This document summarizes guidelines for selecting welding consumables for shielded metal arc welding (SMAW) and submerged arc welding (SAW). For SMAW of carbon steels, electrodes rated E60XX to E70XX are used, while low alloy steels use E70XX to E120XX electrodes. Electrode composition should match the base metal composition. For SAW, fluxes and welding wires are selected based on factors like manganese content, diffusible hydrogen levels, and post-weld heat treatment requirements. Proper electrode/flux selection along with qualified welding procedures are necessary to achieve sound, corrosion resistant welds.
This document summarizes guidelines for selecting welding consumables for shielded metal arc welding (SMAW) and submerged arc welding (SAW). For SMAW of carbon steels, electrodes rated E60XX to E70XX are used, while low alloy steels use E70XX to E120XX electrodes. Electrode composition should match the base metal composition. For SAW, fluxes and welding wires are selected based on factors like manganese content, diffusible hydrogen levels, and post-weld heat treatment requirements. Proper electrode/flux selection along with qualified welding procedures are necessary to achieve sound, corrosion resistant welds.
This document summarizes guidelines for selecting welding consumables for shielded metal arc welding (SMAW) and submerged arc welding (SAW). For SMAW of carbon steels, electrodes rated E60XX to E70XX are used, while low alloy steels use E70XX to E120XX electrodes. Electrode composition should match the base metal composition. For SAW, fluxes and welding wires are selected based on factors like manganese content, diffusible hydrogen levels, and post-weld heat treatment requirements. Proper electrode/flux selection along with qualified welding procedures are necessary to achieve sound, corrosion resistant welds.
SELECTION OF WELDING CONSUMABLES BASIC SELECTION CRITERIA
code requirements special requirements service conditions
The welding consumables for welding of carbon , low alloy and stainless steels are selected based on guidelines provided in ASME II-C .
SMAW CONSUMABLES FOR STEELS
For Carbon steels - SFA 5.1 E60XX & E70XX For Low alloy steels- SFA 5.5 E70xx UPTO E120xx
Additional metallurgical factors: - mechanical properties at low temperature applications. - chemical composition (in most cases, matching composition with low % of C and higher % of Mn) .
SMAW CONSUMABLES FOR STEELS - Heat treatment: the components like dished end blanks, petal dished end assembly may undergo normalizing treatment due to process requirement. if matching consumable is used there may be drastic reduction in the strength values of the weld.
S. No. Consumable type Technical condition UTS (MPa) As welded SR normalized 1. E 7018 530 525 480 2. E 7018-A1 540 535 530 3. E8018 550 540 500 SMAW CONSUMABLES FOR STEELS For stainless steels- SFA 5.4 CR/NI
-composition to match base material.
-corrosion requirements: control of delta ferrite to near zero percentage gives excellent corrosion results, this in turn micro fissuring of welds. So solution lies in selecting suitable consumables having excellent crack resistance behavior and also controlled ferrite.
SMAW CONSUMABLES FOR STEELS
- Soundness and structural stability : when operating temperature is in the range of 530c - 750c carbide precipitation occurs along the grain boundaries and corrosion resistance is drastically reduced in HAZ area. This leads to a typical failure known as knife line attack .this failure can be minimized with use of extra low carbon consumable or by using stabilized grade.
WELDING CONSUMABLES FOR SAW
Fluxes (Composition) Neutral Type Active Type Alloy Fluxes Fused Bonded Agglomerated
Welding Wires For Saw Low Mn Type EL Grade EL8 Medium Mn Type EM Grade EL12 High Mn Type EH Grade EH14 Carbon Content Is Given By The Numerical Value Of The Grade
WELDING CONSUMABLES FOR SAW
FACTORS TO BE CONSIDERED (S F A 5.17 AND 5.23) F7A2-EH14 - as welded condition FS6A0-EM13K F7P6-EM12K After heat treatment F7P4-EC1 DIFFUSIBLE HYDROGEN CONTENT
SOME ASSUMPTION ON SHOP
Conclusion: - proper electrode and flux selection is a necessity for a sound weld . - But ultimately WPS and PQR plays an important role in all above . - Opinion of electrode supplier is also a good choice
Oxy-Acetylene Welding and Cutting: Electric, Forge and Thermit Welding together with related methods and materials used in metal working and the oxygen process for removal of carbon
Oxy-Acetylene Welding and Cutting
Electric, Forge and Thermit Welding together with related methods and materials used in metal working and the oxygen process for removal of carbon