Welding Manual For SP Electrode

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INDEX
S NO DESCRIPTION PAGE NOS
1 PREFACE- MAINTENANCE & REPAIR WELDING 6-7
2 STAINLESS STEEL ELECTRODES – INCONEL TYPE 8-12

(Difficult to Weld Steels & Thermal Shock Applications)
3 MEDIUM CARBON STEEL ELECTRODES 13-16
(Moisture Resistant & Low Heat Input, High Tensile Strength
Applications)
4 STAINLESS STEEL ELECTRODES – 30/10 CLASS 17-21
(Super Critical, High Strength, High Ductility Applications & Joining
Dissimilar Steel)
5 ARC STEEL ELECTRODES DIAMETER 1.6 MM 22
(Low Heat Input Electrodes for Dissimilar & Difficult to Weld Steels)
6 HIGH TENSILE STAINLESS STEEL ELECTRODES 23-24

(For Joining Dissimilar Steel SS to MS & Unknown Stainless Steel & Heat
Resistant Application)
7 STAINLESS STEEL ELECTRODES 25-29
(Crack Resistant & Low Heat Input, High Tensile Strength Applications)
8 CAST IRON ELECTRODES 30-32

(Ferrous Base Non Machinable Applications)
9 CAST IRON ELECTRODES 33-34
(Ferro Nickle Base Machinable Applications)
10 HARD FACING ELECTRODES 36-39
(Non Machinable Abrasion Resistance Applications)
(Work Hardening with Extreme Impact & Abrasion Resistance
Applications)
(Chromium Iron Type for Superor Abrasion Resistance & Impact
Applications)
13 HARD FACING WIRES 47-48
( For Abrasion Resistance & Impact Applications)
(Work Hardening with Extreme Impact & Abrasion Resistance
Applications)
15 HARD FACING ELECTRODES 51
(For Protective Coating against High Abrasion Resistance & Erosions)
(For Protective Coating against High Abrasion Resistance & Erosions at
Elevated Temperature)
17 HARD FACING TUBULAR ELECTRODES 54-56
(For Protective Coating against High Abrasion Resistance & Erosions)
(Work Hardening for Manganese Steel Resistance to Heat & Corrosion)
19 CUTTING ELECTRODES 59-60
20 WELDING WIRE FOR JOINING & BUILT UP MIG/CO2 WELDING 61--64
21 WELDING WIRE FOR HARDFACING 65-67
22 SPECIAL EFFECTS OF ALLOYING ELEMENTS IN STEEL 68
23 IS SPECIFICATIONS 69
5
Maintenance & Repair Welding
Why it is different?
Production welding generally is done under optimum conditions. The specifications are set,
the appropriate equipment is provided for, the chemistry of base metals is known, the
parameters are readily controlled and / or controllable, and if necessary, prototypes can be
made and subjected to destructive tests to confirm physical properties of the welds. In
contrast, maintenance and repair welding presents wide disparities compared to production
welding. Operating problems involve a host of unknowns, restraints and limitations.
Welding alloys have to possess special features to overcome the handicaps of field welding.
Problems relating to pre and post heat, heat of application, base metal distortion and
dilution, cracking, bond strength, solidification rates and weldability.
Failure due to poor design and excessive loads:

Maintenance welders have to contend with other factors - such as poor design of parts
which failed in service, modification of parts in the field (such as add-ons, reinforcements,
etc.) and older equipment subjected to stresses by production demands which exceeded the
original requirements.
“The right consumables for repair & maintenance welding produce the best results”
Welding is a skill that takes much practice to master, and selecting the correct electrode for
the job can be equally challenging. Electrodes are available in a wide range of a type, each of
which provide different mechanical properties and operates with a specific type of welding
power source.
Factors we should consider when selecting an electrode include base metal type, joint fit-up
and welding positions.
The selection of a correct type of welding electrode for specific application is a very
important consideration in metal arc welding. Metal welding electrodes are used for various
applications in Steel Industries including high carbon steel, stainless steel, cast iron etc.
The first step in choosing an electrode is to determine our base metal composition. Our goal
is to match (or closely match) the electrode composition to the base metal type, which will
help to ensure a strong weld. If we are in doubt about the composition of base metal, ask
our self following questions:
Q. What does the metal look like?
If we are working with a broken part or component, check for a coarse and grainy internal
surface, which usually means the base material is a cast metal.
Q. Is the metal magnetic?
If the base metal is magnetic, chances are good that the base metal is carbon steel or alloy
steel. If the base metal is not magnetic, the material could be manganese steel, 300 series
austenitic stainless steel or a nonferrous alloy such as aluminum, brass, copper or titanium.
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Maintenance & Repair Welding
Q. What kind of sparks does the metal give off when touched by a grinder?
As a rule of thumb, more flare in the sparks indicates a higher carbon.
Q. Does a chisel “bite” into the base metal or bounce off?
A chisel will bite into a softer metal, such as mild steel or aluminum, and bounce off of harder
metals, such as high carbon steel, chrome-moly or cast iron.
FACTORS WHILE SELECTING ELECTRODE:
1. Identify base metals

2. Weld Geometry (Joint Fit-up)
3. Welding Positions
4. Other Factors
o Tensile strength of the required weld.
o Base metal composition.
o Electrode diameter
o The rate of deposit the weld metal.
o The type of current used.
o Penetration required.
o Metal thickness.
o The experience of the welder.
o The specifications and service Condition.
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CATEGORY: INCONEL TYPE ELECTRODES
(1) SPECIAL WELDING ELECRODE UCS: 72203003000001
SAP DESCRIPTION: ELEC, TY-1, INCON, DIAMETER 4.0MM, SPL JOIN

TYPE: TYPE-1, MATERIAL: INCONEL TYPE, DIAMETER: DIA 4.0MM
APPLICATION: JOINTS
CATEGORY: FE-2 TYPE SUITABLE FOR ALL STEEL JOINTS, DIFFICULT TO WELD STEELS,
RESISTANCE TO THERMAL SHOCK AND OXIDATION APPLICATIONS
PREFERRED MAKE:
1. M/s EWAC Alloys, Product: XHD-2222,
2. M/s Ador Fontech, Product: SPAC 0400
1. M/s EWAC Alloys, Product: XHD-2222
STAINLESS STEEL ELECTRODES

Kiln Tyre Crack Repair
Special flux coated electrode for joining and repair of heavy and massive sections and
dissimilar steels
Typical Applications: Rotary kiln tyres, hear treatment equipment such as retorts, racks,
trays, tongs etc, earth moving equipment, cryogenic equipment, joining dissimilar
combinations of steels.
Outstanding Features:
• Suitable for both joining and overlaying.
• Excellent resistance to corrosion, oxidation and thermal shock.
• Extraordinary weldability without electrode overheating.
Strong tough welds.
Recommendation:
For all steels including heat-treatable types, difficult-to-weld types and those with unknown
composition. Also for nickel alloys and their dissimilar combinations. A key characteristic is
that deposits are able to withstand stresses produced by thermal cycling or by strains
caused by weld shrinkage in massive sections.
Procedure:
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Clean weld area, removing all fatigued and damaged metal. Bevel heavy section 60 degree.
Pre-heating necessary only for crack-sensitive base materials or massive parts. Deposit
stinger or 2-x weaved beads using short arc and minimum amperage, back whipping
all craters. Chip slag between passes, wire brush and peen each deposit. Cool slowly.
Recommended Amperages:
Size (MM) I-Range II-Range
2.50 90-125 80-90
3.15 130-170 110-130
4.00 160-200 140-160
I - Range
Tensile Strength: 63 Kg/mm (90,000 psi)
Elongation: 30 - 35%
2. M/s Ador Fontech, Product: SPAC 0400

Electrode for welding Inconel 600 and similar nickel base, composition alloys
Alloy Basis: Ni, Cr, Mn, Fe
Properties: The electrode gives soft stable arc on low currents. Deposits are tough and have
excellent resistance to scaling at high temperatures and corrosion resistance at both normal
and elevated temperatures. Also exhibits good thermal shock resistance. The weld metal
exhibits very good fracture toughness at -196ºC. Very good resistance to general and
intergrannular corrosion and stress corrosion cracking. Deposits are similar to ENiCrFe-3.
Technical Data:
UTS: 62-78 kgf/mm2
Elongation: 28-32%
Impact Strength at +20º C: 100 J at -196ºC 80 J
Typical Applications:
Basic Flux coated nickel base electrode for welding Inconel 600, inconel, incoloy monel,
nickelchromium- iron alloys, HK alloys, stainless and heat resisting steels. Also for welding
dissimilar metals such as carbon steels, stainless steels, nickel and nickel alloys to each
other. For use on equipment and components made of pure nickel for fabrication of
corrosion resistant tanks and containers, heat exchangers, furnace components, fittings, etc.
Highly suitable for a wide range of dissimilar joint combinations between nickel base alloys
and low alloy steels.
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Procedure:
Clean the work piece thoroughly. Use short arc and ensure minimum heat input, using
lowest possible amperage and adopt stringer bead technique. Dry electrode for 1 hour
Welding Current at 300ºC:
Size (Ø mm)/Length 2.5x350 3.2x350 4.0x350
Current (amps) 40-60 80-110 1 20-140
SAP DESCRIPTION: ELEC, TY-2, INCON, DIA 4.0MM, SPL JOIN

TYPE: TYPE-2, MATERIAL: INCONEL, DIAMETER: DIA 4.0MM, LENGTH: 350MM,
APPLICATION: JOINTS
CATEGORY: FE-3 TYPETYPE SUITABLE FOR ALL STEEL JOINTS, DIFFICULT TO WELD STEELS
AND CORRSION RESISTANCE APPLICATIONS
PREFERRED MAKE:

1. M/s EWAC Alloys Ltd.,Brand: CPGW 034
2. M/s Ador Fontech Ltd., Brand: LH-521
3. M/s Esab India, Brand: O.K.92.26
4. M/s D&H Secheron, Brand: Lotherme 510 N
1. M/s EWAC Alloys Ltd., Brand: CPGW 034

An advanced nickel alloy electrode for welding and overlaying of dissimilar steels and nickel
alloys
Principal applications:
• Joining & cladding of cryogenic steels, special composition martensitic/austenitic
steels, difficult-to-weld steels and nickel alloys of inconel type
• Useful for achieving crack-free joints when welding dissimilar combinations amongst
ferrous and nickel-based alloys.
Characteristics:
• Smooth operating characteristics with easy slag removal
• Weldable in all positions
• Smooth,bright weld deposits are mechanically sound and of radiography quality
General:A new generation nickel-based electrode for critical welding of steels and nickel
alloys. Use of fully alloyed core wire, combined with precise flux coating formulation
ensures best mechanical properties of the weld deposit even after dilution with base
materials.
Technical Data: Tensile Strength: 56 kg/mm2 min
Elongation (L=4d): 30% min.
Codification: AWS/SFA 5.11 ENiCrFe-3, ASME SEC 11-C
Size (mm) 2.5 3.15 4.00
Current (amp) 45-70 70-100 90-130
2. M/s Ador Fontech Ltd., Brand: LH-521

Ni-Cr-Fe basis coated stick electrode for heat resistance
Specifications:
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Alloy Basis Ni, Cr, Mn, Fe, Nb

AWS / A 5.11 Ni Cr Fe-3
Properties:
The electrode gives soft stable arc on low currents. Deposits are smooth, tough and has
excellent resistance to scaling, corrosion resistance at normal as well as elevated
temperatures. Also possesses good thermal cycles and shock resistance. Any amount of
buildup is possible. The deposit is tough and free from porosity.
Technical Data:
UTS 55-60 kgf/mm2
Elongation 30-35%
This is a versatile electrode for welding of nickel, inconel, monel, nickel-chromium-iron
alloys. Weld deposits are similar to ENiCrFe3. HK alloys, steel, stainless steel and heat
resisting steels. Also for welding dissimilar metals such as carbon steels, stainless steels,
nickel, nickel alloys to each other. For use on equipment and components made of pure

nickel, for fabrication of corrosion resistant tanks and containers, heat exchangers, furnace
components, boilers, fittings, anchors, mill trunnions, symmetry gears, etc. Very good for
repair of cracks in kiln tyres.
Procedure:
Clean the area to be welded. Preheat sections above 25 mm to 100ºC. Adopt short arc,
stringer bead technique, chip the slag completely. Allow the job to cool slowly to room
temperature.
Welding Current:
Current DC (+)
Size (Ø mm)/Length 2.5x350 3.2x350 4.0x350 5.0x350
Current (amps) 60-80 90-110 110-140 140-160
3. M/s Esab India, Brand: O.K.92.26

Extreme toughness, spalling and oxidation resistance joins dissimilar metal combinations
An electrode that joins any difficult-to-weld steels, dissimilar steels, Nickel, Chromium and
Cobalt alloys with same or dissimilar metal. OK 92.26 yields a really crack proof weld metal.
It is relatively tolerant to dilution. The weld metal has good impact strength down to -200°C,
and good tensile strength up to 800°C. Corrosion and oxidation resistance of the deposit is
remarkable. It can also be used for welding low temperature steels such as 5% and 9% nickel
steel. The special formulation of the electrode is also suitable for overlaying previously
hardfaced layer before further hardfacing. It has high thermal spalling resistance.
Alloy Base: Ni, Cr, Fe, Mn, Nb, Ta, Mo, Cu, Si, C.
Special Features:
• Excellent resistance to corrosion, oxidation and thermal shock.
• Smooth and stable arc with low spatter loss. All positional welding electrodes.
• Redrying is not required due to vacuum packed.
Properties:
UTS: 64-68kg/mm2
YS: 40-42 kg/mm2
Elongation A4, %: 40%
Current Range: (DC+)
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Size (mm) Length (mm) Current Range (Amp)
2.50 300 50-80

3.20 350 90-130
4.00 350 120-150
5.00 350 150-200
4. M/s D&H Secheron, Brand: Lotherme 510 N

A high Nickel-Cr-Mn-Nb Alloy for extreme thermal shocks resistance, high temperature and
cryogenic applications exhibiting sustained creep properties for multiple numbers of years.
Characteristics: LoTherme-510 N producing high quality Nickel alloy deposits. It operates in
all conventional positions. Excellent weld finish, steady arc, and good slag remove-ability.
Applications: LoTherme-510 N is a universal, all positional electrode, designed for joining
and surfacing of Nickel & Nickel Alloys, inconel alloys, Nickel-Cr-Fe based materials, 9% Ni
Steels for cryogenic applications for very high-temperature applications and applications of

extreme thermal cycles, possessing much higher UTS and Elongation compared to many
other products. It is recommended for welding different steels, such as austenitic to ferrite
steels, as well as for cladding on unalloyed and low-alloyed steels.
Typical Applications: include cement kiln rings, blast furnace components, reformer tubes,
chemical containers & liquid gas installations.
Typical Mechanical Properties of All Weld Metal:
Ultimate Tensile Strength : 65 Kgf/mm
Elongation (L=4d) : 38 %
CVN Impact Strength (@RT) : 90 Joules
-------"----- (at Minus 196°C) : 60 Joules
Hardness : 180 BHN
Welding Technique: Ensure that the electrodes are dried at 250°C for 2 hours before use.
Clean the weld area free of rust, oil, grease, paint, or any other surface contamination. To
ensure minimal heat input, use short arc and stringer bead technique.
Current Conditions: DC(+)
Size (mm) 5x350 4x350 3.15x350 2.5x350
Dia x Length
Current Range (Amps) 150-180 110-140 80-100 50-70
– Ra
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CATEGORY: LOW HEAT INPUT ELECTRODES
(1) SPECIAL WELDING ELECRODE UCS: 72203003200009 & 72203003200010

SAP DESCRIPTION: ELEC,TY-4,MS LH,DIA 3.15/3.2 MM,SPL JOIN & ELEC,TY-4,MS LH,DIA
4.0MM,SPL JOIN
TYPE TYPE-4, MATERIAL: MILD STEEL (LOW ALLOY), DIAMETER: 3.15/3.2 MM & 4.0 MM
APPLICATION: JOINING
CATEGORY: LOW HYDROGEN ELECTRODE FOR HIGH TENSILE STRENGH, DUCTILE AND
IMPACT RESISTANCE JOINING AND LAYERING OF MILD, MEDIUM CARBON AND LOW
ALLOY CRITICAL COMPONENTS REPAIR.
PREFERRED MAKE:
1. M/s EWAC Alloys, Product: Xuper 660 NH
2. M/s Esab India, Product: Terroweld DLH
MEDIUM CARBON STEEL ELECTRODES

1. M/s EWAC Alloys, Product: Xuper 660 NH
Boom of Excavator
Moisture resistant electrode for welding low alloy and high tensile steels
Crane jibs, frames, truck chassis, heavy equipment maintenance.
• Low hydrogen electrode with nonhygroscopic coating.
• Suitable for cast steels containing Sulphur and phosphorous for better castability /
machinability.
• High arc force purges out impurities.
• High tensile, ductility and crack resistance. Anti-spalling under extreme pressure.
• X-ray quality weld deposits.
Recommendation:
For medium carbon steel, low alloy and high tensile steel, ‘problem’ steel and structural
steel sections. Elements like sulphur, phosphorous etc. which produce porosity are purged
from molten pool by electrode arc action.
Procedure:
Clean weld area. Maintain medium to short arc length. Horizontal fillet welds can be made
using the contact technique. Vertical joints should be welded from the bottom up by
weaving rapidly. Do not whip. Slag is easily removed by chipping.
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2.50 70-80 60-70
3.15 120-135 100-115
4.00 150-165 125-150
5.00 185-200 165-185
XHD 2222 ac /
Tensile Strength: 57 Kg/mm2 (81,000 psi)
(2) M/s Esab India, Product: Terroweld DLH
This low alloy high strength weld metal is recommended for building up and joining heavy
sections of low, medium carbon and low alloy steels in critical components. The weld
deposit is ductile and crack resistant. This process along with the special flux enables the
electrode to be used directly in critical field condition without welding precautions as

electrode redrying, preheating the workpiece, etc. The electrode needs no baking upto 8
hours after opening the VacPac.
Alloy Base: Fe, Mn, Ni
Special Feature: No welding precautions are required.
Applications:
Joining & build-up of medium tensile steels, restrained joints, steel castings, heavy machine
components, etc., dragline bucket and chains, dipper stick, repairing cranks and
undercarriage, dozer blades repair, chassis of earthmoving equipment like dumper, shovel,
dragline etc. and repairing pulleys of dragline.
Properties:
UTS: 54-59 kg/mm2
Elongation: 28-32%
Current Range: (AC 50, DC±)
Size Length Current Range
(mm) (mm) (Amp)
3.15 350 90-135
4.00 350 140-165
5.00 350 170-220

SAP DESCRIPTION: ELEC, TY-3, MS LH,DIA 4.0MM, SPL JOIN
TYPE: TYPE-3, MATERIAL: MILD STEEL LOW HYDROGEN DIAMETER: DIA 4.0MM, LENGTH:
350MM
APPLICATION:JOINING
CATEGORY: ELECTRODE FOR JOINING, LAYERING MILD, MEDIUM AND DIS-SIMILAR
METALS. HIGH STRENGH, DUCTILE AND CRACK RESISTANT WELDS.
PREFERRED MAKE:
1. M/s EWAC Alloys, Brand: E-66 not found
2. M/s Esab India, Brand: Terroweld DBL
3. M/s Diffusion Engineers, Brand: DIFFUALLOY 800 ELH
4. M/s D & H Secheron, Brand: LOTHERME 352
5. M/s Ador Fontech, Brand: LH 104
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1. M/s Esab India, Brand: Terroweld DBL

Terroweld DBL deposits a high strength low alloy weld metal recommended for building up
and joining of low, medium carbon and low alloy steels. It is also suitable for giving buffer
layers on medium and high carbon steels prior to hard surfacing. The weld deposit is
extremely ductile and crack resistant. Produces excellent result in highly constrained heavy
machinery joining. Low heat formulation suitable for joining thin section without risk of
burn-through.
Alloy base: Fe, Mn, Si, Ni
Special Features:
• Super-ductile weld.
• Suitable for high speed welding.
• Bonds easily with parent metal
Applications:

Joining and build-up of medium tensile steels, joining dissimilar sections, restrained joints,
giving buffer layers on pipes, angles, pressure vessels, cross members, gun plates, steel
castings, heavy machine components, etc. Perfect in welding steels like free-cutting steels,
where sulphur and other alloys are added.
Properties:
UTS: 52-55 kg/mm2
Elongation: 28-32%
Size Length Current
(mm) (mm) Range(Amp)
3.15 450 90-135
4.00 450 140-165
5.0 450 170- 220
2. M/s Diffusion Engineers, Brand: DIFFUALLOY 800 ELH
A newly formulated basic-coated “Extra Low Hydrogen” “Lo Temp” alloy designed for X-ray
quality welds on mild steels, medium carbon and low alloy high strength steels. Deposits
exhibit very high strength and provide unique resistance to hydrogen-induced
embrittlement.
Applications: Diffualloy 800 ELH is recommended for x-ray quality welds on a variety of
medium carbon and low alloy high tensile steels, providing unique hydrogen free deposits
with superior impact resistance at normal and sub-zero temperatures. Recommended
applications include high pressure piping, overhead cranes, hoists, steel casting defects,
steel gears, sprockets, loco frames, hubs, pumps etc.
Procedure: Clean weld area to remove surface contamination and gouge/grind all cracks.
Use electrode on AC/DC + at the lowest amps; Maintain a short arc (can be used for `contact
welding’ also); Deposit stringer or modified weave technique. Allow to cool and slag is
removed easily. Preheat is usually not necessary unless very heavy sections are involved.
Technical Data:
Size (mm) : 3.15 4.00 5.00
Recommended Welding Current (Amps) : 100 - 140 130 – 170 160 – 200
Tensile Strength : 55-60 kgf/ mm2
Yield Strength : 44-48 kgf/ mm2
Elongation (l = 5d) : 30% Min.
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CVN Impact Strength at – 200 C : 8-10 kgfm/cm2
3. M/s D & H Secheron, Brand: LOTHERME 352
A low heat input electrodes for mild, medium carbon steels, cast steels and for buffer
layers.
Characteristics: LoTherme-352R is a low heat input AC/DC electrode, operates equally well
in all conventional positions. High quality, high strength, crack free radiographic welds are
the special features of LoTherme352R. Welds display excellent ductility and toughness.
Applications: LoTherme-352R is suitable for repair of bogies, both cast and fabricated. Also
suitable for welding mild, medium carbon steels, difficult steels, steels heavy structures,
repair of Co-Co bogies, plant and equipment subject to dynamic loading and impact. It is
also suitable for depositing buffer layers before hard surfacing.
Ultimate Tensile Strength: 57 kgf/mm
Elongation (L=4d): 26 %

Welding Technique: Redry the electrodes at 250°C for one hour before use. Clean the weld
area completely free of oil, grease, paint, rust or any other foreign matter. For welding
heavy sections in cast steel, preheating of the part may prove beneficial. Use short arc.
Current Conditions: DC (+)/AC
Size (mm) 5x350 4x350 3.15x350 2.5x350
Dia x Length
Current Range 170-210 140-170 100-130 60-90
(Amps)
Alloy Basis: Mn, Si, C
Properties:
The weld bead has good appearance and slag peels off easily. The weld metal is tough,
extremely ductile, resistant to cracking and of radiographic quality.
Technical Data:
UTS: 50-58 kgf/mm2
Elongation: 22-29%
Used for joining and building up of low and medium carbon steels. Ideal for joining dissimilar
sections, restrained joints and oil soaked parts, castings. Can also be used as a cushioning
alloy under hardfacing deposits. Finds applications in pressure vessels, pipes, flanges,
vehicle chassis, cross members, gun plates, heavy machinery parts, steel castings, C-frames,
H-frames, crusher rotor discs, etc.
Procedure:
Clean the area to be welded. Adopt short arc, on DC power source with reverse polarity. It is
recommended to dry the electrode at 300°C for one hour before use to get better results.
Welding Current: Current AC/DC (+)
Current (amps) 60-85 100-140 140-180 170-220
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CATEGORY: STAINLESS STEEL ELECTRODES (30/10 CLASS)
(1) SPECIAL WELDING ELECRODE UCS: 72203003700002, 72203003300004 &

72203003700001
SAP DESCRIPTION: ELEC, TY-1, 30/10,DIA 2.5MM,SPL JOIN
ELEC, TY-1, 30/10,DIA 3.15/3.2MM,SPL JOIN
ELEC, TY-1, 30/10,DIA 4.0MM,SPL JOIN
TYPE: TYPE-1, MATERIAL: STAINLESS STEEL CHROMIUM/NICKEL 30/10 C, DIAMETER
2.5MM/3.15 MM/4.0MM, LENGTH: 350MM
APPLICATION: JOINING
CATEGORY: SUPER CRITICAL, HIGH STRENGH & HIGH DUCTILITY APPLICATIONS AND FOR
JOINING DIS-SIMILAR METALS
PREFERRED MAKE:
1. M/s EWAC Alloys, Brand: 680 CGS
2. M/s Esab India, Brand: OK 68.81
3. M/s Stanvac Chemicals, Brand: FERROGOLD 303

4. M/s Hardcarb Tech Pvt Ltd, Brand: VT 29/9
5. M/s Ador Fontech, Brand: LH 106 SMP
1. M/s EWAC Alloys, Brand: 680 CGS
Shaft Keyway Crack

Weld metal with high toughness, high strength & ductility for joining dissimilar steels
Joining dissimilar steels, dies, tools, springs, machinable build-up & overlay.
• Refined grain structure with improved strength and ductility.
• Superior crack resistance.
• Spray type metal transfer.
• Joining steels of unknown composition.
• Machinable built up and overlay.
Recommendation:
Frigid arc coating plus high alloy core generates highly ionized arc for spray transfer of weld
metal. Addition of special micro alloying elements produces refined grain structure.
Recommended for similar and dissimilar steels. Suitable for joining steels of different
section thickness.
17
Procedure:
Clean weld area. Bevel heavy 0 0 sections. Tilt electrode 10 -15 in direction of travel. Burn-
off rate is rapid and uniform permitting rapid advance with no “sticking” or “drifting”.
Restrict weaving to 2-3 X electrode diameter. Peen to relieve stresses. Slag releases easily.
Restrict 0 Preheat to 150 C max.
2.50 60-70 45-60
3.15 80-100 70-80
4.00 120-145 100-120
5.00 170-200 145-170
- Range
Tensile Strength: 85 Kg/mm (1,20,000 psi)
2. M/s Esab India, Brand: OK 68.82

Versatile electrode for joining any steel to any steel
OK 68.82 deposits a high strength oxidation and corrosion resistant weld metal suitable for
dissimilar steel joining and building-up applications. The weld metal, being free from
dilution effects and having high strength combined with good elongation, can successfully
join thick section of any unknown steel and steels which are difficult to join. The high scaling
temperature of weld metal makes the electrode usable for working at high temperatures.
Alloy Base: Fe, Cr, Ni, Mn
Special Features:
• Extremely smooth running performance. ‘
• Fail-safe’alloying.
• Bonds with any steel.
• Self-releasing slag.
Applications:
Joining unknown steels, steels of limited weldability, and dissimilar steel joining.Reclamation
of shafts, universal coupling, gear teeth, pump casings, rolling mill spindles, buffer layers
prior to hardfacing in mining and earthmoving equipment, coal pulverisers, pinions, crusher
roller gears etc.
Properties:
UTS : 79-86 kg/mm2
Elongation : 22-29%
(mm) (mm) (Amp)
2.50 350 50-80
3.15 350 75-110
4.00 350 100-140
5.00 350 130-160
3. M/s Stanvac Chemicals, Brand: FERROGOLD 303

Ferrite balanced, super strength, non-cracking alloy, for maintenance & repair of all steels
18
Super High Strength yet Non-cracking Maintenance Welds for Increased Safety: Ultra high
tensile strength, yield strength & holding power - e.g, a fillet weld of 4 passes of Ferrogold
303 is generally equivalent in strength to a fillet weld of 16 passes of a mild steel electrode.
Excellent work hardening qualities. Does not require embrittling heat treatment to obtain its
ultra high tensile strength.
Special "Ionised Arc Transfer" Drastically Reduces Spatter & Electrode Overheating: Easily
usable even on the smallest AC machines. Lesser distortion, less warpage & less stress.
Superb Crack Resistance: Unmatched fine grained micro structure. Excellent ferrite-
austenite balance with perfectly distributed ferrite throughout the weld deposit. Ferrite rich
structure is highly resistant to fissures, cracking, hot cracking & under bead cracking
practically any type of cracking under practically all conceivable conditions. X-ray quality
welds of outstanding quality even on dissimilar steels & composite steel structures.
All Weather: Can be uniquely water quenched (or rapidly weather quenched when welding
in cold climates) with no adverse effect on its physical properties.
Excellent Impact Resistance: Resists impact equal to or better even than steels specially

designed for impact resistance (manganese, Ni - Mn, Mo -Mn......)
Excellent All-Position Weldability In Both AC & DC: Unusually fine drop type "ionised- arc"
transfer even on alternating current, reduces spatter & prevents overheating. Insensitive arc
gap - can be varied from contact to medium long without loss of arc stability.
Special Slag Formulation Eliminates Slag Interferance In Horizontal Fillets: Virtually self-
releasing slag. Eliminates the possibility of slag entrapment & makes electrode excellent
even for multi - pass weldments. Does not under cut, overlap or fill- up. Smooth, regular
well formed beads, uniform in cross section. Reduces need for preheating on
"problemsteel", welding.
Tough: Superb resistance to heat, corrosion & shock. Possesses very high elongation & good
machineability. Excellent fatigue resistance for long lasting repairs. Super high notch
toughness.
VIRTUALLY INSENSITIVE TO SURFACE CONTAMINANTS: Enables secure welding even over
painted, rusted, oily, dirty & wet surfaces, making it a unique tool for successful emergency
repair work, especially "on - site" & at odd hours when time inadequacy & where the
damage situation does not allow proper surface cleaning.
All weldmetal mechanical properties:
Tensile strength Yield strength Elongation

Rm (MPa) RP 0,2 (MPa) A5(%)
>850 >550 >27
Hardness: Temperature Resistance :

1st layer - 180 HB -200 C to +9000 C
2nd layer - 210 HB
Welding Instruction: Current (A)
1.60mm 2.50mm 3.15mm 4.00mm
35-50 60-80 90-110 100-140
Welding positions: Flat Vertical up, Horizontal Overfeed Vertical down
19
Applications: Ideal for repair of spring plates, drill bits, moulds, dies, chains, crane booms,
shafts, tools, armour plates.
4. M/s Hardcarb Tech Pvt Ltd, Brand: VT 29/9

Specially formulated austenitic-ferritic stainless steel welding deposit (high ferrite content)
for welding "difficult-to-weld" and dissimilar steels which need high integrity, safety, and
welder-friendly usability. The weld metal remains ferritic, even after dilution with an
austenitic base metal forming elements such as Mn, Ni und C and is thus highly crack
resistant. Produces plastic weld metal of high tensile strength, impact proof, tough, and acid
and heat resistant up to 1,000° C.
Classification:
Covered stick electrode EN 14700 E Fe 11
Mechanical properties of pure-weld-metal (typical values):
Hardness* 180 - 200 HB (as welded)
330 - 370 HB (work hardened)

Tensile strength (R ) 700 - 800 Mpa m
Yield strength (R ) 500 Mpa p0.2
Elongation (A ) 20% 5
Impact strength (DVM) > 30 J (+20°C)
Service Temperature 300 °C
Weld deposit density ~ 8.00 g/cm
Weld Process SMAW
* Typical hardness of pure-weld-metal on mild steel. Actual values are dependent on base
material composition, number of layers, cooling rate and welding conditions.
Weld Deposit Characteristics:
Duplex austenite-ferrite microstructure with about 40% ferrite. Combination of high alloy
and high ferrite content gives extreme tolerance to dilution on a wide range of hardenable
and alloy steels with minimum or no preheat. Weld deposit work-hardens and gives good
wear and friction resistance. Useful for resistance to corrosion and to high temperature
scaling up to about 1000°C, but not recommended for structural applications above 300°C
or for welds to be post-weld heat treated, owing to embrittlement.
Welding recommendations:
• The surface to be welded should be free from grease, oil, rust and other foreign
matter.
• All cracked or fatigue metal should be removed by gouging and grinding prior to
welding.
• Multi-layer weld deposits are possible without any limitations.
• Preheat is normally not required for small components and buffer layers. A 100-
250°C preheating is desirable for thicker high carbon steels to avoid possible HAZ
quench cracking and to control peak hardness.
• Parts which have been preheated should be wrapped or covered with heat–
retardant material to slow cool parts.
Recommended uses and applications:
• For joining difficult-to-weld base materials such as: highcarbon steel, tool steel,
spring steel, manganese steel, casehardening steel, high-speed steels, cast steels,
screening steels.
20
• For joining above materials to other dissimilar steels.

• For surfacing and repair welding rails, shafts, couplings, impellers, hot work tools,
pressing and trimming tools, as well as stamping dies.age 1/2
• A short, non-contact technique is recommended for both fillet and butt- welding.
Use a slightly longer arc-length for beadon- plate welding. Deposit stringer beads or
2x to 3x weave beads. Do not weave more than three times the electrode diameter
otherwise slag interference may be encountered.
• The weld deposit is machinable with metallic carbides or Cubic Boron Nitride (CBN)
tipped tools.
Availability & Recommended Weld Parameters:
Product code Ø (mm) Ø (inch) Current (A) Polarity Weld positions (EN ISO 6947)
NVT29.9E16 1.60 1/16 20 - 35
NVT29.9E20 2.00 5/64 30 - 60
NVT29.9E25 2.50 3/32 50 - 80
NVT29.9E32 3.20 1/8 70 - 100

NVT29.9E40 4.00 5/32 90 - 140
NVT29.9E50 5.00 3/16 130 - 180
Re-baking: 1 h. 350 °C ± 10 °C (if necessary)
5. M/s Ador Fontech, Brand: LH 106 SMP
Austeno-ferritic electrode with excellent ductility and high tensile strength
Alloy Basis: Cr, Ni, Mn
Properties: The weld metal has Nuclei treated element which produces Controlled Grain
Structure as well as Controlled Ferrite Content. This combination gives higher strength as
well as ductility which is required when welding difficult to weld steels. Electrode has "spray
type" transfer and weld beads are smooth with uniform ripples. Can be used on low
amperage, has easy striking and re-striking characteristics. The weld metal is crack, heat
resistant and is extremely tough. The weld metal is resistant to shocks due to impact. The
deposit is machinable and shock proof.
Technical Data: UTS: 70-90 kgf/mm2, Elongation: 22-25%
Typical Applications: For joining dissimilar steels of unknown composition with different
thickness, welding of dies, springs, shaft splines, gears, punches, etc. For depositing
cushioning layer on difficult to weld steels before depositing final surfacing layer.
Procedure: Clean the affected area from oil, grease, etc. Bevel 90° U groove using LH 900.
Hold short arc and deposit stringer beads. Preheat as necessary. Chip the slag between
passes. Maintain inter-pass temperature below 200°C. Allow the job to cool slowly.
Current (amps) 50-70 80-110 110-150 140-180
21
CATEGORY: LOW HEAT INPUT 18/8/5 ELECTRODES FOR MAINTENANCE

APPLICATION
SPECIAL WELDING ELECRODE UCS: 72203003200003
SAP DESCRIPTION: ELEC, XUPER-680S, 1.6MM
MATERIAL: HIGH TENSILE 30/10, MANUFACTURER: EWAC ALLOYS LTD, DESIGNATION,
BRAND: XUPER-680S, DIAMETER: 1.6MM, SPECIAL WITH HIGH TENSILE 30/10 SUPERIOR
PREFERRED MAKE:
1. M/s EWAC Alloys Ltd. (Proprietary)
ARC STEEL ELECTRODES

Jaw Crusher Shaft
Very low heat input electrode for joining, built-up of dissimilar & difficult to weld steels
Typical Applications: Joining and buttering of thin, difficult to-weld steels including cast
steels, high carbon steels, high alloy steels, tool steels and steels of unknown composition.
e.g. bearing areas of shafts, edge build-up of gears, keyways, bellows etc.
• Low dilution, lowest thermal stresses.
• Easy arc strike even at very low amperages.
• High strength and ductility of weld deposit due to refined grain structure.
• Superior crack resistance, even when diluted with high Carbon Steels.
Recommendation: A special Cr-Ni alloy giving high strength joints with excellent resistance
to cracking. Low amperage enables welding of thin cross sections. Proprietary formulation
of flux coating permits low-heat input welding in all positions. “Cool arc” flux coating plus
high alloy core wire generates highly ionized arc for “spray type” transfer of weld metal for
welder comfort and negligible HAZ. Weld deposits with refined grain structure ensures high
strength, high toughness and ductility.
Procedure: Clean weld area. Deposit with 0 0 electrode tilted 10 -15 in direction of travel.
Burn-off rate is rapid and uniform, permitting rapid advance with no “sticking” or “drifting”.
Weld with short arc length and minimal weaving. Remove slag between passes.
Recommended Amperages: Size 1.6, Amperage 25 - 35Amperage

22
SAP DESCRIPTION: ELEC, TY-1, 25/20, DIAMETER: 4.0MM, SPL JOIN
TYPE: TYPE-1, MATERIAL: STAINLESS STEEL CHROMIUM/NICKEL 25/20 C, DIAMETER:
4.0MM, LENGTH: 350MM, APPLICATION: FOR HEAT RESISTING STEELS
PREFERRED MAKE:
1. M/s Diffusion Engineers, Brand: DIFFUALOY-910
2. M/s EWAC Alloys Ltd, Brand: STAINRODE-D
3. M/s Ador Fontech, Brand: LH-126
1. M/s Diffusion Engineers, Brand: DIFFUALOY-910

Characteristics:
HIGH TENSILE STAINLESS STEEL ELECTRODES

A versatile low temperature, all positional austenitic stainless steel electrode for welding of
AISI and 310 stainless steel. Ideal for joining dissimilar and unknown stainless steels and for
joining these to steels.
Applications: Diffusaloy 910 is designed for applications involving elevated temperatures.
Alloy provides excellent resistance to high oxidation and maintains high strength at
temperatures upto 11000 C. Ideal applications include furnace parts, heat exchangers, heat
treatment boxes, furnace stands, heating elements, kiln cooler plates and for clad steels
Procedure: Clean weld area. Clamp and tack weld at short intervals. Use electrode on AC/DC
+ at lowest possible amps. Maintain very short arc and chip slag between passes. Avoid
weaving.
Technical Data : DIFFUSLAOY 910Size (mm)
: 2.50 3.15 4.00 5.00
Welding Current (Amps) : 40-70 60-100 80-135 130-175
Elongation (l=4d) : 30% (min)
CVN Impact Strength at +200 C : 8-12 Kgf/mm2
Tensile strength : 57 kgf/mm2
Coating Colour : White
Tip Colour : Grey
2. M/s EWAC Alloys Ltd, Brand: STAINRODE-D

Excellent electrode for joining wide range of SS and MS base metal for oxidation and heat
resistance applications
Valves, tanks, heat exchangers, heat treating boxes and baskets.
• Ideal for oxidation and heat resistance.
• Ideal for joining of stainless steel of unknown composition.
• Smooth, rapid, spatter-free deposition.
Recommendation:
Excellent weldability, no spatter, high strength and elongation for 25/20 type stainless steel
and other unknown stainless steels. Designed for applications requiring a high degree of
oxidation resistance and high strength at temperatures up to 1000°C. Used also for welding
stainless steel to mild steel.
Procedure:
23
Clean weld area. Tack at short intervals when jigs are not available. Square butt weld
thickness upto 10 gauge. Heavier sections should be bevelled 60°. Maintain short arc and
deposit stringer beads. Avoid weaving. Deposit a number of light beads. Use an intermittent
welding sequence to prevent overheating. Remove slag. Use electrode positive with DC
machine. Minimum open circuit voltage for AC: 55 V.
Excellent electrode for joining wide range of SS and MS base metal for oxidation and heat
resistance applications Coal Burner Nozzle
2.50 3.15 4.00Size (mm)
60 – 70 85 – 100 115 - 135I - Range
40 – 50 55 – 75 80 - 105II - Range
HIGH TENSILE STAINLESS STEEL ELECTRODES

Tensile Strength: 66 Kg/mm2 (95,000 psi)

Fully Austenitic heat resistance stainless steel electrode for welding 25/20 stainless steel
Alloy Basis: Fe, Cr, Ni
Properties: Fully Austenitic weld deposit, heat resistant upto 1200ºC in oxidizing and
sulphur free atmosphere.
Technical Data:
UTS: 55-65 kgf/mm2
Elongation: 30-35%
Welding of Austenitic stainless steels, heat resistant Cr-Ni steels of the type 25 Cr / 20 Ni
(NCT, AISI 310, Ugine NS 30, Avesta 254 E, Sandvik 15 RE 10). Also suitable for welding of
steels with high carbon content often used in the cement industry for anchor welding,
Furnace linings, furnace parts, burners, heat treatment pots and baskets.
Procedure:
De-grease and clean the area to be welded. For heavy thickness prepare a 60° included
angle V. Fit up should be accurate for long joints. Weld at regular intervals and use jigs &
fixtures to avoid distortion. Use DCRP (DC+) on DC Power Source for good ripple & finish.
Stringer bead technique with shortest possible arc length is recommended.
Current (amps) 50-75 90-110 120-140
50 STAINLESS
24

SAP DESCRIPTION: ELEC, TY-3, 30/10, DIA 4.0MM, SPL JOIN
TYPE: TYPE-3, MATERIAL: STAINLESS STEEL CHROMIUM/NICKEL 30/10 C, DIA: 4.0MM,
APPLICATION: NORMAL, HIGH TENSILE STRENGH
HIGH TENSILE & CRACK RESISTANT STAINLESS STEEL ELECTRODES

PREFERRED MAKES:
1. M/s Weldcraft, Brand: KOLDWELD -14C
2. M/s D&H Secheron, Brand: Lotherme-469
3. M/s ESAB India, Brand: DURO CHROME
4. M/s EWAC Alloys Ltd, Brand: CPBH-015
1. M/s D&H Secheron, Brand: Lotherme-469

A low heat input electrode for crack free, high strength welds on all steels.
Characteristics: LoTherme-469 is an ideal low heat input electrode for high strength welds
on steels. Pleasing operating characteristics, smooth weld beads, high strength crack
resistant weld metal are features associated with this electrode.
Applications: Ideally recommended for high strength joints in steels, dissimilar joints in
carbon, low alloy steels, dissimilar joints in carbon steels to stainless steels, etc., Typical
applications include gears, dies, shafts, earth moving machinery, general machine parts, etc.
Typical Ultimate Tensile Strength of Weld Metal: 2 80 Kgf/mm
Welding Technique: The electrodes should be dry. Redry the moist electrodes at 250°C for
one hour. Use short arc and stringer beads. Use Pre-heating wherever necessary.
Current Conditions: DC(+) / AC
Size (mm) 5x350 4x350 3.15x350 2.5x350
Dia x Length
Current Range 150-180 90-110 70-90 50-70
(Amps)
2. M/s ESAB India, Brand: DURO CHROME

Dissimilar and unknown steel strength joining
Esab Durochrome is an electrode for welding complex dissimilar alloys and high strength
steels with low heat input giving sound joints, free from any cracks and fissures. The
electrode is also suitable for depositing buffer layers prior to hard surfacing on high strength
and high alloy steels. The deposit is corrosion resistant and resists high temperature
oxidation. It provides excellent metal to metal frictional resistance.
Alloy Base: Fe, Cr, Ni, Mn
Special Features:
• Operates at low amperages on both AC & DC.
• Smooth arc, fine ripples and easily detachable slag.
• The duplex structure steel weld metal is extremely tolerant to dilution.
Applications: Welding of high strength alloy steels, dissimilar joints, re building of chemical
agitator blades, shafts, rolling mill spindles, bucket lips, steel mill wobblers, coupling boxes,
mill hammers, bar mill guides, sinter plant parts, etc.
Joining and surfacing of high carbon, low and high alloy steels, tool steels, spring steels,
manganese steels, case hardening steels, etc.
25
Properties:
UTS: 77-82 kg/mm2
Elongation: 30-35%

(mm) (mm) (Amp)
2.50 350 40-65
3.15 350 55-95
4.00 350 85-135
5.00 350 110-165

Austeno-Ferritic Alloy Steel Electrode for High Strength and Crack Resistant Welds
Alloy Basis: Cr, Ni, Mn
Properties:
Rutile flux coated electrode depositing Austeno-Ferritic, crack-resistant weld metal with
approx. 25-30% ferrite. Smooth weld bead with clean edge. Excellent slag removal (self-
peeling characteristic). Practically no spatter loss and under cuts.
Technical Data:
UTS 70-80 kgf/mm2
Elongation (L=4d) 30-32%
Most suitable for joining armour steel, Austenitic Manganese steel, cast steel, forged steel
and stainless steel to carbon steel or steels of unknown composition. For surfacing of
grooved rolls, springs, dies, punches, crowns, and repair of drop forged dies and also as a
cushioning layer before hard facing.
Procedure:
Clean the joint thoroughly. Remove all fatigued or damaged metal. On thick walled work-
piece make 90° U groove. Preheat if required according to the base metal. Adopt short arc
with recommended current. Peen the bead and cool slowly to room temperature.

Current (amps) 50-80 80-100 110-140
26
SPECIAL WELDING ELECRODE UCS: 72203003700055 & 72203003700052

SAP DESCRIPTION: ELEC, TY-2, 30/10, ,DIA 3.15/3 MM,SPL JOIN & 4.0 MM
TYPE: TYPE-2, MATERIAL: STAINLESS STEEL CHROMIUM/NICKEL 30/10 C, DIAMETER:
3.15MM, LENGTH: 350MM, APPLICATION: JOINING, CATEGORY: CRITICAL, HIGH STRENGH
& CRACK FREE APPLICATIONS

PREFERRED MAKES:
1. M/s ESAB India, Brand: TERROWELD DS-3
2. M/s D&H Secheron, Brand: LOTHERME-468
3. M/s Diffusion Engineers, Brand: UNIALOY-624
4. M/s EWAC Alloys Ltd, Brand: E-680
1. M/s ESAB India, Brand: TERROWELD DS-3

Strength joining for dissimilar and unknown steels
Terroweld DS3 deposits a high ferrite stainless steel deposit suitable for joining, building up
and buffering applications. The specially designed microstructure of the weld deposit
ensures superior resistance to crack, corrosion and oxidation. The electrode is suitable for
joining dissimilar, unknown and dif cult to weld steels. It is suitable for welding thick
sections with deep groove in all positions. Weld deposit is of excellent quality ensuring fail-
safe performance.
Alloy Base: Fe, Cr, Ni, Mn, Si
Special Features:
• Deposit gives high strength, combined with excellent resistance against impact,
friction.
• Heat and corrosion resistant surfacing.
• Smooth arc and fine ripples.
Applications:
Joining, surfacing and rebuilding shafts, spindle, gears, pinions, springs, bull gears and
sprockets, pump, gear box casing, rolling stock couplings, universal coupling, chassis frames,
shovel booms, wobblers, kiln tyres, hammer shafts etc. Also used as a buffer layer before
hard surfacing of mining and earth-moving machinery.
Properties:
UTS: 80-86 kg/mm2
Elongation:30-34%

Size (mm) Length (mm) Current Range (Amp)
2.50 350 60-90
3.15 350 70-100
4.00 350 100-130
5.00 350 110-140
27
2. M/s D&H Secheron, Brand: LOTHERME-468

A universal low heat input high strength, high alloy electrode for crack-free welds and
overlays on steels of widely varying compositions. Unique Dissimilar Steel joining alloy.
Characteristics: Lotherme-468 are so chosen that it is highly favorable for producing welds
which have complete freedom from hazards of cracking on a wide variety of similar &

dissimilar steels. It operates equally well on AC as well as on DC(+) in all conventional
welding positions. Extremely low spatter. Easily detachable slag. Very smooth weld finish,
which takes high polish, hene suitable for frictional wear resistance.
Applications: It is ideally suited for high strength, crack free welds and overlays subject to
service under wear, friction, impact, heat & corrosion on carbon, low alloy, applications
include dies, tools,leaf and coil springs and similar parts and surfacing hot dies, gear teeth,
forged shaft, earth moving equipment and machine parts.
Ultimate Tensile Strength: 85 kgf/mm2
Elongation (L=4d): 23 %
Welding Technique: Dry the electrode at about 125 degree C for one hour before use.
Clean the weld area free from oil, grease, dirt or any other surface contamination. Hold a
short arc. Do not weave the electrode. Weld with stringer beads. Intermittent welds may
be necessary for welding high alloy and hardenable steels. Peening will relieve internal
stress. For certain high alloy tool steel preheating is recommended.
Current Conditions: DC9+)/AC
Size (mm) 5x350 4x350 3.15x350
Current Range (Amps) 140-170 100-130 75-95
3. M/s Diffusion Engineers, Brand: UNIALOY-624

A unique high alloyed low heat electrode for high strength, crack resistant joining of
unknown and dissimilar steels, Hadfield, high carbon and alloy steels. Also recommended
for tough and wear resistant overlays on all steels. Controlled ferrite austenite duplex
structure provides resilience with very high strength.
Applications: Used for splines, threads, keyways of shafts, spur gear tooth, wear plates of
hydraulic excavator buckets, gear box main shafts, counter shafts, leafsprings etc.
Procedure:
1) Gouge out/grind, worn, damaged and fatigued metal/cracks.
2) Use the electrode on AC/DC+ power source.
3) Employ short stringer beads.
4) Use skip and staggered welding sequence.
5) Chip slag between passes. Peen the deposits while hot.
6) Preheat is usually not required unless very heavy sections are involved.
Technical Data :
Size (mm)Ǿ : 2.5 3.15 4.00 5.00
Recommended Welding Current (Amps) : 40 - 90 80 – 110 110 –150 140 - 190
Tensile Strength : 85 kgf/ mm2
Coating Colour : Blue Tip Colour : YELLOW
28
4.M/s EWAC Alloys Ltd, Brand: E-680

Swing Gear
A high alloy electrode for welding dissimilar steels and unknown steels - high carbon to all
steels.
Typical Applications: Chassis frames, gears, springs, tool steels, dissimilar alloy steels
joining.
• Very high tensile strength and ductility.
• Easy strike and re-strike.
• “Cold arc” coating leading to low heat input.
• Superior for joining dissimilar steels.
• Outstanding resistance to shock & impact.
• Easy slag removal.
• High frictional wear resistance.
Recommendation: For high strength welds & overlays on all steels requiring best possible
properties. For leaf and coil springs, vanadium - molybdenum spring steels, mild steel,
medium carbon steels and dissimilar steels.
Procedure: Clean weld area and ensure joint preparation. For certain high strength 0 low
alloy steels, preheat up to 150 C is recommended. Hold a short arc. Run stringer beads.
Intermittent welding may be used specially on high alloy steels. Cool each pass before
chipping slag. Ensure job temperature should not exceed 0 300 C to get all properties.
Size (mm) I- Range II-Range
2.50 60 – 70 50 - 60
3.15 90 – 100 75 - 90
4.00 110 – 140 90 - 110
5.00 160 – 180 150 – 160
29
CATEGORY: CAST IRON ELECTRODES
(1) Ferrous Base Non- Machinable Cast Iron Electrodes

SPECIAL WELDING ELECRODE UCS: 72203003000007,
SAP DESCRIPTION: ELEC, TY-1, CI NM, DIA 4.0MM, SPL JOIN
TYPE: TYPE-3, MATERIAL: HARD FACING ALLOY, DIA 4.0MM
APPLICATION: LOW TEMPERATURE NON MACHINABLE, CATEGORY: LOW TEMPERATURE
HARD FACING TYPE
PREFERRED MAKES:
CAST IRON ELECTRODES (NON MACHINABLE)

2. M/s Diffusion Engineers, Brand: Ferrocast 102
3. M/s Ferrite Metal Solutions Pvt Ltd, Brand: Felix-824
Innovative alloy with strong arc force and cleaning action for contaminated cast irons
Typical Applications: Buttering layer on contaminated cast irons, cast Iron defects, cast
Iron furnace equipment sealing oil-soaked cast Iron parts.
• Nickel-free deposits.
• Spray type of metal transfer.
• High tolerance to impurities.
• Excellent colour match to gray cast iron.
Recommendation:
Non-conductive coating prevents side arcing; greatly aids welding in tight corners and
deep holes. Used as a buttering on all cast irons. Exceptional performance on
contaminated surfaces. Deposit exhibit colour match on cast irons.
Procedure:
Clean weld area, drill holes at the starting and end of crack on Cast Irons. Use Eutec-
Chamfer Trode electrode for preparing U-groove. Deposits offer spray type of metal
transfer. The welding alloy should be deposited on base metal with the electrode tilted
30
slightly in the direction of travel. Do not weave. Use short beads not exceeding 30 mm,
back whip crater. Remove slag by chipping and brushing. Not recommended for joining
only buttering.
3.15 105-125 70-95
4.00 130-150 95-120
2. M/s Diffusion Engineers, Brand: Ferrocast 102

A specially designed, low heat input `LoTemp’ electrode with strong arc force and quick-
freezing spray transfer, to seal contaminated surfaces in old, dirty, greasy cast irons.
Deposits of Ferocast 102 R condition the surface for subsequent joints in cast iron with
Greloy 850.
Applications:
For conditioning the contaminated of cast iron prior to use of Greloy 850. Deposits quick
freezing and non-machinable. Can be used for joining guards on machine tools, motor and
generator housings. For foundry defects, requiring grind finish and goods colour match.
Procedure:
Gouge out / grind all cracks. Use electrode on AC / DC + at lowest possible welding current
within the range. Hold medium to long arc length. Employ short, skip and staggered welding
sequences.
Technical Data:
Size (mm): 3.15 4.00
Recommended Welding
Current (Amps): 90 – 120 120 –150
Tensile Strength: 40 kgf / mm2
Coating Colour: Black Grey
Tip Colour: Red
3. M/s Ferrite Metal Solutions Pvt Ltd, Brand: Felix-824
Premium high strength iron based non machinable electrode for contaminated cast irons.
Special Features:
• Good results on contaminated, oil soaked and heat oxidised cast irons.
• High resistance to cracking.
• Specially fromulated flux produces high arc force to flush away impurities and give
posrosity free welds.
• Excellent colour match with the base metal
Typical Properties:
Tensile Strength: 60000PSI
Yield Strength: 46000 PSI
Hardness: 39 HRC
31
Applications:
• Ideal For Repair Of Cracked Machine Bases , Burned Furnace Grates , Pedestals , Oil
Pans , Frames And Housings , Dies , Agricultural Equipment , Build-Up Of Abrasion
Worn Areas , Pump Housings And Low Quality Cast Iron Etc .
• Used Also For Joining Cast Iron To Steel
International Specifications:
AWS/ASME A 5.15 Est,
DIN 8573 : E Fe- 1,
ISO 1071 : E Fe

Recommended Amperage Settings:
Diameter (mm) 3/32(2.5) 1/8(3.15) 5/32(4.0)
Minimum Amperage 50 70 90
Maximum Amperage 80 120 130
Welding Techniques: Remove all rust and scale from the surface to be welded. Adjust
amperage within recommended range and deposit electrode maintaining a short to medium
arc length. Tilt the electrode in the direction of travel. Use stringer bead or moderate weave
technique and back - whip all craters. Use reverse polarity on dc/ac.
32

(2) Ferro-Nickle Base Machinable Cast Iron Electrodes
SAP DESCRIPTION: ELEC, TY-1, CI, DIAMETER: 4.0MM, SPL JOIN FENI
TYPE: TYPE-1, MATERIAL: CAST IRON, DIAMETER: 4.0MM, LENGTH: 350MM
APPLICATION: M/CABLE ALL POSITION FERRO- NICKEL BASE
PREFERRED MAKES:
1. M/s Diffusion Engineers, Brand: CINOD 160
3. M/s EWAC Alloys Ltd, Brand: XYRON-223
1. M/s Diffusion Engineers, Brand: CINOD 160

Characteristics: A low heat input, ‘Lo Temp’ nickel alloy electrode formulated for high
CAST IRON ELECTRODES ( MACHINABLE)

strength welding of nodular iron. This new alloy electrode produces superior weld join in
grey malleable nodular and alloy cast iron such as nickel resist with exceptional crack
resistivity. All positional weld ability and excellent machinability.
Applications: Recommemded for use on machine beds, pump casing, valve bodies, valve
flanges, ball housings, motor covers, friction press discs etc. Especially suitable for superior
penetration of contaminated surface, with out the aid of a buffer layer.
Procedure: Gouge / grind out cracks with bevel angles of 70 – 90 deg. Deposit short, stringer
beads with short arc. Peen the weld deposit while hot. Complete repair at hand heat.
Preheat is usually not necessary unless very heavy sections are involved.
TECHNICAL DATA : CINOD 160
Size (mm) : 2.50 3.15 4.00 5.00
Welding Current (Amps) : 50-85 80-120 100-140 120-170
Tensile strength : 35-40 Kgf/mm2
Hardness : 180-210 BHN
Coating Colour : Black
Tip Colour : Pale Rose
Extremely crack resistant nickel iron alloy electrode for welding Cast Iron
Alloy Basis: Ni, Fe, C
Properties: Electrode with excellent welding characteristics. The deposit is machinable and
crack-proof. Good bonding on difficult to weld cast iron.
Technical Data: UTS 35-45 kgf/mm2
Typical Applications: An unique electrode for cold welding of cast iron without preheat and
for joining cast iron to mild steel. Also suitable for surfacing cast iron parts subject to
erosion, corrosion and high temperatures. Best suited for repairing intricate cast iron parts,
water pump housing, electric motor bodies and covers, machine frames, cylinder blocks and
gears. Also ideal for salvaging foundry castings, gear box, differential housing, lathe beads,
sugar mill rollers, glass moulds and cast iron dies. Very good for hubs/rollers of VRMs.
33
Procedure: Clean the welding zone and check the surface for cracks and defects. Use short
arc with low current to deposit stringer bead not exceeding 25 mm. Hot Peen the deposit to
reduce residual stresses.
Welding Current: Current AC/DC (-)
Current (amps) 50-70 90-120 100-130
3. M/s EWAC Alloys Ltd, Brand: XYRON-223

Versatile electrode for welding of heavy sections and crack sensitive applications
CAST IRON ELECTRODES ( MACHINABLE)

Gear Box Housing
Machine bases, pumps and differential housings, cast iron dies
• Excellent weldability.
• For heavy cast iron sections.
• Machinable deposits.
• For joints subjected to hydrostatic pressure.
Recommendation: For crack-sensitive applications such as castings involving hydrostatic
pressure, joints under restraint, dissimilar thicknesses and the general welding of very heavy
sections. Excellent for joining cast iron to steel. Circumferential pipe welds, especially heavy
wall thicknesses, can be made without danger of cracking. Dense
weld deposits are completely machinable.
Procedure: Clean weld area. Vee out cracks with Eutec ChamferTrode after drilling holes at
the ends of the cracks.Preheat is not required in most cases except for restraint joints
preheat to 250°C. Direct arc on deposited weld metal. Lightly peen to relieve stress.
Chip slag between passes. Use skip welding sequence in complicated assemblies. Cover
casting and allow to cool slowly.
Size
3.15 110-120 85-100
4.00 130-145 110-120
34
CATEGORY: HARDFACING ELECTRODES
QUESTIONS TO ANSWER BEFORE HARD FACING
1. What is the hard faced part of equipment supposed to do?

If a material is to be processed, what is its nature?
1. What is the wear problem? Are abrasions, impact, heat, friction, corrosion
present? Which one is the most predominant?
2. What is the base metal composition-manganese, carbon, low alloy steel? What
welding procedures are recommended for this base metal? Preheat? Slow
cooling?
3. What is the condition of the base metal? Are cracks, holes, eroded areas, wear,
work-hardened metal present? Is any old hard facing left on the surface? Is
buildup welding needed before hard facing?
4. In what position will the welding be done? What areas must be covered? What
HARD FAING ELECTRODES

sequence should be followed? What pattern should be used?
5. What welding process should be used? Arc or oxyacetylene? Manual,

semiautomatic or automatic? What equipment is needed? What is needed in the
way of welding skill?
6. Must the deposit meet hardness or other specifications? Is machining required?
7. What buildup and hard facing materials are needed?
8. What welding electrode diameter is needed? What quantities will be used?
9. What is the importance of shortest possible arc and stringer bead technique in
this hard facing range?
35
(1) Abrasion Resistance Coating Type Electrodes

SPECIAL ELECTRODES UCS: 72203003400007
SAP DESCRIPTION: ELEC, TY-3, HD FCG,DIA 4.0MM,SPL LT NM
TYPE: TYPE-3, MATERIAL: HARD FACING ALLOY, DIAMETER: 4.0MM
APPLICATION: LOW TEMPERATURE NON MACHINABLE, CATEGORY: LOW
TEMPERATURE HARD FACING TYPE
LOW TEMPERATURE MACHINABLE HARDFACING ELECTRODES

PREFERRED MAKES:
2. M/s Ador Fontech , Brand: LH-725
3. M/s Wear Resist Technologies, Brand: XLW 58H-SP
4. M/s ESAB India, Brand: Terroweld CRC
5. M/s Diffusion Engineers, Brand: Abrocar 84
6. M/s Stanvac Chemicals , Brand: Super gold 700 GCM

A versatile electrode for superior abrasion resistance
Ring Type Coal Crusher

Typical Applications: Jaw crusher plate, excavator bucket, lips, teeth, fan blades, hammers,
scrapper, augers, pulveriser.
• Excellent resistance to abrasion.
• Smooth bead appearance.
• High resistance to erosion.
• Superior weldability.
Recommendation: For steel parts requiring resistance to severe abrasive wear. Deposits
polish in service providing a very low coefficient of friction & erosion resistance. Very
smooth highly ionised spray transfer. All position welding electrode.
Procedure: Clean weld area. Use Eutec- ChamferTrode electrode to remove fatigue or
damaged metal. Preheat if necessary as per CE. Deposit the alloy directly on base metal. Do
not preheat on 14%Mn steels. Deposit a buttering layer of EuteTrode 400, inter pass
temperature should be 0 below 150 C for Mn steel. For air hardenable steel use EuteeTrode
36
670 as cushion layer. For cast iron use Xyron 224 as cushion layer. Restrict deposits to
maximum 2-3 layers.
3.15 110-130 90-110
4.00 150-170 130-150
5.00 180-200 160-180

II - Range
Hardness: 60-68 HRc (3 layer)
2. M/s Ador Fontech , Brand: LH-725

Surfacing Electrode Chromiun Carbide Deposits
Alloy Basis: Cr, Mn
Properties: Weld deposit is extremely hard and wear resistant. "Chromium Carbide" is
distributed uniformly in the weld matrix. Maximum two layers to be deposited for better
results.
Technical Data: Hardness 60-65 HRC
Typical Applications: Ideal for agitator blades, scrapper blades, conveyor screws, clay
extruder screws. Coal crusher rolls in thermal power plants, oil expeller worms, tooth points
and buckets of excavators, digger teeth, bucket tip edges, cement die rings, muller tyres,
plough shears, crusher hammers in cement plant, Chinese long walls in underground
mines.For components subject to metal to metal wear and abrasion with mild impact likely
to be absorbed elastically. Surfacing of mild and low alloy steels for wear resistant
properties.
Procedure:
Clean the affected area with wire brush. Hold the electrode at approx. 90º to the surface
and deposit the weld beads. Chip the slag between passes. Maximum
two layers are recommended.
Size (Ø mm)//Length 3.2x350 4.0x350 5.0x350
Current (amps) 100-130 110-140 140-180
3. M/s Wear Resist Technologies, Brand: XLW 58H-SP
General Characteristics: A chromium - iron alloy electrode with unique coating for high
abrasion resistant overlays on plain carbon steels, Manganese steels, and grey cast irons.
Carbides are uniformly distributed in hard martensitic matrix. This offers excellent
resistance to low stress scratching type as well as high stress gouging type abrasion of metal
coal, ore and minerals.
Applications: Bucket teeth, Crushing hammer, Jaw crusher Mill, screws, Crusher mantle
Scraper blade.
Procedure: Grind / gouge out worn and fatigued metal. Use AC/DC+ power source. Employ
stringer bead, deposit with skip welding technique. Chip slag (very little) between passes.
For multilayer build up using buffer or cushion. Layer of XL-BM (on High manganese steel),
XL-BU (on steel) and carbon steel, XL-C30 (on Cast Iron)
Mechanical Properties: Hardness: 60 - 65 Rc
Availabilities:
Diameter Length Current
37
(mm) (mm) (amps.)

3.15 350 70-110
4.00 350 100-150
5.00 350 140-210
PACKING: 5 Kgs
4. M/s ESAB India, Brand: Terroweld CRC

Resistance to high-stress particle abrasion at low heat input
A low heat input hardfacing electrode depositing a complex carbide type weld metal.
Deposit is highly resistant to abrasion & moderate impact coupled with good oxidation
resistance at elevated temperatures. It has easy striking and re-striking properties, with
smooth and stable arc giving low spatter. Relief cracks are desirable on the deposit.
Alloy Base : Fe, Cr, Mn, C
Special Features
• Extreme resistance to abrasion, oxidation and moderate impact.
• Smooth arc, fine ripples and a fluid but controlled slag which is easily detachable.
• Flat bead can be produced whenever necessary.
• Easy striking and re-striking properties.
Applications: The electrode can be successfully applied in earth moving equipment, coal
handling, agriculture implements, mining equipment, cement and refractory industries, iron
and steel industries and railroads.
Properties: Hardness : 58-62 HRC
Applications: The electrode is suitable for hardfacing, shafts, racks and pinions, links and
pins, valve seats of cast steel, mixer arms, feed gears, knives, loading buckets and track
rollers.
Properties: Hardness : 54-60 HRC
Current Range : (DC+, AC 70)
Size (MM) Length (MM) Current Range
(Amp)
3.15 450 120-140
4.00 350 140-185
4.00 450 150-185
5.00 350 165-250
5.00 450 170-250
5. M/s Diffusion Engineers, Brand: Abrocar 84

Characteristics: A low heat input ‘Anti-wear’ iron base alloy electrode for abrasion
resistance overlays on plain carbon and Hadfield manganese steel and grey cast iron.
Deposits exhibit uniform distribution of carbides in a hard martensitic matrix that ensures
high hardness and superior reistance to low stress scratching abrasion by minerals.
Applications: Bucket teeth, crusher mantles, pulverizer hammers, jaw crusher, plow shares,
scrapers, road rippers, bucket lips, pug mill screws, fan blades in mining, earthmoving and
cement industries.
Procedure: Gouge / grind out worn and fatigued metal. Employ lowest possible welding
current. Skip and staggered weld. Use stringer beads. For multi-pass buildup and overlays,
38
use cushion layers of Tufaloy 320, Hadmoloy 140, Greloy 850 etc. depending upon the base
metal.
Technical Data : ABROCAR 84
Size (mm) : 4.00 5.00
Welding Current (Amps) : 100-150 140-200
Hardness : 58-62 RC

Coating Colour : Grey
Tip Colour : Cherry Red
6. M/s Stanvac Chemicals , Brand: Super gold 700 GCM

For abrasion resistance and moderate impact resistance
• Basic coated SMAW electrode for hardsurfacing.
• Good for severe abrasion and moderate impact resistance.
• Suitable up to 500o C.
• 120% Recovery.
Typical mechanical properties:
Undiluted Weld Metal Maximum Value Up to:
Structure Martensitic cast iron
Hardness: 1 layer 59 HRc
2 layers 61 HRc
3 layers 65 HRc
4 layers 67 HRc
Wear Coefficient 2% (SiO2 as abrasive)
Machinability Grinding only
Recommended current: DC Straight (-), AC
Recommended amperage settings:
Size(mm) 1/8 (3.25) 5/32 (4.0) 3/16 (5.0)
Amp 85-120 115-150 150-190
Welding positions: Flat, Horizontal, Half up
Deposition rates:
Diameter (mm) Length Electrodes per lb(Kg ) Arc Time of Deposition min/lb (Kg)
1/8 (3.25) 14” (350) 19 (43) 41 (90)
5/32 (4.0) 14” (350) 12 (27) 27 (60)
3/16 (5.0) 14” (350) 8 (18) 19 (42)
Welding techniques: Select the minimum required amperage and utilize a medium arc gap.
For smooth flat welds use a 3 x weave. There is minimal slag which can be over welded
without prior removal. Only 2 passes are required for development of the full benefits of
this alloy. Cross crack stress relieving is normal.
Applications: For conveyor screws, mixer blades, pump and crusher parts operation in sand,
clay, cement, and coal.
39
(2) Work hardening for Extreme Impact and Abrasion Electrodes

SAP DESCRIPTION: ELEC, TY-2, HD FCG WH, DIA 4.0MM,SPL
TYPE: TYPE-2, MATERIAL: HARD FACING ALLOY STEEL WORK HADENING
WORK HARDENING WITH EXTREME IMPACT & ABRASION ELECTRODES

DIAMETER: 4.0MM
APPLICATION: SPECIAL, CATEGORY: FOR BUFFER LAYER BEFORE HARD FACING,
WORK HARDENED TO 40 RC
PREFERRED MAKES:
2. M/s Ador Fontech , Brand: ZIPPARC HD-62E
3. M/s Wear Resist Technologies, Brand: XL-BM –SP
4. M/s ESAB India, Brand: Duro Mangan (Spl)
5. M/s Diffusion Engineers, Brand: Hadmoloy 140
6. M/s Stanvac Chemicals, Brand: Super gold 400NM

A versatile electrode with excellent resistance to impact with work hardening capability
Typical Applications: Crusher hammer, wobblers, frogs, sprockets, bucket teeth, wear parts,
shovel track pads, under carriage components, scraper blades.
• Tough overlay on manganese steel and alloy steel.
• For severe impact, shock and hammering applications.
• Frigid arc coating for lowest possible amperage.
• Work hardens in service.
Recommendation: A ferrous base electrode with additions of Ni, Mn & other elements to
improve welding properties. Ideal Cushion layer before hardfacing on Mn steel, low carbon
steel, low alloy steel.
Procedure: Clean weld area. Use Eutec- ChamferTrode electrode to remove damaged metal.
Do not preheat manganese steels. Maintain a short to medium arc length. On Mn steel keep
bead length 75-100 mm at a time. Inter-pass temperature should 0 be maintained below
150 C for Mn steel by following back-step t e chnique . S k ip we lding i s recommended on
large parts. Peening while hot reduces residual stresses. Cool slowly.
3.15 120-140 100-120
4.00 160-190 130-140
5.00 180-200 160-190
Hardness:
As deposited 25-30 HRc
Work hardened 35-45 HRc
40
2. M/s Wear Resist Technologies, Brand: XL-BM –SP

General Characteristics: Special coated austenitic-manganese steel electrode for the
welding of surface layers on worn-out components made of austenitic manganese steel

which are mainly subjected to impact loads. Strain-hardening considerably improves the
hardness and the resistance to wear of the alloy. Also suitable for joining of manganese
steel to steel.
Applications: Hammers, Crusher rolls, rail crossings, and dredger teeth. PROCEDURE:
Prepare weld groove using XL - CUT, grind surfaces to remove hard spots. Clean weld area
thoroughly. Ensure electrodes are completely dry. Weld using a "short" arc procedure with
the electrode almost vertical. A "touch" technique can be used for horizontal welding.
Weaving should be limited to about 5 times electrode size.
Mechanical Properties: Hardness of weld deposited: 200 - 250 HB
After work hardening: 450 - 550 HB.
Availabilities:
Diameter Length Current
(mm) (mm) (amps.)
2.50 350 90-110
3.15 350 130-150
4.00 350 160-180
PACKING: 5 Kgs.
3. M/s ESAB India, Brand: Duro Mangan (Spl)

Work hardening for extreme impact and abrasion
A basic coated electrode depositing an austenitic manganese steel weld metal. The deposit
is highly resistant to heavy impact and abrasion. The deposit is work hardenable. The
electrode is recommended for surfacing of worn-out austenitic manganese steel parts.
Superior arc stability than available grades of Mn Steel electrodes. It is very easy to use in all
positions.
Applications: Austenitic manganese steel components, crusher jaws, crusher hammers,
crusher mantles, dredger bucket teeth, cement grinder rings, manganese steel railway
points & crossings, manganese steel components used in the mining industry.
Properties:
Hardness : As deposited : 24-26 HRC
Work hardened : 43-45 H RC
Welding Procedure: The surface to be welded should be without prior work hardening. 14%
Mn steel should never be preheated for welding. It can also be used to give impact
protection on carbon steels.
Alloy Base: Fe, Mn, Ni, Cr
Special Features: Build-up is free from cracks (with proper welding procedure).
Welding should be done in stringer beads directing the arc towards the weld pool keeping
the heat input to the base metal minimum. Skip welding/back step welding can also be
adopted.
The weld bead can be peened with ball pen hammer immediately after welding. Quenching
has no adverse effect on welding and should be adopted whenever possible after slag
41
removal and peening. If possible the Mn steel job can be submerged in water during
welding.
CURRENT RANGE : (AC 70, DC±)

(mm) (mm) (Amp)
3.15 450 80-120
4.00 450 130-170
5.00 450 160-220
4. M/s Diffusion Engineers, Brand: Hadmoloy 140

Characteristics: A tough austenitic low heat input ‘Antiwear’ alloy for wear resistance
overlay and build up on steels particularly Hadfield manganese steel. Deposits are tough and
work harden under repeated pounding/impulsive loads and exhibit very high resistance with
high impact toughness make the electrode ideally suitable for build up and cushioning of
Hadfield steels prior to capping with harder abrasion-resistant deposits.
Applications: Recommended for pulverizer hammers, bucket teeth, sprockets chain links,
crusher mantels, rollers, crusher roller, crusher jaws, bucket latch bars and keys, wear
plates, wobblers, hammer mills and shovel track pads.
Procedure: Gouge out/grind worn/fatigued metal. Use electrode on AC/DC+. Employ short,
stringer beads. Use skip and staggered welding sequence. Water-quench deposits and do
not allow the temperature of Manganese. Steel to go beyond 2500 C.
TECHNICAL DATA : HADMOLOY 140

Size (mm) : 4.00 5.00
Welding Current (Amps) : 120-160 150-200
2
Tensile strength : 80 kgf/mm
Yield strength : 52 kgf/mm2
Hardness as deposited : 180-220 BHN
Hardness work hardened : 400-450 BHN
Coating Colour : Dark Grey
Tip Colour : Apple Green
5. M/s Stanvac Chemicals, Brand: Super gold 400NM

Joining and cladding electrode for manganese steel that can be flame cut
Characteristics:
• Spray transfer allows for smooth uniform overlays.
• Work hardens easily in service.
• Rare alloy that can be flame cut.
42
Microstructure: In the as deposited condition the microstructure consists of a soft

manganese alloy austenite which rapidly work hardens under impact loading.
Flux Color: Dark Grey

Typical Mechanical Properties:
Undiluted Weld Metal Maximum Value Up to:
Tensile Strength 116,000 PSI (800 N/mm2)
Elongation 38%
Hardness Brinell 170-220. Rockwell B87 -96,Vickers 180-230
Work Hardness Brinell 380-550, Rockwell C41-54, Vickers 400-580
Recommended Current: DC Reverse (+) or AC

Recommended Amperage 1/8(3.25) 5/32(4.0) 3/16(5.0)
Settings: Diameter (mm)
Minimum Amperage Maximum 90 125 160

Amperage
125 170 225
Welding Positions: Flat, Vertical up, Horizontal, Overhead

Deposition Length Weldmetal Electrodes Arc time of Amperage Recovery
Rates: (mm) / Electrode per Ib(kg) deposition Setting Rate
Diameter of min/ Ib
(m.m) weldmetal (kg)
1 /8 (3.25) 14” (350) .94oz 17(38) 24(53) 110 120%
5 /32 (4.0) 14” (350) (26g) 11(24) 19(42) 150 120%
3/16(5.0) 14” (350) 1.45oz 7(16) 13(29) 195 120%
(41g)
2.3oz
(64g)
Welding Techniques: Clean metal of oils and fatigued sections. Most importantly, do not a
allow weld interpass temperature to exceed 500°F (260°C).
Applications: For repair of rail equipment and construction equipment manufactured of

manganese steel.
43
(1) Low Heat Input Electrodes for high Abrasion & Mild Impact
applications
SAP DESCRIPTION: ELEC, TY-1,HD FCG,DIA 4MM,SPL MT NM
TYPE: TYPE-1, MATERIAL: HARD FACING ALLOY, DIAMETER: 4MM, LENGTH: 350MM
HARDFACING ELECTRODES FOR HIGH ABRASION & MILD IMPACT

APPLICATION: MEDIUM TEMP NON MACHINABLE, CATEGORY: MEDIUM
TEMPERATURE HARD FACING ALLOY WITH ABILITY WITHSTAND OXIDATION
RESISTANCE AT ELEVATED TEMPERATURES
PREFERRED MAKES:
1. M/s Diffusion Engineers, Brand: ABROLOY-300
2. M/s Valency Compound, Brand: CRCN-60
3. M/s ESAB India, Brand: COBALARK MX
4. M/s EWAC Alloys Ltd, Brand: CHROMOCARB N6006 29
1. M/s Diffusion Engineers, Brand: ABROLOY-300

A highly alloyed, low heat input Antiwear chromium iron type electrode for abrasion
resistance overlays on carbon low alloy, stainless and Hadfield manganese steel. Deposits
contain large volume fraction of carbides in a hard matrix ensuring super resistance to low
stress, scratching and high stress grinding abrasion and low angle particle impact erosion.
Smoothes dense and shiny weld deposits resists sliding wear.
Applications: Cane knives, dozer end bits, dozer blades, grinding mill diaphragms, rubber
mixing blades, end discs of banbury rotors, dredger cutters, dredger pump casing, impellers,
augers, screws, conveyers, paddles and wear pads.
Procedure: Gouge out/grind worn and fatigued metal. Use electrode on AC/DC+. Hold short
arc and deposit stringer beads. Use back-step staggered welding sequence. Chip slag
between passes.
Technical Data : ABRALOY 300
Size (mm) : 3.15 4.00 5.00
Welding Current (Amps) : 80-120 120-160 150-200
Hardness : RC 57-60
Coating Colour : Light Grey
Tip Colour : Sky blue
2. M/s Valency Compound, Brand: CRCN-60
Description: HIGH CHROMIUM IRON ALLOY FOR RESISTING MULTIPLE WEAR OF ABRASION,
FRICTION AND OXIDATION
Application: Augur screws, guide, wear pads, conveyors, sugar mill fibrizer, hammers.
Typical properties: Hardness - RC 57-60
Size & Current: Size (mm) 3.15 4.0 5.0
Amps 80- 125 120- 160 150- 200
3. M/s ESAB India, Brand: COBALARK MX
44
Preformed stabilised carbides for high temperature complex wear

Cobalarc-the future of hardfacing. This range of tubular electrodes gives a host of
advantages over conventional coated electrodes in respect of hardfacing applications owing
to its unique features.
• The prime weapons that provide the hardness in hardfacing deposits are the metallic
and non metallic carbides. In coated electrodes, the carbides are formed at the time

of welding. Carbides, preformed, cannot be used in these electrodes because the
high hardness renders them dif cult to produce. But, Cobalarc electrodes have the
advantage that the preformed carbides are put inside a hollow mild steel tube.
• In hardfacing controlling the heat input is important because greater dilution will
lower the hardness of the deposit. In this respect, Cobalarc gives a major headway
because only a thin walled tube has to be melted instead of a solid wire. So the heat
requirement will be considerably less and automatically the heat input will really be
low.
• The low heat input also reduces the heat-affected zone in the base metal.
• Cobalarc provides economy as the total loss involves only .butt end loss and very
negligible slag loss. Moreover, the butt end does not contain any carbide
inside - it is only the hollow tube that is lost, so the actual loss is even lower.
• The slag formation is very small in Cobalarc. So the welder can apply the next run
without wasting any time for deslagging. This gives an immense advantage of speed
and productivity. So in 1 hour of arcing, Cobalarc gives 2-2.5 times the weight of
deposit than coated hardfacing electrodes.
• A near absence of slag does not mean that Cobalarc deposits are exposed to the
atmosphere for oxidation. The outer coating contains ingredients that burn in the
welding arc and generate copious amount of fumes, which provides the shielding to
the weld pool.
• This outer coating has one more function. Since it contains non-hygroscopic
stabilizers the mild steel tube is free from rusting giving these electrodes an
indefinite shelf life. The rigid tube also protects the preformed carbides from
degeneration over time.
Cobalarc MX is the ultimate in welding technology. It has autogenous fume shielding over
preformed carbides in a tubular form, which gives the user genuine low heat input and in
nite shelf life by dint of its nonhygroscopic coating. In this case, preformed carbides in the
tube route have been adopted to derive supersaturated composite alloy with high volume
fraction of extreme abrasion resistant alloys along with complex stabilized carbides. While
the electrode is best to solve critical wear problems at high temperature, it also performs
better than chromecarbide electrodes even at room temperature. The deposit is absolutely
unparalleled in its resistance to  ne particle abrasion. Oxidation and corrosion resistance
upto 1200°C.
Alloy Base: Fe, C, Cr, Mo, Nb, V, W, Ti
Special Features: Exceptional resistance to severe  ne and coarse particle abrasion at
ambient to temperatures around 800°C. Low spatter level. Unmatched deposition rates -
high integrity deposits. Compared to solid cored electrodes, the current requirement is low
so the dilution by parent metal is contained to a minimum. Non-hygroscopic coating needs
no storage precaution in nite shelf life.
Applications:
45
Exhaust fans handling high temperature  ue gases with ash, catalyst particles, ash ploughs,
conveyer screws, sinter plant components, copper ladles and other nonferrous industry
applications, zinc industry blast furnace bells, Paulworth chutes, etc.
Properties:
Hardness : 66-70 HRC
Current Range : (AC 70, DC±)

(mm) (mm) (Amp)
5.0 400 90-120
6.3 450 120-140
8.0 450 130-170
4. M/s EWAC Alloys Ltd, Brand: CHROMOCARB N6006
Unique Chromium-Carbide Bearing Electrode with Superior Abrasion and Impact
Properties
For use on most carbon, low-alloy and manganese steels
Resistant to coarse particle abrasion with moderate impact
Provides dense, smooth, easy to clean deposits
Description: ChromCarb N6006 is an electrode for the overlay and protection of carbon,
alloy and manganese steels. A high chromium carbide content makes it especially favorable
against coarse particle abrasion, moderate gouging impact and mild corrosion in any
number of service conditions.
• Muller tires • Anvils • Dredger parts • Bucket arms • Pug mill paddles
Technical Data: Typical Hardness: 57-60 HRC (as deposited)
Typical Carbide Hardness: 1200 (Cr7 C3 )
VPN Current & Polarity: DCEP (+) or AC
Availability and Recommended Amperages:
Dia. 1/8“ (3.2mm) 5/32“ (4.0mm) 3/16“ (4.8mm)
Amp. 90-130 120-160 150-210
Welding Parameters: Preparation: Clean weld area of scale and/or oxide. A nominal preheat
of 150°F is advised if part is below 40ºF or over 1” thick. For higher carbon steels higher
preheats will be needed. Check the Reference Section for information regarding specifi c
preheating levels for specifi c steel grades.
Note: Do not preheat Hadfi eld manganese steel castings above 400°F as this will cause
time-temperature embrittlement.
Technique: For base metals with high hardenability a buffer layer is highly recommended
prior to application of ChromCarb N6006. For Manganese steels, use EutecTrode 40; for air-
hardenable steels, use EutecTrode 680 and for cast irons, Xuper 2233N. Only one pass of
ChromCarb N6006 should be used on cast irons. Maintain a medium arc and incline the
electrode at a 45° angle in the direction of travel. Excessive weaving (more than 2 times the
electrode diameter) is not advised as wide beads can cause excessive base metal
overheating and degrade the weld deposit wear properties. Back whip craters to reduce
crater-cracking tendencies. Allow parts to slow cool in still air. High carbon steels and air
hardenable steels should be covered with a heat-retardant blanket.
46
CATEGORY: HARDFACING WIRES
(1) For Protective Hard Facing Subject To Extreme Abrasion with Mild Impact
SPECIAL WELDING WIRE UCS: 72203004200053

SAP DESCRIPTION: SPL WIRE HDFCG MT NM TY-1 DIA 2.4MM
WIRE, FLUX CORED MATERIAL: HARD FACING ALLOY, CATEGORY: MEDIUM"
"TEMPERATURE, PROTECTIVE HARD FACING LAYER, NON MACHINABLE TYPE"
DIAMETER: 2.4MM
HARDFACING WIRES FOR HIGH ABRASION & MILD IMPACT

PREFERRED MAKES:
1. M/s EWAC Alloys Ltd, Brand: OA-4630
2. M/s Ador Fontech, Brand: O-7062

Proprietary alloy steel formulation in a tough matrix excellent for fine particle abrasion
or erosion under moderate impact conditions. Ideal application Mixer blades,
Humidifier paddles, ID fans, Drag chains etc.
Hardness: 62-67 HRC

HIGH TEMPERATURE EROSION / ABRASION
Hardness : 52-56 Rc
Severe abrasion up to 450°C
(2) For High Hardness, Wear Resistant, Moderate Impact Subject To Extreme Abrasion
SPECIAL WELDING WIRES UCS: 72201009501301
SAP DESCRIPTION: SPL WIRE HD FCG HT NM TY-2 DIA 2.4MM
SPL WIRE HD FCG HT NM TY-2 DIA 2.4MM, "WIRE,FLUX CORE,DIA:2.4MM, MATERIAL:
HARD FACING ALLOY STEEL CATEGORY": HIGH TEMPERATURE, NON MACHINABLE
ALLOY, STRONG AGAINST MINERAL WEAR
PREFERRED MAKES:
2. M/s Diffusion Engineers, Brand: CORODUR 65-Z
Welding Process: FCAW Current Condition: DC (+)
47
CATEGORY: HARDFACING WIRES
Complex carbide wire suitable for high abrasive conditions at elevated temperatures.
Applications:
• Sinter star breaker
• BLT chute liners
• Throat armour plates
HARDFACING WIRES FOR HIGH ABRASION & HIGH TEMPERATURE

Major Alloying Elements: Cr, Mn, Cb, Mo, V, W
All Weld Metal Mechanical Properties: Hardness: 60-63 Rc
Packing Data:
Size ø (mm): 2.4 2.8
Weight of spool (kg): 12.5 12.5
2. M/s Diffusion Engineers, Brand: CORODUR 65-Z
Characteristics: CORDIFF 65 Z is highly alloyed C-Cr-Mo-Nb-W-V tubular wire gives weld

deposit of extremely hard carbides. It is used for hardfacing and the weld metal has
excellent abrasion resistance at high temperature. Weld deposit performs extremely well
against strong mineral wear. The weld deposit retains its wear resistance up to 6500C.Best
results are achieved by welding in two layers.
Applications: Blast – furnace bells, fire grates, crusher, sinter wheel breakers, smelter
loading chutes, etc.
Standard: DIN 8555 - MF- 10- 65 - GZ
Major Alloying element: C Si Mn Cr Mo Nb V W
Hardness: 63 - 65 HRC
Welding Parameters: Current: DC+

DIA. (mm) VOLTAGE AMPS
1.6 22 – 25 170 – 230
2.0 24 – 27 220 – 260
2.4 25 – 29 260 – 330
2.8 27 – 30 300 - 360
Standard Packing: Spool = 15 kgs (± 1kg) Spool = 25 kgs (± 1kg) Drum = 200 - 250kgs
48
For Protective Hard Facing Subject To Extreme Abrasion with Mild Impact
SPECIAL WELDING UCS: 72203003400003
SAP DESCRIPTION: ELEC, TY-1, HD FCG, DIA-5.0MM, SPL MT M/C
TYPE: TYPE-1, MATERIAL: HARD FACING ALLOY STEEL, DIAMETER: 5.0MM
LENGTH: 450MM, APPLICATION: MEDIUM TEMP MACHINABLE, CATEGORY: FOR 1000
T SHEAR BLADES, MACHINABLE WITH TUNGSTEN CARBIDE TOOLS
WORK HARDENING ELECTRODES FOR HIGH ABRASION & IMPACT

PREFERRED MAKES:
1. M/s Valency Compounds, Brand: BELTEX-550
2. M/s ESAB India, Brand: DUROBELL
3. M/s Indian Steel and Wire Products Ltd., Brand: Spark Bell-550
1. M/s Valency Compounds, Brand: BELTEX-550

Description: Molybdenum-Nickel Alloy deposit retaining very high strength and
hardness upto 570oc. weld metal is crack free and work hardenable.
Application: Seat area of Blast Furnace Bells, Tong Pins, Furnace Rolls, Hot shear Blades,
Knives, Valve seats, Rolling Mill Rolls etc.
Typical Properties: Hardness: 51-57 RC, At 500o C : 47 RC)
Size (mm) 3.15 4.00 5.00
Amps 85- 120 110- 175 155- 220
2. M/s ESAB India, Brand: DUROBELL

Blast furnace bell and BLT chute reclamation
Durobell is a hardfacing electrode depositing a molybdenum-nickel enriched alloy steel that
provides excellent resistance to both impact and abrasion. The weld deposit exhibits
secondary hardening at high temperature that leads to retention of hardness at 500°C-
550°C. The alloy is amenable to heavy build-up and the deposit is crack-free. The weld bead
is machinable with tungsten carbide tools.
Alloy Base: Fe, C, Ni, Mo
Special Features:
• Machinability with abrasion resistance.
• Smooth arc with low spatter.
• Excellent weld bead appearance.
Applications:
Repair and reclamation of seat area of blast furnace bells & hoppers, BLT chutes, tong-pins,
hot shears, furnace rollers, knives, valve seats, idler rollers of hot strip mills etc.
Properties: Hardness :
As deposited: 53-55 HRC
At 500°C: 46-50 HRC
Current range: (AC 70, DC±)
49

(mm) (mm) (Amp)
3.15 450 90-120
4.00 450 115-175
5.00 450 160-225
WORK HARDENING ELECTRODES FOR HIGH ABRASION & IMPACT

3. M/s Indian Steel and Wire Products Ltd., Brand: Spark Bell-550
Air-Hardening machinable weld deposit for resistance against abrasive wear with
moderate impact at elevated temperature
Characteristic: Spark Bell 550 is a heavy coated hard-facing electrode which offers a high
resistance to severe abrasion and impact at an elevated temperature. The weld deposit
retains its hardness up to 49 Rc. The electrode deposits contain Nickel & Molybdenum rich
weld metals.
Special Features: Spark Bell is ideally suited for repairing of Blast Furnce Bell and similar
parts.
Applications:
• Blast Furnace Bells and Hoppers
• Foundry parts
• Tong Pins, Cutting Knives, Valve Seats & Rolling Mill guides
• Hot Shears, Crusher Jaws
• In Steel Plants for equipment used at elevated temperatures
•
Hardness:
• 500 Hv (49 Rc) at 400oC
• 475 Hv (47 Rc) at 450oC
• 460 Hv (46 Rc) at 500oC
• 415 Hv (42 Rc) at 560oC
Current range: (AC 70, DC±)

(mm) (mm) (Amp)
3.15 450 90-120
4.00 450 115-175
5.00 450 160-225
50
SPECIAL ELECTRODE UCS: 72203003400039

SAP DESCRIPTION: ELEC, TY-4,HD FCG,DIA 4.0MM,SPL LT NM
TYPE: TYPE-4, MATERIAL: HARD FACING ALLOY, DIAMETER: 4.0MM, LENGTH: 350MM
APPLICATION: LOW TEMPERATURE NON MACHINABLE
CATEGORY: LOW TEMPERATURE HARD FACING ALLOY WITH HIGH RESISTANCE TO
ABRASION WITH IMPACT
HARDFACING ELECTRODES FOR HIGH ABRASION WITH IMPACT

For Protective Coating against Abrasion & Erosion of Carbon & Austenitic Steels
PREFERRED MAKES:
2. M/s EWAC Alloys Ltd, Brand: XHD-6710

Electrode for excellent abrasion resistance
Application:
• Dredging Buckets
• Refractory Press Screws
• Cement Press Screws
• Conveyor Screws
Hardness: 60-65 RC

Very high abrasion resistant alloy with extra high deposition rates
Typical Applications: Reclaimer bucket, stacker bucket, dragline buckets, lips, tooth points,
cutting edges, scraper blades, crushing hammers, conveyor chains, mixer blades, sludge
pumps etc.
• High resistance to wear from combined abrasion, pressure and moderate impact.
• Easy handling, rapid deposition rate, very thin slag.
• Thick single pass deposits with extra high yield.
Recommendation: A unique electrode for anti-wear coatings on carbon steels and
austenitic manganese steels. The weld deposits have very high content of hard constituents
making extremely resistant to intense abrasion under pressure combined with moderate
impact.
Procedure: Remove all damaged and fatigued metal. Maintain medium arc length and
electrode vertical, deposit stringer or 1½ X weave patterns, back fill craters. Single pass
overlay is normally recommended. If more build up is required, use cushion layer of
XHD 646 for steel, EutecTrod 400 for 14%manganese steels and Xuper 2240 for cast iron.
Use hard silicon carbide wheels for grinding.
Size Amp-1 Amp-2
3.15 150 – 170 100 – 120
4.00 210 – 250 160 - 200
5.00 250 – 280 190 - 200
Hardness: 62 - 68 HRc (2 layer)
51
SPECIAL ELECTRODE UCS: 72203003400040
HARDFACING ELECTRODES FOR ABRASION RESISTANCE AT HIGH TEMPERATURE

SAP DESCRIPTION: ELEC, TY-2, HD FC
G WH, DIA 4.0MM, HT NMSPL
APPLICATION: HIGH TEMPERATURE NON MACHINABLE, CATEGORY: HIGH
TEMPERATURE HARD FACING ALLOY WITH ABRASION RESISTANCE AT ELEVATED
TEMPERATURES
For Protective Coating against Abrasion & Erosion at elevated temperature for Carbon
& Austenitic Manganese Steels
PREFERRED MAKES:
Kiln Inlet Tongue Plate

Weld metal with outstanding abrasive wear resistance even at elevated temperature
Typical Applications: Sinter star crusher, grate bars, clinker conveyor chains, coke pusher
shoes, augers, billet conveyor guides, hot slag conveyor, blast furnace hoppers, pug mill
knives.
• Excellent resistance to abrasive wear at elevated temperature.
• Easy handling with high deposition rate.
• Thick single pass deposits with extra high yield.
• Very thin slag.
Recommendation:
An advance electrode for overlaying of carbon steel and austenitic manganese steels for
applications subjected to abrasion & erosion at elevated temperature. The deposit consists
of high percentage of special constituents which retain abrasion 0 resistance up to 650 C.
52
Procedure:
Remove all damaged & fatigued weld metal and clean weld area. Maintain short to medium

arc length, deposit stringer or 1½ X weave patterns. Back whip crater. For high carbon
steels, 0 preheat up to 250 C. Use XHD 646 as a cushion alloy if more build up is required.
For austenitic manganese steel do not allow temperature of 0 parts to rise more than 150 C
& use EutecTrode 6450 as a cushion layer. Slow cool after welding.
Size Amp-1 Amp-2
3.15 150 – 170 120 - 140
4.00 200 – 220 140 - 160
5.00 230 – 250 160 - 180
Hardness: 62 - 68 HRc (2 layer)
Alloy Basis; Cr, Nb, V
Properties: The weld deposit consists of a high percentage of special alloying elements
which retain abrasion-resistance up to 630ºC.Soft, stable, easily controllable arc and thick
weld deposits, negligible slag.
Technical Data: Hardness 62-66 HRC at ambient temp, 40 HRC at 630ºC
Metal recovery 230%
Typical Applications: Sinter-handling equipment, blast-furnace bells and hoppers, clinker-

conveyor chains, cokepusher shoes, excavator buckets, gyratory crusher mantles, etc.
Procedure: Clean the affected area with wire brush. Deposit LH 7450 holding short/medium
arc. Do not deposit more than 2 layers.

Current (amps) 110-130 130-150 160-210
53

SAP Description: ELEC, TY-1, HD FCG ,DIA 6.0MM,HT NMSPL
APPLICATION: HIGH TEMPERATURE NON MACHINABLE
For Protective Coating against Abrasion & Erosion of Carbon & Austenitic Steels
PREFERRED MAKES:
1. M/s Diffusion Engineers, Brand: VIDALOY-23
2. M/s Stanvac Chemicals, Brand: FERROGOLD-611T
1. M/s Diffusion Engineers, Brand: VIDALOY-23

The Vidaloy tubular electrode is a proven concept for a successful hard facing and it is the
most techno economical product compared to any other series of product.Vidaloy23, the
product mentioned is a tubular electrode that consists of hard austenitic matrix with
Carbide of Chromium, Niobium, Molybdenum, Tungsten and Vanadium. This is designed for
resistance to severe and corrosion at both ambient and elevated temperature upto 800 C.
Vidaloy 23 is being successfully used on applications like other forms, Sinter Breakers, Blast
Furnace Bells and Hoppers.
Hardness: RC 62-64 Matrix.
Carbides: In excess of 2000 Vickers
Chemical analysis: All weld metal composition
Carbon : 5.0% Chromium: 22.0% Columbium: 6.0%
Molybdenum: 6.0% Tungsten: 2.0% Vanadium: 1.0%
Vidaloy23 like any other tubular electrodes has got number of additional features over hard
facing electrodes and few of which are given below.
Economical: Vidaloy is designed to give the lowest cost per tones when related metal wear.
Energy Cost: Vidaloy electrodes require lower amperages- less base metal dilution- less heat
input- lower power cost.
For 6.00 mm diameter only 80 to 125 amperage is required For 8.00 mm diameter 130 to
200 amperage is applicable.
Metal Yield: Very little slag is formed giving deposition efficiency of upto 90%.10 kg.
Electrode gives upto 9 kg of weld.
Alloy Yield: Tubular electrodes are filled with highest percentage of carbide forming alloys;
best possible wear resistance is obtained.
Skill: Vidaloy electrodes are easy to use, requiring no special storage required the flux
coating is good for years even in damp conditions.
BASE METALS : Vidaloy tubular electrodes can be applied to cast iron, manganese steel and
mild steel without preheat, carbon & alloy steels may need preheat upto 500 degree C.
Out of Position: The 6 mm electrode is designed for all positional welding.
Yield and Recovery rates: practical trials have proved that Vidaloy tubular electrodes offer
twice the value for money of conventional extruded rods and the following comparison
prove the reason why Vidaloy electrodes have better for money.
Conventional VidaloyExtruded tubularElectrodes Electrodes
Total weight of electrode inc. stub end 160 g 120 g
Weight of solid core 50 g --
54
Weight of powder/filler 100 g 70 g

Weight of tube 40 g
Weight of deposit after welding 75 g 100 g
Efficiency/ yield 75 100
----- = 46.8% ----- = 83.3%
160 120
Efficiency/yield = Weight of hard facing deposited expressed as a % of the weight
of electrodes used.
Weight of hard facing deposited × 100
= ------------------------------------------------
Weight of electrodes purchased.
Considering all the above facts it is needless to say that Vidaloy tubular electrodes are the
latest variety of hard facing alloy in terms of price and performance.
For your information the product Vidaloy23 (of 6 mm size) is already been supplied to Bhilai
Steel Plant-Single roll Sinter crusher job Superconditioning by this electrode since last 8-10
years and for TISCO Burden area hardfacing doing with same electrode since last 7-8 years
which has worked successfully.
2. M/s Stanvac Chemicals, Brand: FERROGOLD-611T

Features:
• The tubular construction of the Ferrogold electrodes permits extremely high alloy
concentrations & ensures alloy enriched deposit at all times.
Tubular Alloy Cored Electrodes: Ferrogold antiwear electrodes are available in
tubular form, 6, 8 and 12 mm diameters. Both 8 and 12 mm have swagged 6 mm
aluminium stub attached to the gripping end of the electrode. This enables all
Ferrogold antiwear electrodes to be used with any type of electrode holder.
Although the 12 mm diameter may seem a rather large diameter electrode,
particularly if compared to solid core manual hard facing electrodes, it is worth
noting that the Ferrogold tubular electrodes require less than half the amperage to
that of a similar sized solid core product.
• Flux Coating: The special flux coating makes the Ferrogold range extremely versatile.
The 12 mm diameter may be applied with the amperages as low as 195 amps and for
rapid deposition as high as 440 amps.
• Weld Bead Widths: The same 12 mm electrode can be deposited on plate edges in
narrow 5 mm beads without the edge burning and gives very low dilution of the
substrate. Alternatively the 12 mm diameter electrode can be used for wide smooth
deposits 50 to 75 mm wide by weaving a similar width to that required.
• Metal Recovery: The metal recovery from the Ferrogold hard facing electrodes is
extremely high and with the 12mm diameter there are only four stub discards for
each kg of electrodes.
• Multilayers: When multi layers are required no chipping of slag covering is needed,
as little or no residual slag occurs. The metal recovery from the Ferrogold hard facing
electrodes is extremely high and with the 12 mm diameter there are only four stub
discards for each kg of electrodes.
• Easy to Apply & Re-Strike: Ferrogold hard facing electrodes are the easiest of hard
facing electrodes to apply as no special skills are required to obtain first class results.
55
• Arc Length: Arc length is not crucial. Longer arc length, say 10 to 12mm, gives a soft
spray type metal transfer with a smooth finish.

• Heterogeneous Deposits: Deposits are mostly heterogeneous; that is carbide
particles in a tough, less hard matrix. This deposit combination gives alloys with the
dual value of high abrasion resistance as well as a good impact resistance.
• AC or DC: These electrodes may be applied with either AC or DC current. A full range
of grades from Manganese Build-up types to Tungsten Carbide grades is available.
• ANTIWEAR HARDFACING TUBULARS
Electrode Selection: A study of a part to be treated and the form of wear generation is
important in making the correct electrode grade and size selection. On large parts the
larger diameter electrodes should be used for greater deposit control at faster rates and
lower labour costs. The 6 mm diameter may also seem large when compared to smaller
solid core electrodes, however, when it is realised these Ferrogold hard facing
electrodes may be deposited at as low as 70 amps and easily used for overhead and
vertical deposits (a rare feature for iron based electrodes) a clearer understanding of the
unique characteristic of the Ferrogold hard facing range is more easily appreciated.
High Quality: The high quality of the Ferrogold electrodes ensures the best results at all
times;they are internationally regarded as equal to the best available anywhere.
Moisture Resistant Flux Coating: Incidentally the Ferrogold flux coating is totally
moisture resistant. The flux coating has an infinite storage life. There is absolutely no
moisture pick-up which is a problem with so many other manual electrodes.
When compared to similar grades of small diameter alloy cored wires the Ferrogold
electrodes due to lower dilution rates and extremely high alloy concentrations often give a
service life improvement in excess of 300%. Comparative testing shows a swing back from
smaller diameter wire to the Ferrogold antiwear electrodes. Big savings in labour and
production result.
Ferrogold(T)- Complex Carb 611T: Complex Carbide Electrode- Iron Base

• Identification White End Tip
• Composition - carbon, chromium, niobium, molybdenum, vanadium, tungsten
• Deposits are heat resisting to 850 -900 C Applications include steelworks spike
crusher rolls, grizzly bars, blast furnace bell chutes and other parts submect to high
temperatures and high abrasion
• AC or DC current Hardness 60-68Rc. Relief checks are normal
• 6mm suitable for vertical and overhead deposition
• Amerage 6mm 80-130 8mm 120-180 12mm 190-400
• Impact resistance is only moderate
56

SAP DESCRIPTION: ELEC, TY-1, HD FCG WH,DIA 4.0MM,SPL
WELDING ELECTRODE TYPE: TYPE-1, MATERIAL: ALLOY STEEL (SS) WORK
HARDENING, DIAMETER: 4.0MM, APPLICATION: SPECIAL, CATEGORY: WORK
HARDENING TYPE FOR JOINING MANGANESE STEEL, RESISTANCE TO HEAT AND
CORRSION, CUSHION MATERIAL AND HIGH STRENGH JOINTS
PREFERRED MAKES:
WORKHARDENING ELECTRODES FOR MANGENESE STEEL

1. M/s Diffusion Engineers, Brand: DIFFUSALOY-618
2. M/s Ador Fontech, Brand: ZIP ARC SS-12-E
1. M/s Diffusion Engineers, Brand: DIFFUSALOY-618

Characteristics: A newly highly alloyed austenitic lo temp electrode for joining and
overlaying manganese steel and other steels. Alloy exhibit exceptional all positional weld
ability and easy slag detachability. Weld deposits have excellent resistant to heat and mild
corrosion. Alloy exhibits exceptional all positional weldability, easy slag detachability & very
high crack resistivity.
Applications: An ideal alloy specially for the positional joining & repair of manganese steel
parts such as shovel, excavator and dragline, track pads, mantle. Can be used for joining all
manganese steels (including 14% Hadfield steel) to themselves and to other steels. Alloy has
excellent heat resistance upto 900 deg C & resistance to corrosion caused by atmosphere,
seawater & weak acids.
Procedure: Gouge / grind out cracks, damaged or fatigued metals. Use skip & staggered
welding sequence. On manganese steel, do not allow base metal temperature to go beyond
250 deg C .
TECHNICAL DATA : DIFFUSALOY 618
Size (mm) : 3.15 4.00 5.00
Welding Current (Amps) : 60 – 100 100 – 160 140 - 190
Hardness (as deposited) : 90 – 100 RB
(work hardened) : 32 RC
Tensile strength : 65 Kgf/mm2
Elongation (L=5d) : 30 - 40%
Coating Colour : White
Tip Colour : Deep Green
2. M/s Ador Fontech, Brand: ZIP ARC SS-12-E

The ZIPARC range of maintenance and surfacing alloys have been specially formulated as
solutions to wear and industrial maintenance problems. Apart from saving downtime, the
need for carrying an inventory of expensive spare parts is minimised. These products are
also extensively used to extend the life of critical components SS 12 E. An economical
electrode for austenitic manganese steels.
57
WORKHARDENING ELECTRODES FOR MANGENESE STEEL

Crane Wheel Welding
A high alloy electrode for wear protective coating & high strength joining
For joining: Under carriage parts,sprockets, ripper shanks.
For Build-up: Gear teeth, impactors, sprockets, trencher teeth, bucket teeth, hammers,
augers, under carriage components, scrapper blades, crusher jaws.
• Excellent resistance to impact and scoring.
• Rapid hardening property.
• Excellent operating characteristics with fast deposition rate.
• Excellent crack resistance.
Recommendation: A high alloyed electrode for similar & dissimilar joining, clading
applications subjected to compressive service. Outstanding weldability with extra high
deposition rate. Weld metal is completely machinable with tungsten carbide tools.
Procedure: Clean weld area. Deposit stringer beads or use 2X weave pattern. Back whip to
fill up craters and remove slag between passes. Peen deposits where maximum crack
resistivity is required. Cool naturally. On 14% Mn steel, use skip welding or back step
technique 0 to prevent heating above 150 C.
Size Amp-1 Amp-2
2.50 100 – 140 75 - 100
3.15 140 – 170 90 - 130
4.00 180 – 250 120 - 160
5.00 210 – 260 160 - 190
Hardness: As deposited 80-90 HRb, Work hardened 28-32 HRc
58
CATEGORY: CUTTING ELECTRODES

SAP DESCRIPTION: ELEC, TY-1,DIA 4.0MM,SPL CUT ROD
TYPE: TYPE-1, DIAMETER: 4.0MM, LENGTH: 350MM
APPLICATION: CUT ROD F/CUTTING METAL, CAN NOT BE GASCUT
PREFERRED MAKES:
1. M/s Electrarc India, Brand: REX SUPREME
2. M/s Weld Craft, Brand: KOLD CUT
3. M/s D&H Secheron, Brand: LOTHERME -801
4. M/s EWAC Alloys Ltd, Brand: CUT ROD
CUT ROD FOR FERROUS & NON FERROUS MATERIAL

1. KOLD CUT of M/s Weld Craft

KOLDCUT is an all position excellent cutting and piercing electrode. It works at high
amperage without overheating of electrode. lt is suitable for cutting and piercing of
both ferrous & nonferrous metals.
Outstanding features:
Versatile cutting electrode, cuts through any metal.
Exothermic coating concentrates arc at the desired area.
Does not get overheated at high amperage
Produces negligible slag
Procedure : Use KOLDCUT with straight polarity. When arc is struck, push and pull (Sawing
action) Holding the electrode at 450 angle to cut. For piercing holes, push the arc vertically
in and out until the metal is pierced. Use DC polarity for best results.
Operating data:
Size (dia. X length)mm : 3.15x350 4.00x350 5.00x350
Current {ac/dc(+)} amps : 150-180 220-280 280-350
2. M/s D&H Secheron, Brand: LOTHERME -801
For cutting and piercing all ferrous and non-ferrous metals and alloys without the need for
any auxiliary equipment.
Characteristics: LoTherme-801 is designed to produce fairly smooth cuts and pierce metals
in all positions. The special coating withstands high current without overheating. A forceful
arc renders it possible to cut all metals and alloys without the necessity of supplementary
gas, compressed air or oxygen or special torches.
Applications: LoTherme-801 is meant for cutting and piercing carbon steels, low alloy steels,
stainless steels, cast irons, nickel and nickel alloys, copper, brass, bronze, aluminium and
other metals and alloys. Although the cut will not be as smooth as that produced by gas
cutting of carbon steel, the application of LoTherme-801 extends to various ferrous and
non-ferrous metals which cannot be cut by conventional gas cutting process. The electrode
is also suitable for cutting and piercing out of position jobs, rivets, risers, etc., where gas
cutting is not convenient.
Welding Technique: Mark the area to be cut or pierced with chalk. Hold the electrode at an
angle of 45° to the job and use a sawing motion to cut. Manoeuvre LoTherme-801
59
CATEGORY: CUTTING ELECTRODES
continuously in sawing motion, pressing it against the surface of the metal. The high arc-
force produced by the electrode and the manual pressure ensures and rapid cutting. For
piercing, position the electrode perpendicular to the part. Strike the arc and apply push in
and pull out motion till the part is pierced.
Current Conditions: AC/DC (-)
Size (mm) 5x350 4x350 3.15x350 2.5x350
Current Range (Amps) 280-320 200-240 150-180 120-150
3. M/s EWAC Alloys Ltd, Brand: CUT ROD
CUT ROD FOR FERROUS & NON FERROUS MATERIAL

Special electrode for all position cutting and piercing of all metals
Typical Applications: Piercing, cutting stainless and cast iron, cleaning castings, removing
flash and risers.
Outstanding Features: • Versatile, cuts through any metal
• Exothermic coating with concentrate arc.
Recommendation: For highest speed, all position cutting and piercing of all metals using
standard electric arc equipment. Also for chamfering, gouging, cleaning out defects, burning
rivets, beveling metal prior to welding. Ideal for cutting and piercing mild carbon steel,
stainless steels, cast iron, malleable iron, nickel and nickel alloys, aluminium, copper,
bronze. No special skill, supplementary equipment or oxygen tanks are required. Slow burn-
off rate leaves little residue, requiring comparably less finishing. Electrode not overheat, can
withstand high amperage.
Procedure: Marks or scribe line where cut is desired. On DC machine, use straight polarity.
No special holder or compressed air needed. When applying EWAC CutTrode electrode, use
both the arc-blow, caused by the exothermic coating, plus pressure with the hand. When
arc is struck, push and pull, holding electrode at a 45° angle and using a sawing motion to
cut. The closer the arc, the faster, cleaner, cooler the cut. For piercing holes, hold electrode
vertically, and push in and out.
Metal Thickness Sizes Amperagesetal Thickness
Upto 25mm 3.15 150-350
6.5mm to 37.5mm 4.00 165-375
12.5mm to 75mm 5.00 175-400
Special Electrode for cutting all conducting metals
Properties; Special electrode with an exothermic coating which gives a stable arc during the
cutting or piercing process. The kerfs are clean and narrow. Suitable for all positions and all
conducting metals. Produces negligible slag.
Typical Applications: Cutting and piercing of steel, cast iron, copper materials, aluminium.
Excellent for burning rivets, dismantling work at site and for cutting off unwanted metal in
foundry castings.Making holes in wear plates at site. Oxyacetylene or compressed air need
not be used.
Procedure: After striking the arc, swing the arc back and forth as in see-saw motion.
Maintain the motion and at the same time dig the arc deeper and deeper into the metal. For
piercing holes, push the arc in and out until the metal is pierced.
60
CATEGORY: CONTINOUS WIRE FOR JOINING & BUILT UP

SAP DESCRIPTION: OA-4907/ O-1050 (2.4 mm)
SPL WIRE JOIN LH MS TY-1 DIA 2.4 MM, WELDING WIRE, FLUX CORE, MATERIAL:
MILD STEEL, LOW HYDROGEN, CATEGORY: SELF SLAG PEELING TYPE, DIAMETER:
2.4 MM
PREFERRED MAKES:
WELDING WIRE FOR JOINING – OPEN ARC WELDING

Carrier Roller
Open arc self-shielded flux cored wire for joining, fillet welding and build-up applications
Typical Applications: Repairs to machine bases, housings, tanks, agricultural equipment
maintenance of heavy mining and construction equipment, fabrication of wear parts.
• Smooth operating characteristics with easily detachable slag.
• High depos i t ion rate and efficiency.
• Smooth, well-rippled weld beads require very less finishing.
Recommendation: Continuous electrode for rapid joining, fillet welding and build-up of low
carbon steels in single or multipass applications. Deposits have high strength and are crack
resistant (Not recommended for sub-zero temperature applications).
Welding Procedure: Clean weld area. Remove earlier damaged metal. On heavy sections
bevel to 90°. Preheat if required. Run stringer beads or use 2X weave bead technique.
Backwhip to fill craters. Remove slag between passes. Allow natural cooling.
Welding Parameters: Hardness: 20 - 30 HRc
Size(mm) Voltage Amerage Stick Out (mm)
1.6 26 – 29 170 – 240 25 - 35
2.4 28 – 32 200 – 300 40 - 60
2.8 28 – 32 250 – 350 45 - 60

UTS: 50-58 kgf/mm2
Properties: Good abrasion and moderate impact wear. Distribution Chutes, Troughs, Mill
side liners, Cheek Plates, crusher liners, Bucket liners, Transition chutes, cooler ducts.
61
SPECIAL WELDING WIRE UCS: 72203004200036 & 72203004200037

SAP DESCRIPTION: SPL WIRE JOIN MS MIG-T TY-1 DIA 1.2MM & 1.6MM
WIRE, TUBULAR , 1.2MM, MATERIAL : MILD STEEL WIRE FOR MIG- MAG WELDING,
CATEGORY : AWS-A-5, 20 E 71-T-1, DIAMETER : 1.2 MM
PREFERRED MAKES:
1. M/s EWAC Alloys Ltd, Brand: CPS 660
2. M/s Ador Welding , Brand: AUTOMIG FC 71-T -1
3. M/s ESAB India , Brand: O K TUBROD 15.14A
WELDING WIRE FOR JOINING – MIG/CO2 WELDING

1. M/s EWAC Alloys Ltd, Brand: CPS 660
All positions flux-cored gas shielded continuous welding wire for fabrication of low carbon
and low alloy steels. This combines the high deposition rate of flux cored wire with the high
efficiencies of solid wire. Providing an exceptionally smooth, stable arc, low spatted and
minimal slag coverage. The E71T-1 is used shipbuilding, machinery, bridges, structural
fabrions, automated or robotic welding. Suitable for mild steel or high grade high tensile
such as pressure vessels, offshore drilling platforms, pipelines, railway wogons, machinery
and automobiles etc.
Code & specification:
ASME/ SFA/ AWS A5.20, Class E71T-1C
Yield strength : 450Mpa
Tensile strength : 520Mpa
Elongation (L=4D) : 28%
Charpy V- notch Impact : 100 Joules (at-180 C)
Typical Undiluted Weld Metal Analysis:
Carban Manganese Silicon Sulphur Phosphorus
0.05 1.3 0.40 <0.02 <0.03
Suggested welding parameters (dc+):

Carbon Flat Vertical - up Overhead
Volts Amperages Volts Amperages Volts Amperages
1.2 mm 23-30 150-250 22-26 150-220 23-26 150-220
1.6 mm 25-34 180-300 21-27 180-250 22-27 150-230
Shielding Gas:
• Co2 shieding gas with a low dew point (below -400 C) at a flow rare of 20-25
liters per minute is recommended.
• Electrode wire stick out 15-20mm
62
2. M/s Ador Welding , Brand: AUTOMIG FC 71-T -1

All positions flux-cored gas shielded continuous welding wire for fabrication of low carbon
and low alloy steels. This combines the high deposition rate of flux cored wire with the high
efficiencies of solid wire. Providing an exceptionally smooth, stable arc, low spatted and
minimal slag coverage. The zuperMag E71T-1 is used shipbuilding, machinery, bridges,
structural fabrions, automated or robotic welding. Suitable for mild steel or high grade high
tensile such as pressure vessels, offshore drilling platforms, pipelines, railway wogons,
machinery and automobiles etc.
Code & specification:

ASME/ SFA/ AWS A5.20, Class E71T-1C
Yield strength : 450Mpa
Tensile strength : 520Mpa
Elongation (L=4D) : 28%
Charpy V- notch Impact : 100 Joules (at-180 C)
Typical Undiluted Weld Metal Analysis:
Carban Manganese Silicon Sulphur Phosphorus
0.05 1.3 0.40 <0.02 <0.03
Suggested welding parameters (dc+):

Carbon Flat Vertical - up Overhead
Volts Amperages Volts Amperages Volts Amperages
1.2 mm 23-30 150-250 22-26 150-220 23-26 150-220
1.6 mm 25-34 180-300 21-27 180-250 22-27 150-230
Shielding Gas:
• Co2 shieding gas with a low dew point (below -400 C) at a flow rare of 20-25 liters per
minute is recommended.
• Electrode wire stick out 15-20mm
3. M/s ESAB India , Brand: O K TUBROD 15.14A

ESAB 71T1 is an all position rutile flux cored wire designed for optimum performance with
100% CO2 shielding gas. it produces a slag with good coverage that is easily removable as
well as a weld metal that is consistently free of slag inclusions and porosity.
Classifications weld metal SFA/AWS A2.20 : E71T-1EN ISO 17632-A
: T 42 0 P C 1 H10
Approvals ABS 2Y400
BV 2Y40
63
IRS 2Y40SM
LR 2Y
Approval are based on factory location please contact ESAB for more information.
Welding Current DC+
Alloy Type C-Mn
Typical Tensile Properties

Condition Yield strength Tensile strength Elongation
C1 shielding gas
As welded 500 MPa 550 MPa 28%
Typical charpy V- Notch Properties

Condition Testing Temperature Impact value
C1 shielding gas
As welded 0 0C 95 J
As welded -20 0C 40 J
Typical Weld Metal Analysis %

C Mn Sl
0.05 1.10 0.45
Current Range
Diameter Current Voltage
1.5 mm 150-410 A 22-34
1.2 mm 140-300 A 21-32-V
64
CATEGORY: CONTINOUS WIRE FOR HARDFACING

SAP DESCRIPTION: SPL WIRE HD FCG LT M/C TY-4 DIA 2.8MM
WIRE, FLUX CORED, MATERIAL: HARD FACING ALLOY,
CATEGORY: LOW, TEMPERATURE, PROTECTIVE HAR FACING LAYER, MACHINABLE
WITH CARBIDE TOOLS, DIAMETER: 2.8MM
PREFERRED MAKES: (Proprietary)

M/s Diffusion Engineers, Brand: CORODURE 450
CORODUR 450 is a tubular wire that produces a low alloyed deposit for hard facing of
approximately 450 HB. The deposit is tough and resistant to impact loads. Deposits are
forgeable and machinable.
Crane wheels rails, guiding rolls, hydraulic cylinders
TYPICAL ALL WELD METAL ANALYSIS (%) Base =Fe
WELDING WIRE FOR HARDFACING

C Si Mn Cr Mo V
0,3 0,8 1,0 4,5 0,4 0,2
Hardness HRc 42-45

PARAMETER FORMS OF DELIVERY
Diameter Voltage Amps Unit Weight
1,2 18-24 140-220 Coil BS 300 15 kg
1,6 20-24 160-260 Coil B 450 25 kg
2,0 22-26 240-280 Drums 300 kg
2,4 24-27 280-340
2,8 25-28 320-400
G =Gas shielded, 0A= Open Arc, SA= Submerged Arc
65
CATEGORY: CONTINOUS WIRE FOR JOINING

SAP DESCRIPTION: SPL WIRE JOIN 30/10T TY-2 DIA 1.6MM
WIRE, FLUX CORE, MATERIAL: STAINLESS STEEL(30/10),TYPE:E-312
CATEGORY: CRITICAL - HIGH STRENGH AND CRACK FREE APPLICATIONS
DIAMETER: 1.6MM
PREFERRED MAKES:
1. M/s EWAC Alloys Ltd, Brand: OA 688
2. M/s Ador Fontech, Brand: O 2060
3. M/s Diffusion Engineers, Brand: CORODURE 324
1. M/s EWAC Alloys, Brand: OA 688

Characteristics: Repair & re-conditioning of Bearing housing, Gears, Jaw crusher
WELDING WIRE FOR DISSIMILAR STEEL

plates. Designed for joining MS, Low alloy, Medium alloy, SS & Dissimilar steels
Tensile Strength: 1,05,000 (PSI)
2. M/s Ador Fontech, Brand: O 2060

Characteristics: Joining and buildup of unknown steels
Tensile Strength: UTS : 68 kgf/mm2
66
CATEGORY: CONTINOUS WIRE FOR JOINING

SAP DESCRIPTION: TINWELD1 (IN 500 GMS JAR),
PREFERRED MAKES:
M/S EWAC ALLOYS, Brand: Tinweld 1 (Proprietary)
WELDING WIRE FOR DISSIMILAR STEEL

Bearing Housing
Paint-on solder paste for soldering of dissimilar metals except Al and Mg
Instruments, gauges, tinning, radiator repair, costume jewellery.
• Paint-on solder-flux paste.
• All purpose - for use on all metals except aluminium and magnesium.
• Easy to use -place and indirect heat.
Recommendation:
A newly formulated paint-on solder paste combined with flux.
Recommended for soldering dissimilar metals other than aluminium and magnesium. Ideal
for applications where preplacement of solder is required for furnace and automatic soldei
ng. Low temperature soldering alloy good fluidity and joint strength. For torch, furnace or
solder iron.
Procedure: Clean joint area. Paint the alloy on all surfaces to be joined by means of a brush
or spatula. If a wire is to be joined, it may be dipped into the paste. With a torch keep the
flame at about 50 mm from the work and constantly in motion until the clear flux flowing to
the top starts to darken. In furnace, 250° to 275°C is the best operating temperature. With
solder iron, apply directly or indirectly to the area. Allow part to cool for solidification.
Remove flux with a damp cloth or rinsing in hot water.
Bonding Temperature: 190 C
Tensile Strength: 7000 psi
67
ANNEXURE-1
SPECIFIC EFFECTS OF ALLOYING ELEMENTS IN STEEL
ALUMINIUM
• De-oxides efficiently
• Restricts grain growth (by forming dispersed oxides or nitrides)
• Alloying element in nitriding steel
CHROMIUM
• Increases resistance to corrosion and oxidation
• Increases hardenability
• Adds some strength at high temperatures
• Resists abrasion and wear (with high carbon)
MANGANESE
• Counteracts brittleness from sulphur
• Increases hardenability inexpensively
• Contributes to increased tensile strength
• Imparts work-hardening property to steel
MOLYBDENUM
• Raises grain-coarsening temperature of austenite
• Deepens hardening
• Counteracts tendency towards temper brittleness
• Raises hot and creep strength, hot hardness
• Enhances corrosion resistance in stainless steels
• Forms abrasion-resisting particles
NICKEL
• Strengthens un-quenched or annealed steels
• Toughens pearlitic-ferritic steels (especially at low temperature)
• Renders high-chromium iron alloys austenitic
• Imparts work-hardening property to steel
SILICON
• Used as general-purpose de-oxidizer
• Alloying element for electrical and magnetic steels
• Improves oxidation resistance
• Increases hardenability of steels carrying non-graphitizing elements
• Strengthens low-alloy steels
68
Annexure- II “ IS: SPECIFICATIONS”
IS SPECIFICATIONS:
1. IS:814 –
Covered electrodes for MMAW of carbon and carbon Manganese steel.
2. IS:1395 –
Low & Medium alloy steel covered electrodes for MMAW.
3. IS:8666 –
Cu & Cu alloy covered electrodes for MMAW.
4. IS:5206 –
Covered electrodes for MMAW of stainless steel & other similar alloy steel.
5. IS:5511-
Covered electrodes for MMAW of cast iron.
6. IS:7303-
Covered electrodes for surfacing of metal by MMAW.
7. IS:1278 –
Filler rod for gas welding.
8. IS:6419-
Welding rods & bare electrodes for gas shielded arc welding
69
INAUGRATION OF WELDING MANUAL BY HONOURABLE SHRI ANJANI KUMAR,
ED (WORKS)- BSP IN SEPTEMBER,2021
70
71
72

Welding Manual For SP Electrode

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1

S NO DESCRIPTION PAGE NOS

1 PREFACE- MAINTENANCE & REPAIR WELDING 6-7

2 STAINLESS STEEL ELECTRODES – INCONEL TYPE 8-12

6 HIGH TENSILE STAINLESS STEEL ELECTRODES 23-24

8 CAST IRON ELECTRODES 30-32

Failure due to poor design and excessive loads:

Q. What does the metal look like?

Q. Is the metal magnetic?

As a rule of thumb, more flare in the sparks indicates a higher carbon.

Q. Does a chisel “bite” into the base metal or bounce off?

FACTORS WHILE SELECTING ELECTRODE:

1. Identify base metals

o Base metal composition.

o The rate of deposit the weld metal.

o The type of current used.

o The experience of the welder.

o The specifications and service Condition.

(1) SPECIAL WELDING ELECRODE UCS: 72203003000001

SAP DESCRIPTION: ELEC, TY-1, INCON, DIAMETER 4.0MM, SPL JOIN

1. M/s EWAC Alloys, Product: XHD-2222

STAINLESS STEEL ELECTRODES

2. M/s Ador Fontech, Product: SPAC 0400

STAINLESS STEEL ELECTRODES

(2) SPECIAL WELDING ELECRODE UCS: 72203004000017

SAP DESCRIPTION: ELEC, TY-2, INCON, DIA 4.0MM, SPL JOIN

STAINLESS STEEL ELECTRODES

1. M/s EWAC Alloys Ltd., Brand: CPGW 034

2. M/s Ador Fontech Ltd., Brand: LH-521

Alloy Basis Ni, Cr, Mn, Fe, Nb

STAINLESS STEEL ELECTRODES

3. M/s Esab India, Brand: O.K.92.26

Size (mm) Length (mm) Current Range (Amp)

2.50 300 50-80

4. M/s D&H Secheron, Brand: Lotherme 510 N

STAINLESS STEEL ELECTRODES

(1) SPECIAL WELDING ELECRODE UCS: 72203003200009 & 72203003200010

MEDIUM CARBON STEEL ELECTRODES

MEDIUM CARBON STEEL ELECTRODES

(2) SPECIAL WELDING ELECRODE UCS: 72203003100002

1. M/s Esab India, Brand: Terroweld DBL

MEDIUM CARBON STEEL ELECTRODES

MEDIUM CARBON STEEL ELECTRODES

(1) SPECIAL WELDING ELECRODE UCS: 72203003700002, 72203003300004 &

STAINLESS STEEL ELECTRODES

1. M/s EWAC Alloys, Brand: 680 CGS

Shaft Keyway Crack

2. M/s Esab India, Brand: OK 68.82

STAINLESS STEEL ELECTRODES

3. M/s Stanvac Chemicals, Brand: FERROGOLD 303

STAINLESS STEEL ELECTRODES

Tensile strength Yield strength Elongation

Hardness: Temperature Resistance :

4. M/s Hardcarb Tech Pvt Ltd, Brand: VT 29/9

STAINLESS STEEL ELECTRODES

• For joining above materials to other dissimilar steels.

STAINLESS STEEL ELECTRODES

CATEGORY: LOW HEAT INPUT 18/8/5 ELECTRODES FOR MAINTENANCE

ARC STEEL ELECTRODES

Recommended Amperages: Size 1.6, Amperage 25 - 35Amperage

1. M/s Diffusion Engineers, Brand: DIFFUALOY-910

HIGH TENSILE STAINLESS STEEL ELECTRODES