Flux cored wire

Ideal combination of high quality and high

efficiency
Dipl.-Ing. IWE Michael Reimann
Product Manager
OERLIKON Switzerland
Welding conference Lima, Peru 25.11.2005

Arrangement of flux cored wires

Seamless flux cored wire

Metal cored wire

Basic flux cored wire

Rutil flux cored wire

Flux cored wire classification Fluxofil 14 HD

DIN EN 758

T 46 2 P M 1 H5
T
46
2
P
M
1
H5

: Flux cored wire

: Yield and tensile Strenght
: Toughness
: Slag fast freezing slag
: Mixed gas 82% Ar 18% CO2
: All welding position
: Diffusible hydrogen H2

ASME Code Sec.II/C

AWS SFA 5.20 E 71T-1 M H4
E
7
1
T-1M
H4

: Electrode
: Yield, tensile Strenght and toughness
: welding position H,F,VU,OH
: Slag characteristic, shielding gas
: Diffusible hydrogen H2
3

Welding project with Fluxofil 14 HD

Welding project with Fluxofil 14 HD

WPS Fluxofil 14 HD with weldycar

WPS Fluxofil 14 HD with weldycar

Root pass on ceramic backing

WPS Fluxofil 14 HD with weldycar

Front view on round ceramic backing

WPS Fluxofil 14 HD with weldycar

Fixation the weldycar

WPS Fluxofil 14 HD with weldycar

Root pass on ceramic backing

WPS Fluxofil 14 HD with weldycar

Cap welding
Current
I=225A
Voltage
U=24V
Welding speed
Vs=13cm/min
Wire speed
8,0m/min
Weld deposit
3,5 Kg/h
10

WPS Fluxofil 14 HD with weldycar

Joint preparation
Nahtvorbereitung

Schweiparameter

Layers set up
Lagenaufbau

Welding parameters

11

WPS Fluxofil 14 HD with weldycar

Weldycar fixed in transver position

12

WPS Fluxofil 14 HD with weldycar

Transver welding on ceramic in action

13

WPS Fluxofil 14 HD with weldycar

Joint preparation Nahtvorbereitung

Schweiparameter

Lagenaufbau

Layers set up

Welding parameters in transver position

14

Fluxofil 14 HD in project operation

15

Fluxofil 14 HD in project operation

16

Fluxofil 14 HD in project operation

17

Fluxofil 14 HD in project operation

18

Flux cored wire application tank building

19

Flux cored wire application tank building

Joint preparation
Vessel

20

Fluxofil 14 HD Application pipe junction

21

Flux cored wire application hall truss

22

Flux cored wire application exhibition hall

23

Fluxofil 14 HD in all welding position

24

Calculation comparison between solid and flux cored

wire
Schweiverfahren

MAG- Flldraht MAG- Massivdraht

Schweizusatz

Fluxofil 14 HD

Ausfhrungen
Nahtvorbereitung
Lagenaufbau

Halbmechanisiert

12

Lagenzahl/Raupenzahl
Schweiposition
(mm)
Drahtdurchmesser
I (mm)
Schweistrom
U (V)
Schweispannung
Schweigeschwindigkeit Vs (cm/min)
SG (Kg/h)
Abschmelzleistung
ED (%)
Schweizeitfaktor
LS (Euro/h)
Lohnsatz
SZP (Euro/Kg)
Schweizusatzpreis
SP (Euro/l)
Schutzgaspreis
Schutzgasmenge
SM (l/min)
GKF (%)
Gemeinkostenfaktor

Carbofil 1
Halbmechanisiert

90

3L/3R

3L/3R

PF
1,2

PF
1,2

210

140

23

18

26

13

3,0
45

1,5
45

13

13

3,3

0,93

0.01

0.01

15
300

15
300

25

Calculation comparison between solid and flux cored

wire
Schweiverfahren

MAG- Flldraht MAG- Massivdraht

Schweizusatz
Ausfhrungen
Nahtvorbereitung
Lagenaufbau

Fluxofil 14 HD
Halbmechanisiert

12

Carbofil 1
halbmechanisiert

90

Lagenzahl/Raupenzahl
Schweinahtgewicht

SNG (Kg/m)

3L/3R
1,20

3L/3R
1,20

Hauptzeit
Hauptzeit + Nebenzeit

Th ( min/m )
T ( min / m )

24,00
53,33

48,00
106,67

Schweizusatzkosten
Schutzgaskosten

KZ (Euro/m)

3,96

1,12

KS(Euro/m)

0,87

0,87

Lohnkosten
Gemeinkosten
Fertigungskosten

KL (Euro/m)
KG (Euro/m)
KF (Euro/m)

11,56
34,67
46,22

23,11
69,33
92,44

Gesamtkosten

KGe (Euro/m)

51,05

94,43

Ersparnis

Euro/m

43,38

Ersparnis

45,94
26

Fluxofil 14 HD - Data sheet FLUXOFIL 14 HD

Rutile tubular cored electrode for MAG-welding, with fastfreezing slag

Standards:

DIN EN 758
AW S/ASME SFA-5.20

T 46 2 P C 1 H5 / T 46 2 P M 1 H5
E71T-1 H4 / E71T-1M H4

Applications and properties :

The higher filling degree of FLUXOFIL 14 HD results in higher current carrying capacity and deposition rate. Welding
speed is thereby essentially increased which leads to a saving of time and reduction of costs. It can be used in all
positions with only one setting of welding parameters (2 4 volts, wire feed = 9m/min, wire dia. 1,2 mm). FLUXOFIL 14
HD is em ployed in manual welding, as well as in fully mechanized w elding by me ans of the orbital welding unit CITOTRACK OSG-O1 or the vertical welding set CITOTRACK VSG-O1. It is preferably used under mixed shield ing gas
and is characterized by low spatter loss, good slag removal and finely rippled, pore-free welds without undercutting
into the base metal.
Materials:
EN-Designation
S185
S235 to S355
P235
L210 to L415
L290, L320

DIN-Designation
EN-Designation
DIN-/AWS-Designation
St 33
S235 to S355
St 37.0 to St 52.0
St 37-2 to St 52-3
P235 to P355
St 37.4 to St 52.4
St 35.8
P265
St 45.8
StE 210.7 to StE 415.7
L360 to L485
StE 360.7 TM-StE 480.7 TM
StE 290.7TM, StE 320.7T M
P235GH, P265GH
HI, HII
X42 to X65
P295GH
17 Mn 4
StE 255
S(P)275 to S(P)460
StE 285to StE 460
A, B, D, E
AH 32 to EH 36
GS-38
GP240R
GS-45
Please observe admissible operating temperature for welding consumable and base material.
Qualification tests:

T V

Approvals:
DB, ABS, DNV, GL, LRS
Indications as to approvals, see appendix.
Analysis of all-weld metal (typical values in %):
C
0,05

Si
0,55

Mn
1,2

Mechanical properties of all-weld metal (single values are typical values):

Heat treatment
AW
AW = as-welded

Yield strength
[N/mm]

Tensile strength
[N/mm]

Elongation
A5 [%]

>460

550 650

>22

Impact energy ISO-V [Joule]

-20 C
>80

Chemical composition and mechanical properties apply to the use of shielding gas:
DIN EN 439 - M21 (82 Vol. % Ar + 18 Vol. % CO2 )
Shielding gas as to DIN EN 439:
Consumption:

M21 (ARCAL 21), C1 (carbon dioxide)

12 15 l/min for 1,6 mm

Welding parameters and deposition rate, see:

B 131

Form of delivery:
Wire diameters [mm]
Further forms of delivery on req uest.

Wire cage reel K300 (16 kg)

1,0

1,2

1,6

Type of current/Polarity/Welding positions:

27

Fluxofil 14 HD - advantages Easy handling in all welding position

-

High deposition rate in all welding position

To use in fully mechanized welding processes

One side welding on ceramic backing

Less spatter during the welding process

Easy slag removal

Very good penetration

Seamless wire

Less fume and less hydrogen content

High efficiency
28

Application

Metal cored wire

Fluxofil M8

29

Metal cored wire Fluxofil M8 - advantages -

Easy handling in H and F welding position

Seamless wire

Less fume and less hydrogen content

High deposition rate in H and F welding position

To use in fully mechanized welding processes

One side welding on ceramic backing

Less spatter during the welding process

Very good penetration

High efficiency

Very good ristriking

30

Application

Metal cored wire

Fluxofil M8

31

Application

Metal cored wire

Fluxofil M8

32

Application

Metal cored wire

Fluxofil M8

33

Application

Metal cored wire

Fluxofil M8

34

Application

Metal cored wire

Fluxofil M8

35

Variable applications with flux cored wires

36

Variable applications with flux cored wires

37

Variable applications with flux cored wires

38