www.boehler-welding.

com

WELDING CONSUMABLES
FOR EXHAUST SYSTEMS IN AUTOMOTIVE ENGINEERING

BÖHLER WELDING
From the very beginning of welding technology, BÖHLER
WELDING has been one of the leading developers,
manufacturers and suppliers of welding consumables
world-wide. The brand BÖHLER WELDING offers the
entire range of consumables for joint welding.
Ever since 1926 customers and partners in more than
100 countries all over the world have put their trust in
our products and solutions. The technical knowledge
globally gained on site during these eight decades makes
BÖHLER WELDING the preferred partner of leading
enterprises in the most demanding industrial sectors. Our
experienced application consultants will be pleased to
develop together with you the technically and economi-
cally optimum solution for your individual requirements.
2
www.boehler-welding.com
It goes without saying that our extensive product range
is constantly aligned to the current industrial
specifications. As one of the pioneers, we are already
today working in close cooperation with our customers
and partners on the innovative products and solutions
of the future.
If this brochure does not answer all your questions,
we are at your disposal and will be pleased to advise
you.
For more detailed information about the listed welding
consumables and/or our entire range, please refer to
our BÖHLER WELDING manual or visit us on the
internet at www.boehler-welding.com
 www.boehler-welding.com

Requirements of the base material

The requirements for modern motor vehicles are constantly The exhaust system is divided into three sections, each with
increasing. High performance is required along with high different load requirements:
energy efficiency, low weight and minimum exhaust emissions.
The exhaust system plays a key role in this. High temperature section:
(exhaust manifold, catalytic converter, diesel particulate filter)
To save weight, the wall thickness of all parts is being reduced, ■ High resistance to scaling
e.g. catalytic converters and diesel particle filters. These parts
■ Low embrittlement tendency
need to be long-lasting and easy to manufacture. This is where
welding consumables play a decisive role.
Middle section:
(pre-silencer, connection pipe)
Exhaust systems are exposed to extreme mechanical and
corrosive loads. They must withstand temperatures from ■ High temperature- and corrosion resistance
-40°C to 950°C and accommodate the resultant stresses.
Condensate in the interior and brine from outside mean that End sections:
the material must be highly corrosion-resistant. (rear silencer, tail pipe)
■ Wet corrosion due to condensate in interior
■ Corrosion due to brine from outside

Assemblies in an exhaust system

2
3

4
5
6

7 8

Ferritic base materials and Austenitic base materials and

welding consumables welding consumables
1 Manifold 5 Pre-silencer 1 Manifold 5 Pre-silencer
1.4509/1.4511 1.4512/1.4510/1.4113/ 1.4541/1.4828/1.4828(mod.) 1.4301/1.4541
BÖHLER CAT 430L 1.4513/1.4526 BÖHLER FF BÖHLER EAS 2,
BÖHLER CAT 439L Ti, BÖHLER SAS 2
2 Catalytic converter, BÖHLER KW 5, 2 Catalytic converter,
Diesel particulate filter BÖHLER SAS 4 Diesel particulate filter 6 Connection pipe
1.4509/1.4511 1.4541/1.4828 1.4301
BÖHLER CAT 430L 6 Connection pipe BÖHLER A 7 BÖHLER EAS 2
1.4512
3 Front pipe run BÖHLER KW 5 3 Front pipe run 7 Rear silencer
1.4509/1.4512 1.4301/1.4541/1.4828 1.4301/1.4541
BÖHLER CAT 430L, 7 Rear silencer BÖHLER FF, BÖHLER EAS 2, BÖHLER EAS 2,
BÖHLER KW 5 1.4113/1.4512/1.4513/1.4526 BÖHLER SAS 2 BÖHLER SAS 2
BÖHLER KW 5,
4 Connection pipe BÖHLER SAS 4 4 Connection pipe 8 Tail pipe
1.4509/1.4512 1.4301 1.4301/1.4401
BÖHLER CAT 430L, BÖHLER A 7, BÖHLER EAS 2,
BÖHLER KW 5 BÖHLER EAS 2 BÖHLER EAS 4

BÖHLER WELDING Welding consumables for exhaust systems in automotive engineering 3

 www.boehler-welding.com

Welding consumables for exhaust systems

Base
Solid wire Metal-cored wire Application areas
material

1.4828 BÖHLER FF-IG – Manifold, front pipe run

G 22 12 H
ER309 (mod.)

1.4509 BÖHLER CAT 430L CbTi-IG BÖHLER CAT 430L CbTi-MC Manifold, catalytic converter,
G ZCr 18 NbTi L T 17 M M12 1 Diesel particle filter,
ER430Nb (mod.) EC430G Front pipe run,
Pre-silencer
1.4510 BÖHLER CAT 439L Ti-IG –
G Z18 Ti L
ER439

1.4511 BÖHLER CAT 430L Cb-IG BÖHLER CAT 430L Cb-MC

G Z18 L Nb T 17 M M12 1
ER430 (mod) EC430G

1.4512 BÖHLER KW 5 Nb-IG – Pipe runs, silencers

G Z13 Nb L
ER409Nb

1.4113 BÖHLER SAS 2-IG (Si) – Pre-silencer, silencer

1.4513 G 19 9 Nb Si
1.4526 ER347Si
1.4541

1.4301 BÖHLER EAS 2-IG (Si) BÖHLER EAS 2-MC Silencers, pipe runs, tail pipes
1.4316 G 19 9 L Si T 19 9 L MM 1
ER308LSi EC308L

1.4401 BÖHLER EAS 4 M-IG (Si) BÖHLER EAS 4 M-MC Tail pipes
1.4430 G 19 12 3 L Si T 19 12 3 L MM1
ER316LSi EC316L

1.4370 BÖHLER A 7-IG (A 7 CN-IG) BÖHLER A 7-MC Catalytic converter

G 18 8 Mn T 18 8 Mn MM1
ER307 (mod.) EC307 (mod.)

Selection of welding consumables

based on requirements
Austenitic
1.4828(mod.)
The selection of the right combination of BÖHLER
High temperature corrosion resistance

FF
base material and welding consumable
1.4828
is closely linked to the area of use. BÖHLER
It depends on which effect is the most FF

important; corrosion or high temperature Ferritic 1.4509, 1.4511

and the related tendency of some BÖHLER 1.4541
CAT 430L Cb BÖHLER
materials to become brittle. CAT 430L CbTi SAS 2
[+Cr +Ti +Si +Ce]

1.4526, 1.4513 1.4301 1.4571

Some materials are exposed to high 1.4510 BÖHLER BÖHLER BÖHLER
BÖHLER SAS 4 EAS 2 EAS 4
temperatures and corrosion. This CAT 439L Ti
combination quickly pushes the base 1.4512 1.4113
material and the welding consumable to BÖHLER BÖHLER
KW 5 Nb-IG SAS 4
the limits. With the right selection of
welding consumable and welding method Wet corrosion resistance
it is possible to improve these critical [+Cr +Mo (+Ti +Nb -C)]
conditions considerably.

4
 www.boehler-welding.com

Requirements of welding technology

Exhaust systems, like many components in automotive

engineering, are assembled in automated robotic cells. The
clear aim is high productivity: shorter process times, low
reject rates and minimum welding defects paired with as little
reworking (cleaning, reworking of poor welds) as possible.

These aims pose great challenges for the welding consumable.

High welding speeds require low, even feed force and a high
tolerance range. Very good general welding properties are
also required, including clean, regular weld seams which meet
the high quality demanded in automotive engineering.
The welding consumable naturally needs to meet mechanical
and chemical requirements as well.
Weld seam on an exhaust manifold

BÖHLER CAT metal-cored wires Conception of the metal-cored wire

We always focus on quality characteristics when developing
our welding consumables. The new BÖHLER CAT metal-
cored wires have been developed in conjunction with
renowned mechanical engineers to ensure that the products
match the actual robot-specific application profiles.
High welding speeds, low plate thickness, different weld
geometries and different types of arc have been tested for all
exhaust system parts to find a perfectly-matched solution.
For instance, arc behaviours at the most varied settings were
filmed with a high-speed camera. The findings were fed back
into the wire concept to ensure the molten pool, fusion
penetration, gap bridging and stability behaviours with all
BÖHLER metal-cored wires are made of alloyed or unalloyed
strip, depending on the alloy concept. The powder allows for
chemical fine adjustment and its conception permits optimum
welding characteristics. Compared to solid wire, much higher
welding speeds are possible at very high current intensities
with, at the same time, reliable welding results. The wire also
behaves very tolerantly with all arc variants and different gap
widths on parts are also bridged without welding defects.
This enables the user to locate the tolerance ranges within
the weld seam which simplifies the development process with
correspondingly positive effects on production.
[A]
Current intensity

tested arc variants.

250
Metal-cored wires
The results of these tests are the two new metal-
200 Ø 1.2 mm
cored wires:
150
■ BÖHLER CAT 430L Cb-MC Solid wires
■ BÖHLER CAT 430L CbTi-MC 100 Ø 1.0 mm
50 TIME SAVINGS

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 [m/min]

Welding speed
[m/min]

14
The use of the metal-cored wire enables considerably
higher welding speeds
Spray
12 arc
Spray
Wire feed rate

10 arc
Voltage adjustment

Transi-
8 tional arc
Metal transfer in Metal transfer in Metal transfer in
Cross section of a
6 metal-cored wire, CMT arc short arc spray arc
Transitional Ø 1.2 mm
4
arc
Short
arc Short
2
arc
1 Greater working range in
spray arc with metal-
0
cored wire
Solid wire Metal-cored wire Arc study using high speed camera
1.0 mm 1.2 mm

BÖHLER WELDING Welding consumables for exhaust systems in automotive engineering 5

 www.boehler-welding.com

Development test on a robot system

These photographs show samples from the series of tests
carried out on the robot system during the development of
the wires.
The samples comprise two approx. 1.2 mm thick sheet plates
which were overlapped and welded along the overlap.
Different feed speeds and arc types were used to simulate the
different requirements.
1 Short arc
The short arc enables gap-bridging with different gap widths.
In combination with the metal-cored wire, a very good weld
fluidity is achieved even at high welding speeds. If low wire
feed rates are required, the metal-cored wire enables a
stable burning short arc with smooth weld toes and no
notch formation.

The results show that excellent joints were produced with all
settings.

Sam- Current Voltage Wire Welding

ple Arc type intensity [V] feed speed
no. [A] [m/min] [m/min]
1 Short arc 121 12.5 2.8 1.0
2 Spray arc 225 19.6 6.7 2.4
3 Fronius CMT* 211 13.4 7.2 1.8

* Cold welding process

2 Spray arc
1 The spray arc is often selected because it is the fastest and
therefore usually the most economical choice in combination
with the metal-cored wire.

3 Fronius CMT (Cold Metal Transfer)

Modern power source characteristics and “cold welding
CAT 430L CbTi-MC, uncleaned welding samples
processes” can offer further optimisations. The benefits of the
metal-cored wire are also evident here.

CMT arc with CAT 430L Cb-MC

6
 www.boehler-welding.com

Benefits at a glance

Shorter welding times

High welding speed up to 2.5 m/min at corresponding
deposition efficiency.

Reliable joints
No burn through – good wetting behaviour with spray arc and
short arc. BÖHLER metal-cored wires offer very good
gap bridging plus reliable fusion penetration and ignition.
Flawless seams can be welded by robots in a single operation.

Significant cost savings with the use of

metal-cored wires
Ultimately one thing counts above all else in many areas of
production: where and how can you save costs without
compromising quality? These requirements are ever-present,
Short arc welding on robot
particularly in the automotive industry.

Case study – BÖHLER A 7-MC*:

Starting point: Use of BÖHLER A 7-MC

■ Welds on catalytic converter: For the use of our metal-cored wire we made slight
two longitudinal welds, two circumferential welds changes to the parameter settings:
■ Production per day: 1.250 catalytic converters ■ Adjustment of the parameters for a stable spray arc
■ Welding with solid wire ■ Adjustments of the torch position on the robot
■ Reject rate of whole part: > 10.000 ppm ■ Fine adjustments of the torch for the different areas of
■ Reworking rate: 10% the work piece

The whole catalytic converter may be rejected because of

possible through-weld penetration when using solid wire.
This can destroy the sensitive core of the catalytic converter. Benefits of the use of BÖHLER A 7-MC:
Cost per part approx. 400 €! ■ Reject rate of whole part and reworking rate is
practically zero
Reworking is required if the edges are insufficiently joined ■ Improvements in net working capital: less stock needed
and leaks are present. In the case of this kind of welding thanks to reliable process
flaw the leaks need to be located, pre-treated and manually ■ Significant and moreover sustainable cost reductions are
re-welded to ensure that the catalytic converter is tight. possible

So there are clear potential benefits to switching to a modern We shall be happy to help you make the switch so that you
welding consumable – see for yourself! can profit from the clear adventages of our consumables.

* The costs and savings are dependent on various factors and will vary from
one user to another. Values are average figures and are not guaranteed.
The specifications in regard to the type and application of our products
are only for the user’s information. The data specified for the mechanical
properties always refer to the weld metal alone under observance of the
applicable standards. In the weld joint, the weld metal properties are
influenced, among other factors, by the parent metal, the welding position
and the welding parameters. A guarantee of suitability for a certain type of
application requires an explicit written agreement in each individual case.
Subject to modifications.
7
 Published by BÖHLER WELDING

Böhler Schweißtechnik Austria GmbH

Böhler-Welding-St. 1
8605 Kapfenberg / AUSTRIA
+43 (0) 3862-301-0
+43 (0) 3862-301-95193
postmaster.bsga@bsga.at
www.boehler-welding.com

Your partner:
BSGA 04/2012 ENG 1000