Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
CLASSIFICATION,
STORAGE AND HANDLING
R.D.PENNATHUR
MAILAM INDIA LIMITED
WELDING PROCESS
GTAW
SMAW
GMAW
FCAW
SAW
GTAW CONSUMABLES
Gas tungsten arc welding is most commonly used to weld stainless steel and
nonferrous materials, such as aluminum and magnesium, but it can be applied to
nearly all metals, with notable exceptions being lead and zinc.
Its applications involving carbon steels are limited not because of process
restrictions, but because of the existence of more economical steel welding
techniques, such as gas metal arc welding and shielded metal arc welding.
Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or
informally as stick welding, is a manual arc welding process that uses a consumable
electrode coated in flux to lay the weld. An electric current, in the form of either
alternating current or direct current from a welding power source is used to form an
electric arc between the electrode and the metals to be joined.
As the weld is formed, the flux coating of the electrode disintegrates, giving off vapors that
serve as a shielding gas and providing a layer of slag, both of which protect the weld area
from atmospheric contamination.
Because of the versatility of the process and the simplicity of its equipment and operation,
shielded metal arc welding is one of the world's most popular welding processes
The SMAW is most versatile process as flux facilitates addition of alloying element to weld
metal & as such with same core wire many composition of weld metal can be obtained.
FLUX INGRADIENTS
FLUXING AGENTS
SLAG FORMERS
ARC STABILISERS
GAS FORMERS
SLIPPING AGENTS
BINDING AGENTS
GMAW CONSUMABLES
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal
inert gas (MIG) welding or metal active gas (MAG) welding, is a semi-automatic
or automatic arc welding process in which a continuous and consumable wire
electrode and a shielding gas are fed through a welding gun.
A constant voltage, direct current power source is most commonly used with
GMAW.
There are four primary methods of metal transfer in GMAW, called globular, shortcircuiting, spray, and pulsed-spray, each of which has distinct properties and
corresponding advantages and limitations.
Originally developed for welding aluminium and other non-ferrous materials in the
1940s, GMAW was soon applied to steels because it allowed for lower welding time
as compared to other welding processes.
The welding consumable has to have same composition as that of expected of weld
metal..Hence,the consumable availability is a major limitation to process
application. Most popular application is limited to Corbon steel & Nonferrous
material.
GMAW Circuit diagram. (1) Welding torch, (2) Workpiece, (3) Power source,
(4) Wire feed unit, (5) Electrode source, (6) Shielding gas supply
GMAW weld area. (1) Direction of travel, (2) Contact tube, (3) Electrode
(4) Shielding gas, (5) Molten weld metal, (6) Solidified weld metal, (7) Workpiece
FCAW CONSUMABLES
An externally supplied shielding gas is sometimes used, but often the flux itself is
relied upon to generate the necessary protection from the atmosphere.
The process is widely used in production/ construction because of its high welding
speed and portability.
FCAW was first developed in the early 1950s as an alternative to shielded metal
arc welding (SMAW).
SAW CONSUMABLES
IS (Indian)
AWS/ASME (American)
DIN (German)
EN (British)
National/International
Inspection/licenser
Specification
CONSUMABLE SELECTION
The Welding consumables for welding of CS, LAS & SS are selected based on
guidelines provided in ASME II C. The relevant specification for the same are indicated
here below:
SFA 5.1
SFA 5.4
SFA 5.5
SFA 5.9
SFA 5.17
SFA 5.18
SFA 5.20
SFA 5.22
SFA 5.23
SFA 5.29
SFA 5.01
TESTING OF ELECTRODES
PHYSICAL TEST
CHEMICAL TEST
MECHNICAL TESTS
PHYSICAL TEST
UNIFORMITY OF COATING
PROPER BRUSHING OF HOLDING &
STRIKING ENDS
CONCENTRIC COATING
STRIKING END FREE OF FLUX & RUST
ELECTRODES NOT DEFORMED
NO DAMAGE TO COATING IN TRANSIT
FOR COTINUOUS WIRE CHECK SPOOL DAMAGE
UNIFORMITY OF WIRE-LAYER WINDING
CAST & HELIX
PERFORMANCE CHARACTERS
UNIFORM COVERING
CONCENTRICITY
GRIP END/ARC END TRIMMING
CUP FORMATION
ARC INTENSITY/STABILITY
SMOOTH ARC
FLUIDITY/VISCOSITY
SLAG/OXIDE INCLUSIONS
MOISTURE ABSORPTION
LOW SPATTER
COVERING THICKNESS
CRATER CRACKING
IDENTIFICATION
SLAG DETATCHABILITY
FACTORS TO BE EVALUATED
CHEMICAL COMPOSITION
MECHANICAL PROPERTIES
NOTCH TOUGHNESS
ELCTRICAL CHARECTERISTICS
TYPE OF COVERING
OPTIONAL PARAMETERS
MOISTURE CONTENT
DIFFUSIBLE HYDROGEN
SUPPLEMENTARY PARAMETERS
HARDNESS
CORROSION RESISTANCE
FERRITE CONTENT
WEAR RESISTANCE
WELDMETAL CHEMISTRY
CVN IMPACT VALUE AT-SPECIFIED LOW TEMP.
TENSILE/YIELD AFTER PWHT
HARDNESS REQUIREMENT
LOW ALLOY STEEL CONSUMABLES
WELDMETAL CHEMISTRY
TENSILE/YIELD AFTER PWHT
HARDNESS REQUIREMENT
DIFFUSIBLE HYDROGEN CONTENT
CVN IMPACT AS SPECIFIED
FERRITE CONTENT
WELDMETAL CHEMISTRY
CORROSION RESISTANCE
CVN IMPACT VALUE AT -196 DEG C
NON FERROUS CONSUMABLES
WELDMETAL CHEMISTRY
CORROSION RESISTANCE
WELDABILITY
E X X Y Y -1* HZ R
E
XX
YY
1
HZ
R
*M
DESIGNATES AN ELECTRODE
TENSILE STRENGH IN KSI
WELDING POSITION& TYPE OF COVERING
IMPROVED TOUGHNESS
DIFFUSIBLE HYDROZEN 4/8/16
MOISTURE RESISTANCE
MILITARY SPEC. AS AGREED TO
THE ELECTRODES THAT CAN RESIST PICK OF MOISURE ARE CLASSIFIED WITH
SUFFIX R
THE CLASSIFICATION IS BASED ON EVALUATION OF MOISURE AS RECEIVED
CONDITION & AFTER EXPOSURE TO ATMOSPHRE AT 80%RH /27 C FOR 9hrs
E.G. E 70 1 8
E-Manual Metal Arc Welding Electrode
70- Minimum UTS of 70 Ksi(70000psi)
1- Usability of electrode in all positions
8- Basic type of covering with Iron powder
TYPES OF COVERING
RUTILE Vs BASIC
GOOD PERFORMANCE
OPERATES ON AC/DC
GOOD OPERATOR APPEAL
IMPACT AT SUBZERO LOW
REBAKING NOT REQD
.
H2 LEVEL HIGH
POSITIONAL WELDING EASY
SATISFACTORY PERFORMANCE
NOT WELL ON AC
SATISFACTORY
GOOD IMPACT PROPERTIES
CAN NOT BE USED WITHOUT
REBAKING
H2 CAN BE CONTROLLED
POSSIBLE.HIGHER SKILL LEVEL
REQUIRED
E XX XX X* HZ R
E
XX
X
X
X
HZ
R
DESIGNATES AN ELECTRODE
TENSILE STRENGH IN KSI
WELDING POSITIONX
TYPE OF COVERING
CHEMICAL COMP. OF WELD METAL
DIFFUSIBLE HYDROZEN
MOISTURE RESISTANCE
C-Mo STEELS
Cr-Mo STEELS
Ni
Ni STEELS
Mn-Mo STEELS
Mn-Ni-Cr-Mo STEELS
E.G. E 80 1 8 B2
E.G. E 8016 G
E.G. E 80 1 8 D3
E.G. E 80 1 8 C2
E
DESIGNATES AN ELECTRODE
X XX ALLOY COMPOSITION
XX ALLOY ADDITION
X
L-LOW CORBON H-HIGH CORBON
XX 15-DCRP ( ALL POSITION )
16-AC/DCRP ( ALL POSITION )
17-AC/DCRP ( ALL POSITION )
25-DCRP(H & F)
26-AC/DCRP(H & F )
E.G. E 316 L
E-Manual metal arc welding electrode
316-Chemical composition of 17 to 20 Chrome,11 to14
Nickel,2 to 3 Moly
L-low carbon variety
E.G. E 309MOL-16
ER XXX XX X
ER
X XX
ALLOY COMPOSITION
XX
ALLOY ADDITION
E.g. ER 308 L
ER-ELECTRODE ROD
308-CHEMICAL COMPOSITION OF 19 TO22 CHROME,9
TO 11 NICKEL,0.75 MOLY
L-LOW CARBON VARIETY
E.g. ER 309 L Mo
ER-ELECTRODE ROD
309-CHEMICAL COMPOSITION OF 22%-25%
CHROME,12%-14% NICKEL,2%-3% MOLY
L-LOW CARBON VARIETY
E.G. E XXXX
E-MANUAL METAL ARC WELDING ELECTRODE
XXXX- ALLOY SPECIFICATION
E.G. E Ni Cu 7
E-MANUAL METAL ARC WELDING ELECTRODE
NICU7-CHEMICAL COMPOSITION OF
MONEL(70%NICKEL&BALANCE COPPER)
E.G. E Ni Cr Fe3
E-MANUAL METAL ARC WELDING ELECTRODE
NI Cr Fe3-CHEMICAL COMPOSITION OF
INCONEL(60%NICKEL& 13-17% Cr, BALANCE FE)
NICKEL BASED
MONEL BASED
CI CONSUMABLES
PROPERTY
LH/CI
NI DEP.
FeNi DEP
MONEL DEP
MACHINABILITY
NO
GOOD
GOOD
GOOD
COLOUR
MATCHING
NO MATCH
OK
NO MATCH
STRENGH
GOOD
LOW
SATISFACTORY
LOW
TOLERANCE
TO IMPURITY
GOOD
NOT GOOD
SATISFACTORY
NOT GOOD
RECOMMENDED
FOR SMALL
REPAIR
WORK
BEST FOR
ALL JOBS
REQUIRING
MACHINING
FOR SMALL
REPAIR
WORK
SUITABILITY
WHERE
MACHINING
IS NOT REQD.
E.G. E Ni - CI
E
ELECTRODE
NI
CI
CAST IRON
E.G. E Ni Fe - CI
NI Fe
CHEMICAL COMPOSITION OF
FERRO NICKEL BASED
CI
CAST IRON
E.G. E Ni Fe T3- CI
ELECTRODE
NI Fe
TUBULAR/FCAW
SELF SHIELDING
CI
CAST IRON
ER XX S* X Y N HZ
ER
XX
S
*C
X
Y
N
HZ
AWS CLASSIFICATION OF
CARBON STEEL FILLER ROD
E.g. ER 70 S 2
ER-Electrode Rod
70-minimum UTS of 70 Ksi
S-solid Rod
2-minimum CVN Impact Value of 20
Ftlb at Minus 20 Deg Fahrenheit
ER XX S* X HZ
ER
XX
SOLID WIRE
*C
COMPOSITE WIRE
HZ
E.g. ER 90 S B3 L
ER-ELECTRODE ROD
S-SOLID ROD
E.G. ER XXXX
ER- ELECTRODE BARE ROD
XXXX-ALLOY SPECIFICATION
E.G. ER Ni Cu 7
ER- ELECTRODE BARE ROD
NICU7-CHEMICAL COMPOSITION OF
MONEL(70%NICKEL&BALANCE COPPER)
E.g. ER NiCr - 3
ER-Electrode Bare Rod
NiCr-3-Chemical composition of 70%Nickel and
20%Chromium
E X X T XX-JXHX
E-ELECTRODE
X-TENSILE IN KSI
X-POSITION DESIGNATOR
T-FCAW/TUBULAR
X-USABILITY DESIGNATOR
X-SHIELDING GAS C-CO2/M-MIXED
J-20 ftlb AT -40 C
X-D/Q INDICATES SPECIAL MECH.PROPERTIES
HX-HYDROGEN DESIGNATOR
E71 T 1C
E-ELECTRODE
7-TENSILE IN KSI(70)
1-ALL POSITION
T-FCAW/TUBULAR
E70 T 3C
E-ELECTRODE
7-TENSILE IN KSI(70)
0-FLAT/HORIZONTAL POSITION
T-FCAW/TUBULAR
E70 T 8
E-ELECTRODE
7-TENSILE IN KSI(70)
0-FLAT/HORIZONTAL POSITION
T-FCAW/TUBULAR
E X X TX XX-JHX
E-ELECTRODE
X-TENSILE IN KSI
X-POSITION DESIGNATOR
T-FCAW/TUBULAR
X-USABILITY DESIGNATOR
X-CHEMICAL COMPOSITION
X-SHIELDING GAS C-CO2/M-MIXED
J-IMPROVED TOUGHNESS -27JAT 10 C
HX-HYDROGEN DESIGNATOR
E 8 X T1 Ni1C/M
E-ELECTRODE
8-TENSILE IN KSI(80)
X-POSITION DESIGNATOR
T-FCAW/TUBULAR
1-RUTILE TYPE
Ni1-CHEMICAL COMPOSITION-1%Ni
C-CO2 SHIELDING GAS
M-MIXED GAS
E 8X T5 B2CJH4
E-ELECTRODE
8-TENSILE IN KSI(80)
X-POSITION DESIGNATOR
T-FCAW/TUBULAR
5-BASIC TYPE
B2-CHEMICAL COMPOSITION- 2 Cr-1 Mo
C-CO2 SHIELDING GAS
J-IMPROVED TOUGHNESS - 27J AT 10 C
HX-HYDROGEN DESIGNATOR-4ml/100gms OF WELD METAL
E X X XTX-X
E-ELECTRODE
XXX-COMPOSITION OF WELD METAL
T-FCAW/TUBULAR
X-POSITIONAL WELDING DESIGNATOR 0-F/H;1-ALL POSITION
X-SHIELDING GAS 1-CO2/ 3-SELF SHIELDING/ 4-80-20 Ar-CO2/ 5-Ar
E 308T1-1
E-ELECTRODE
308-COMPOSITION OF WELD METAL-18%Cr/8%Ni
T-FCAW/TUBULAR
1-ALL POSITION
1-SHIELDING GAS 1-CO2
E 308T0-3
E-ELECTRODE
308-COMPOSITION OF WELD METAL-18%Cr/8%Ni
T-FCAW/TUBULAR
0-FLAT/HORIZONTAL
3-SELF SHIELDING
STAILESS STEEL
FLUX CORED RODS FOR GTAW WELDING
AWS A5.22-2007
R X X XT1-5
R-WELDING ROD
XXX-COMPOSITION OF WELD METAL
T-FCAW/TUBULAR
1- ALL POSITION
5-100% ARGON
STAILESS STEEL
FLUX CORED RODS FOR GTAW WELDING
AWS A5.22-2007
R 308LT1-5
R-WELDING ROD
308L-COMPOSITION OF WELD METAL
T-FCAW/TUBULAR
1- ALL POSITION
5-100% ARGON
SAW
E.g. F S7 P 4 EXXX HX
FSAWFLUX
SINDICATESFLUXBEINGCRUSHED
SLAG/SLAG+VIRGINFLUX
7MINIMUMUTSOF70KSI(70000psi)
PHEATTREATMENTPPWHT/AASWELDED
4MINIMUMCVNIMPACTENERGYOF20FtLb
ATMINUS40F
EXXXELECTRODEWIRE
HXHYDROGENDESIGNATOR
SAW
E.g. F 7 A6 EM12K
F-SAW FLUX
A- AS WELDED
EM12K-ELECTRODE SPECIFICATION
SHIELDING GASES
HELIUM
ACTIVE GAS-CO2
USED FOR CORBON & LAS
USED ALSO FOR SS IN FCAW
HIGHER SPED,ADEQUATE PENETRATION AT LOWER COST ARE
ITS SALIENT FEATURES.
FOR SOLID WIRE TRANFER MODE IS EITHER SHORT
CIRCUITING OR GLOBULAR
TRANFER TYPE LEADS TO HIGHER SPATTER & ROUGH BEAD
PROFILE
FOR FCAW SPRAY TRANFER IS ACHIVED HENCE MOST
COMMENLY USED GAS
GAS MIXTURES
Ar+CO2
Ar+O2
Ar+O2+CO2
Ar+He
AR+He+O2
Ar+He+O2+CO2
SHIELDING GASES
Arc Characteristics
Penetration Profile
Mode Of Transfer
Spatter Level
Alloy Recovery
Material Types
C
Mn
Si
YS
.059
1.29.
.44
540
.055
1.29
.44
531
.042
1.24
.39
502
.041
1.16
.31
457
UTS
0 Deg C
603
123
586
125
568
109
565
104
-40Deg C
91
84
48
40
FLAT
FLAT
CONVEX
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 .
STORAGE OF CONSUMABLES
STORAGE&DRYING OF SS&NF
CONSUMABLES
VACCUM PACKING
The E7018 welding rods I've been buying are now marked E7018 H4R. What
does the H4R mean? Are these rods different than the E7018 rods I've used
before?
What consumables are better for welding over rusty, dirty steel?
Steel should be cleaned of any oil, grease, paint, and rust before using any
arc welding process. However, if complete cleaning cannot be performed,
consumables that form a slag, have deeper penetration, are slower freezing,
or have higher Silicon and Manganese are recommended for dirty steels
Why are the Charpy impact values from my test welds
lower than that printed on your Certificate of
Conformance?
The test results on our Certificate of Conformance were obtained from
welding an AWS filler metal test plate. Any change in welding procedure
will affect Charpy impact values. Below are common practices for
welding test plates when Charpy impact specimens are required:
Controlled heat input
Controlled preheat and interpass temperature
Even number of passes per layer
Build-up cap pass to maximum allowed in specification
Preheat Temperature
Tp =
350 ( C ) - 0.25
( C ) = CE ( 1 + 0.005 x t )
CE - Carbon Equivalent
t - Thickness in mm
Carbon Equivalent
CE
Mn
Ni Cr+Mo+V
=C+
+
+
20
15
10
E7018:
E8018, E9018, E10018,
E11018:
1 hour at 650-750F
1 hour at 700-800F
1. If the electrodes come in direct contact with water or have been exposed to high humidity,
they should be predried for 1-2 hours at 180-220F first before following the above
redrying procedure.
2. Standard EXX18 electrodes should be supplied to welders twice per shift.
3. Low hydrogen electrodes with the suffix "R" have a moisture resistant coating and may be
left out up to 9 hours or as specified by code requirements.
HOT PRESSED/
COLD SPINNING
SOLUTION
Sl.No CONSUMALE
TYPE
AS
WELDED
SR
NORMALISED
E7018
530
525
480
E7018A1
540
535
530
PROBLEM:
THE SPIRAL COIL WELD JOINTS WERE FOUND TO BE LEAKING
AFTER SHORT SEVICE OF SIX MONTHS
ANALYSIS:
THE WELD JOINTS EXAMINED USING DP INDICATED SEVERE MICRO
FISSURING ON ALL THE JOINTS.
THE EXAMINATION OF WPS/PQR INDICATED ROOT RUN BY GTAW &
BALANCE BY SMAW OF E 8018-B6 CONSUMABLES.
20mm
CROYOGENIC APPLICATION
TYPICAL REQUIREMENT 15 mil LE AT MINUS 196 Deg.C
LOW CORBON(<0.04),NITROGEN(<0.05),
FERRITE(2%)
BASIC SLAG
ANALYSIS
THE CONVENTIONAL E308L-16 ELECTRODES GAVE ERRATIC
RESULTS.
EVENTHOUGH THE E308L-15 ELECTRODES FOUND TO GIVE GOOD
RESULTS, RADIOGRAPHIC RESULTS WERE NOT CONSISTANT
IT WAS POSSIBLE TO OBTAIN GOOD PERFORMANCE AS WELL AS
CONSISTANT RESULT BY MODIFYING THE PRODUCT E308L-16 WITH
CONTROLLED FERRITE(<2%)
BATCH
32.3
17
536
45.4
40
19.2
543
49
1.5
35.3
19
564
47
%E
FN
%
CORROSION APPLICATION
NO
TEST
DURATION
CORR.RATE
mpy
REMARKS
NO OF
CRACKS
FERRITE
NO.
48X5
14
FAIL
NIL
48X5
10.5
REVIEW
NIL
48X5
5.5
ACCPT.
NIL
ANALYSIS
THE COMMONLY AVILABLE CONSUMABLES IN ABOVE GRADES
COMMONLY HAD FERRITE 8-16%
THESE CONSUMABLES EVEN THOUGH SUITABLE FOR THIN
SECTIONS,GAVE VERY LOW %E WHEN USED ON THICKER
JOINTS/SR APPLICATION
THE REASON FOR ABOVE WAS DUE TO FORMATION OF
INTERMEDIATE BAINITE(SIGMA) PHASE
SOLUTION
USE MODIFIED CONSUMABLES WITH CONTROLLED FERRITE
OF 6-9% & QUALIFY THE SAME WITH SR AT 680deg C FOR
1HOUR
WHEN WELDING JOINTS THICKER THAN 20mm ,BUTTER THE
CS/LAS WITH E309&WELD WITH SUITABLE SSCONSUMABLES.
4
8
16
POST WELD HT TEMP
A 550 C
B 500 C
D 700 C
C 600 C
Type
E309/E309MO
E310
ENiCrFe3
E309/E309MO
(Modified)
T
e
c
h
n
I
c
a
l
C
o
n
d
i
t
I
o
n
Mech. Prop
(ASME Specified
As Welded
Mech. Prop
(Actual)
PWHT
As Welded
PWHT
UTS
N/mm2
%
E
UTS
N/mm2
%
E
UTS
N/mm2
%
E
Ferrite
UTS
N/mm2
%
E
Ferri
te
550
30
550-650
30
16
650- 750
10
550
30
550-650
30
550- 650
30
550
30
550-650
30
550- 6O0
30
550
30
550-650
30
580- 680
25
SS18/8 TYPE
WELD METAL
40
20
10
CS TO SS WELDING WITH
E309 TYPECONSUMABLES
CS TO SS WIELDING
WITH CS SIDE BUTTERING
PROBLEMS RELATED
TO CLAD STEEL WELDING
1-2MM
STRIP BACK
& HIGH ALLOY WELD
5mm
SEQUENCE OF WELDING
FIRST SIDE
BASE METAL WELDING
BG &SECOND SIDE
BASE MEATL WELDING
FIRST LAYER
BARRIER LAYER
REPAIR WELDING
CS/LAS WELDING TO BE RESTRITED
1MM BELOW ORIGINAL BARRIER LAYER
T-Thickness
a-Clad thickness
b-High alloy steel
dep. Depth
BALANCE CS/LAS}
WELD METAL
}
t- (d+b)
c-Balance CS/LAS
weld metal
d-Gouging depth
THANK YOU