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pdf Engineering) Esab Welding Handbook - 5 Edition

pdf Engineering) Esab Welding Handbook - 5 Edition

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Published by marshall, of course
another big time textbook, if you need to join some metal, this is a great resource. torch to tig, this'll get you making sparks
another big time textbook, if you need to join some metal, this is a great resource. torch to tig, this'll get you making sparks

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Published by: marshall, of course on Oct 21, 2009
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10/03/2013

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Fifth edition

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Submerged Arc Fluxes and Wires

MIG/MAGITIG Wires and Rods

Flux and Metal Cored Wires

Spool Types

Handwelding Electrodes

Gas Welding Rods

Storage and Handling

Quick Guide for selection of Filler Mater.ials

• I

I

ESAB

ESAB AS BOX 8004 S-402 77 GOTEBORG SWEDEN

Phone +46 31 50 90 00 Tgm esabsaJes Fax +46 31 50 91 70t 50 94 80

\

Contents

~UTOMATIC, SEMI-AUTOMATIC AND TIG WELDING

MANUAL.ARC WELDING

List of products for automatic welding

List of products for, semi-automatic and TIG welding General recommendations for submerged arc welding

14

List of electrodes for manual metal arc welding in numerical order according to product designation

48

15

General

General recommendations for gas shieJded metal arc welding

Types of electrode, their characteristics and use Choosing the correct electrode

50

Standards and classification codes Classification system of the Classification Societies

Classification designations and approved applications for the different grades of filler materials

Codes for ESAB's filler materials for automatic and semi-automatic welding

~ according to the American Welding Society (AWS), British Standards (8S) and Deutsche Industrienormen (DIN). Table 1

Approved filler materials OK Flux/OK Autrod combinations for ship steel, automatic welding. Table 2

Approvals of the Classification Societies. ESAB's filler materials for submerged arc and electrosfag welding. Table 3

Approvals on ESAB's filler materials for gas shielded metal arc welding. Table 4 Filler materials for steel and aluminium-tables of equivalents

OK filler materials for SA, - MIG and TIG welding of:

'ainless steel according to SIS, AFNOR, AISI, BS and DIN Standards. Table 5

5

Standards, classification system and codes ISO Codification system for mild steel electrodes

Codes for ESAB electrodes according to AWS, DIN and ISO. Table 9

Approvals of the Classification Societies for ESAB electrodes. Table 10

6

Electrodes for welding ship steels

Approved electrode grades for different ship steels. Table 11

Electrodes for welding AIS! stainless steel. Table 12

8

9

Calculation of electrode consumption

10

Choice of electrodes, for hardfacing and maintenance Choice of electrodes for joining dissimilar materials

Electrodes for manual metal arc welding Mild steel electrodes

Fematic electrods. 700 mm electrodes for gravity welding

OK electrodes for corrosion resistant and oxidation resistant steel

delding data and joint preparation . ,

Recommended joint preparation and welding data for submerged arc welding with:

OK Flux 1 0.40, 1 0.70, 1 0.71, 1 0.80 and 1 0.81 . Table 5-6

OK Flux 1 0.61 and 10.62. Table 7

Submerged arc welding of stainless steel with OK Flux 1 0.91 and 10.92. Table 8 Choice of wires and fluxes for hardfacing and maintenance

OK electrodes for non-ferrous metals

16

OK electrodes for low alloy steel

18

OK electrodes for hardfacing

19

OK electrodes for cast iron

141

Filler materials, spool types

OK Fluxes for submerged arc welding

20

OK electrode for chamfering and joint preparation, OK Selectrode 21.03 Storage and handling

Solid electrodes for automatic welding

Solid electrodes for semi-automatic welding and bare rods for TIG welding

33 51

Quick guide for selection of filler Materials

Tubular electrodes for automatic and semi-automatic welding

80

Spool types

117

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124

128

129

131

132

134

136

137 138

141

142

123

225 265 271

Standard and Classification Codes for Automatic, Semiautomatic and TIG welding

I n this catalogue the approvals applicable to different electrodes and electrode/flux combinations are given for the different Classification Societies.

The classification references usually consist of a number, which refers to the grade and one or more letters. which state the welding process or welding technique for which the approval applies.

T :::: approved for two-run techniques. i.e. a

butt weld consisting of one run from each side.

M = approved for multi-run welding of butt

welds in which the weld is deposited in more than two runs.

TM = approved for both two-run and multirun welding. •

SA :::: semi-automatic welding, (American

Bureau of Shipping. Bureau Veritas).

S = semi-automatic welding (Germanischer lloyd).

MS == before a figure means ordinary mHd

steel (Lloyd's Register of Shipping).

H == before a figure means high strength.

HT :: high tensile (ship) steeL

A = automatic welding (Bureau Veritas

only) .

Approved grades of filler material for welding different grades of steel

In principle, the following applies to both manual metal arc welding electrodes and filler materials for automatic welding when welding ordinary strength ship steel 400 490 N/mm2

(41 ~50 kp/rnrn-). ' .~

Grade 1 - for welding steel of Grade A to A, 0 and E steels.

Grade 2 - for welding steels of Grades A and o to A, 0 and E steels.

Grade 3 - for welding all combinations of steel in the above strength grades.

For welding high tensile (HT) ship steels corresponding rules are applied by the Classification Societies.

Note 1

Steels having a nominal yield stress of minimum 270 N/mm2 are regarded as high tensile steels according to the rules of the Classification Societies.

The figures included in the classifications can have different meanings in different connections. H, after a fjgure = hydrogen control/ed.

In the next column, a summary is given showing which steel grades can be welded with the different grades of filler materials according to the Classification Societies:

American Bureau of Shipping ASS

American Welding Society AWS

Det norske Veritas DnV

Bureau Veritas BV

Lloyd's Register of Shipping LR

Germanischer Lloyd GL

Note 2

When manual metal arc welding joints, which include high tensile steel, the risk of hydrogen embrittlement should a/ways be taken into account. As a safety precaution, electrodes having a guaranteed low hydrogen content should be used, i.e~ basic electrodes class 3H1 3YH. 3YHH or III H.

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4

Flux Flux

Flux

Flux

Flux

Flux

Flux

Flux

Flux Autrod

Autrod and Tigrod

Autrod Tigrod Tubrod

1 0.61

10.62

10.70 10.71

10.80 10.81

10.92 12~ 10 12~20 12.22 12.24 12.32 12434 12.40 12.51 12.64 13109 13.12 13.13 13.27 13.91 14.00 14.01 14~02 14103 14~04 14~05 14117 14.18 14.30 14.31 14.32 15.00

15.12 15.15 15~ 17 15~ 18

15.19 15~20

ESAB OK

I

l F6AO-EL 12

! F7AO-EM12 \ F6A2-EM12

: F7 AS-EM 12K

F7A6·EH14

I

: F8A8-EA4-A4

\ F9A8-EA3-A3 ~ F6A4-EM12

\ F7A8-EM12K l F7A6-EH14

I F8A4-EA4-A4

F9A8-EA3-A3 F7A4-EL 12 F7A4-EM12 F6A4-EL 12

I F7A4-EM12 F7A5-EM12K F8A2-EH14 F8A4-EA4-A4 F9A4-EA3-A3 F7A2, EL 12, F7A2-EM12 F7AZ-EL 12, F7AO-EM12 F7AO-EM12K

\

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~

BFB 1 65 DC 7 M 2-16

Tubrod 15.30 15~31 15.32 15.33 15.34 15.35

Table 1 Classification of filler materials for automatic and semi-automatic welding

~l~ AWS \ BS Designation I DIN Designation

~~B I : no. I

I I

: : 32522: BFB 6 6723 DC 8B 1-16

~ FMS 1 88 AC 8 M

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1

BFB 1 55 AC 8 M HP 5 2-16

I

BAS 1 79 AC 8 SM 2-16 BAB167AC8MHP52-16

BCS 1 89 AC 8 M 2-16 BAR 1 97 AC 8 SMK

Autrod and Tigrod

16.10 16.11 16.12 16.30 16.31 16.32 16.52 16.53 16,86 16.95

18.01 18.04 18.11 18.15 18~ 16 19.12 19.40 19.82 19.85

BCS 5 71645 DC 8 MB 2-16 S1

S2

S 2 Si S2Mo S3

S3 Me 84

SG 2 SG 3 SG Mo

SG Cr Mo 1

Autrod and Tigrod

8557:

EL12

EM12 EM12K EA2 EH12K

EA4

EH14

ER70 S-6 ER70 S-6 ER80 S-G ER80 S-G ER100 S-G EN2

E71 T-G E70 T-G E81 TG-A1 E111 TG-K3 E87 TG-Ni2 E71 TG-Ni1 E71 T-7 E70 T-4 E308 LT-1 E316LT-1 E309 LT-1 E70 T-5 E71 T-5 E70 T-1

E71 T-1

E81 T1-Ni1 E70 T-1 E71 T-1 E81 T1-Ni1 E81 T5-82

2901 : A 15 (2901 A 31) (2901 A 32)

8559: 8575:

8555: MSG-6-G2-C-60G 8559: 8G B 1 FOlldraht SG R 1 FGlldraht SG R 1 FOl1draht SG R 1 FOlldraht

. •

I

~AWS

. .

; E308 LT-2

I

; E316 LT-2

,

1 E309 T-2

! E308 MoT-2

: E307 T-2

j! E309 LT-2 1

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ER 308 L ER 347 Si ER 308 L s ER 316 L uER318Si"

ER316LSi ER 309 s ER 309 L

(ER 307) (ER 1100) ER 4043

ER 5356 ER 5183 ER Cu

ER Cu AI-A 1

I ER N~ Cr Mo-3 I ER NI Cr-3

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Designation; DIN

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; No.

2901: 308 S 92 (347 S 96) 308 S 93 316 S 92 (318896) 316 S 93 (309 S 94) 309 S 92

1050A 4043A

5056A 5183 (C7) (C13)

15.22 : E91 T5-83 15425 ~ E71 TS-NI2 I

Tubrodur 14~70 14.71 15.40

15.42

15.52

15~60

15470 . ER 410

15.73 ER420

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f

1 ,4316

1 t4551 1.4316

1 ~4430 1.4576 1.4430 1.4829 1.4332 (1.4462) 1.4370

17.32:

, 1733: 1

,

1 1736:

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Designation

SG 1 0- 55 FOlldraht SG 8--200 FOIJdraht SG 1-350 FOfldraht SG 1--400 FOlldraht SG 6-500 FOlldraht UP 6--500, UP 6-55

SG 7- FtJlldraht

UP 5- Fulloraht

SG 6- 50 FOtldraht UP 6- 50 FOlldraht

X2 Cr Ni 19 9

XS Cr N~ Nb 19 9

X2 Cr N 19 9

X2 Cr N Mo 19 12

XS Cr N Mo Nb 19 12 X2 Cr N Mo 19 12

X8 Cr N 24 12

X2 Cr N 24 12

X 15 Cr Ni Mn 18 8 S-Al99.S

S-AI Si 5

S-AI 99.5 Ti

S-AI Mg 5

S-AI Mg 4.5 Mn S-Cu Sn

S-Cu AI 8

SG Ni Cr 21 Mo 9 Nb SG Ni Cr 20 Nb

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List of products

General Recommendations for

Filler materials for submerged arc welding 1 . The flux must be dry. Agglomerated flux-
lilt Fluxes for submerged arc welding es must be protected against moisture
: pick-up.
In the tropical humid area redrying of
~ ~ Page
. OK Flux j T~pe i Chemistry Alloying i Remarks agglomerated fluxes at 250-350C before
- ~
. use i~ recommended. Remaining flux in the


1 _._-- .. -.
Non-alloying Strip cladding 20
1 0416 Agglomerated Basic container of the welding machine should
10.40 Fused Acid Mn-alloying 21 be rernoveo and stored in a drykeeping
10.50 Fused Basic Non-alloying 22 cabinet and thus not be left in the open
10+61 Agglomerated High basic Non-alloying 23 container dunng the night.
1 0462 Agglomerated High basic Non-alloying 24 During transport of fluxes maximum two
1 0.70 Agglolnerated Basic Mn-alloying 26 pallets should be stapled to prevent cruch-
10.71 Agglomerated Basic Non-alloying 27 Ing to the grains.
10.80 Agglomerated Neutral Mn-alloying 29 2. The fusion faces and the plate in the vi-
, Agglomerated Acid Mn-alloying 30 cinity of the joint should be clean and dry.
1 0.81
- Cr-alloying 31
- Agglomerated Neutral The cleaner the joint, the better the chan-
- 10.92
, Agglomerated Acid Cr-alloying Hardfacing 32 s~s of obtaining a satisfactory weld. Rust,
l~ 10496
• mill scale, paint, oil and residues from arc-
-
·
, Solid wire for mild, medium and high tensile steels air gouging or grinding can adversely affect
~

• the quality of the weld metal. The more
~
~
-
• OK j Alloy type LDIN 1 AWS1) I Welding process I Page impurities on the fusion faces the greater
~ the risk of weld metal defects. I

~ Autrod 12.1 0 Unalloyed S 1 A5~17:EL12 Sub arc 33 3. The arc voltage must be kept constant.
• ~
1
- ,
~ S2 A5.17: Sub arc 34 Increased arc voltage gives increased flux
Autrod 12.20 1 % Mn I
I
,
Autrod 12.22 Mn-Si S 2 s A5117:EM12K Sub arc 35 consumption. If the flux contains alloying I
I
~
A5.23:EA2 Sub arc 36 ~
Autrod 12.24 Mn-Mo-alloyed S 2 Mo elements, the amount transferred to the I
Autrod 12~32 1,5 Mn S3 A5.17:EM12K Sub arc 37 ~eld metal will increase as the arc voltage
Autrod 12.34 1,5 Mn-Mo S3 Mo A5123:EA4 Sub arc 38 Increases.
Autrod 12.40 2 Mn S4 A5~17:EH14 Sub arc 39 4~ Multi-run deposits made at moderate weld-
AS.23-ENi2 Sub arc 40 •
Autrod 13.27 2,3 Ni Ing currents have, as a general rule better
a Autrod 13.36 Cu-Ni weather- mechanical properties than one ~r two
ing steel Sub arc 41 I~y~r deposits made at high currents in
Sub arc 42 similar plate thicknesses.
Autrod 13143 Cr-Ni-Mo
NOTE. The chemical analyses given in this
Solid wire for welding stainless steel
cataloous are for aflweld metal deposits made • III
; •
t according to DIN 32522, i.e. with DC+! 580 A
43
Autrod 16t 1 0 20 Cr 1 0 Ni ER308L Sub arc 29V, 33 m/h except for OK Flux 1 0.91 and OK
Autrod 16.30 18 Cr 12 Ni 2,7 Mo ER316L Sub arc 44 Flux 1 0.92, where DC+. 420 A, 27 V and 30
Autrod 16.53 24 Cr 13 Ni ER309L Sub arc ... 45 m/h have been used. Wire 0 4 mm.
The, mechanical properties are obtained ac-
cording to welding conditions given in DIN
8~57 .. (That means the same welding data as
given In DIN 32522)
. Other welding conditions may give weld metal
~
l analyses and m~chanical properties which dif ~
fer from those given in the catalogue. i j

!

• I

,

i

j

l

j

j

I

~

14

- -- .. ---- -.--- - .-- ~-~_~*'~A~~*~. ~~~& ~~=.~±~_~. ~.~&~~nl~~~ •. a~t ~d ~Q~~~_I

• - .. "I'

Table 6 Typical welding data for submerged arc fillet welding mild steel and carbon .. manganese structural steels with OK Flux 10.40, OK Flu 10.70, OK Flux 10.71, OK Flux , 0.80 and OK Flux 101811

Type of joint Plate I Wire I Throat

thickness I diam thickness

Welding Data and Joint Preparation

Table 5 Typical welding data and recommended joint preparation for submerged arc welding mild steel and carbon ... manganese structural steels with OK Flux 1 0.40, OK Flux 10.70, OK Flux 10.71, OK Flux 10.80 and OK Flux 10.81.

..

1

Type of joint: Plate

thickness mm

Single welding head

Wire e mm

Run No.

Arc voltage V

Welding current A

Welding speed m/h

mm

mm

mm

Arc voltage V

• • - - 'P" ...

....-.-

,- - - -..... - .

- .... - - - -'I - _ _...... _

Welding current A

Welding speed m/h

50

6

4

35 35 35 35 35 35 35 35 35 35

1 2 1 2 1 2

1 2 1 2

300 350 450 500 500 550 600 700 650 750

2 6 ~ 8 ~10

3 4 4

3 4 5

8

4

46

1

20

1

j: 30-32

30-32 30-32

450 575 650

45 42 36

16 5 1 35 700 35 Twin wire
700
2 36 800

18 6 1 36 850 30 2x2.S 4 34 800 65
-

2 38 850 - 2x2.5 5 34 800 45
--10
20 6 1 36 925 27
t ~ 2
""""--= - 2 38 850 Two welding heads + - /

10

4

42

38

~ 8 ~12 215

5 5 6

4 4 7

12

5 5

5 5

14

35

215 220

-

-

32-34 32-34 33-35

36 36

800 850 875

50 35 25

825 850

27 22

18 6 1 36 700 30 - 4 4 +32 800 85

2 36 850 ~38 700
70°

20 6 1 36 800 25 4 4 +32
- 800 75
2 36 850 ~38 700

_._6-8 25 6 1 36 850 20

2 36 950 - 5 4 +32 600 65

30 6 1 36 900 15 ~35 500
2 36 1000 - 5 5 +32 600 42
~35 600
III
2 2 1 28 325 75 2.5

30 31

4

450 510 525-

600 625

1

40

6 8

3 3 3 3

1

30

32

26 23

1

Cu

1

33 33

10

12

1

l !

j

,

r

l

I \

\

1

,

I !

• I

• • l1li

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