result in weld metal defects or in an deterioration in Mechanical properties.The manufactures guaranteed values are obtainable only when specified technical parameters are followed in full .