WELDING CONSUMABLES

CLASSIFICATION,

STORAGE AND HANDLING

R.D.PENNATHUR
MAILAM INDIA LIMITED
 CHOICE OF WELDING CONSUMABLES

• IS MOST IMPORTANT STEP IN ACHIEVING SOUND WELDS TO

PERFORM SATISFACTORILY IN SERVICE

• SELECTION BASED ON TECHNICAL ANALYSIS IS THE BEST

METHOD

• SELECTION IS TO BE BASED ON BASE MATERIAL,WELDING

PROCESS ,SERVICE CONDITION & AVAILABILITY OF
CONSUMABLES.

• COMMONLY USED CONSUMABLES ARE ELETRODES,SOLID

WIRE,FCAW & WIRE /FLUX COMBINATION FOR SAW PROCESS
 TYPE OF WELDING CONSUMABLES

• *FLUX COVERED STICK ELECTRODES

• LIGHT COATED
• MEDIUM COATED
• HEAVY COATED
• *BARE SOLID ROD (FILLER ROD)
• *BARE SOLID WIRE (ELECTRODE / FILLER ROD)
• *FLUX CORED WIRE (ELECTRODE)
• *BARE SOLID STRIP (ELECTRODE)
• *SHILEDING GAS (IN CYLINDERS)
• *SHIELDING FLUX (GRANULAR POWDER)
 WELDING PROCESS
 GTAW

 SMAW

GMAW

FCAW

SAW
 GTAW CONSUMABLES

• Gas tungsten arc welding is most commonly used to weld stainless steel and
nonferrous materials, such as aluminum and magnesium, but it can be applied to
nearly all metals, with notable exceptions being lead and zinc.

• Its applications involving carbon steels are limited not because of process
restrictions, but because of the existence of more economical steel welding
techniques, such as gas metal arc welding and shielded metal arc welding.

• Furthermore, GTAW can be performed in a variety of other-than-flat positions,

depending on the skill of the welder and the materials being welded.

• GTAW requires in principle the filler wire of composition to be achieved

 CONSUMABLES FOR SMAW

• Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or
informally as stick welding, is a manual arc welding process that uses a consumable
electrode coated in flux to lay the weld. An electric current, in the form of either
alternating current or direct current from a welding power source is used to form an
electric arc between the electrode and the metals to be joined.

• As the weld is formed, the flux coating of the electrode disintegrates, giving off vapors that
serve as a shielding gas and providing a layer of slag, both of which protect the weld area
from atmospheric contamination.

• Because of the versatility of the process and the simplicity of its equipment and operation,
shielded metal arc welding is one of the world's most popular welding processes

• The SMAW is most versatile process as flux facilitates addition of alloying element to weld
metal & as such with same core wire many composition of weld metal can be obtained.
SCHMATIC REPRESENTATION OF SMAW
 FLUX INGRADIENTS

• FLUXING AGENTS

• SLAG FORMERS

• ARC STABILISERS

• GAS FORMERS

• SLIPPING AGENTS

• BINDING AGENTS

• DEOXIDISERS AND ALLOYING ELEMNTS

 ADVANTAGES OF FLUX COATING

• TO STRIKE AND MAINTAIN ARC

• TO PROVIDE A GAS SHEILD OVER MOLTEN WELDPOOL

• TO DEOXIDISE AND REFINE WELDMETAL

• TO ADD ALLOYING ELEMENTS IN WELDMETAL

• TO PROVIDE A SLAG BLANKET ON MOLTEN WELDPOOL

• TO INCREASE DEPOSITION EFFICIENCY

 GMAW CONSUMABLES

• Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert
gas (MIG) welding or metal active gas (MAG) welding, is a semi-automatic or
automatic arc welding process in which a continuous and consumable wire
electrode and a shielding gas are fed through a welding gun.
• A constant voltage, direct current power source is most commonly used with
GMAW.
• There are four primary methods of metal transfer in GMAW, called globular, short-
circuiting, spray, and pulsed-spray, each of which has distinct properties and
corresponding advantages and limitations.
• Originally developed for welding aluminium and other non-ferrous materials in the
1940s, GMAW was soon applied to steels because it allowed for lower welding time
as compared to other welding processes.
• The welding consumable has to have same composition as that of expected of
weld metal..Hence,the consumable availability is a major limitation to process
application. Most popular application is limited to Corbon steel & Nonferrous
material.
GAS METAL ARC WELDING
 GMAW SCHMATIC ARRANGEMENT

 
 

GMAW Circuit diagram. (1) Welding torch, (2) Workpiece, (3) Power source,
(4) Wire feed unit, (5) Electrode source, (6) Shielding gas supply
 GMAW WELD AREA

GMAW weld area. (1) Direction of travel, (2) Contact tube, (3) Electrode
(4) Shielding gas, (5) Molten weld metal, (6) Solidified weld metal, (7) Workpiece
 FCAW CONSUMABLES
• Flux-cored arc welding (FCAW) is a semi-automatic or automatic arc welding
process. FCAW requires a continuously-fed consumable tubular electrode
containing a flux and a constant electric current welding power supply.

• An externally supplied shielding gas is sometimes used, but often the flux itself is
relied upon to generate the necessary protection from the atmosphere.

• The process is widely used in production/ construction because of its high welding
speed and portability.

• FCAW was first developed in the early 1950’s as an alternative to shielded metal
arc welding (SMAW).

• The advantage of FCAW vs. SMAW is that FCAW is continuous consumable

process with high productivity.This in combination with addition of alloying elements
through flux has made it possible to manufacture various specifiction consumables
in economical quantity.
FCAW SCHMATIC REPRESENTATION
 SAW CONSUMABLES

• Submerged Arc Welding (SAW) is a common arc welding process.

• It requires a continuously fed consumable solid or tubular (flux cored) electrode.
• The molten weld and the arc zone are protected from atmospheric contamination
by being “submerged” under a blanket of granular fusible flux .
• When molten, the flux becomes conductive, and provides a current path between
the electrode and the work.
• This thick layer of flux completely covers the molten metal thus preventing spatter
and sparks as well as suppressing the intense ultraviolet radiation and fumes that
are a part of the other welding process..
• SAW is normally operated in the automatic or mechanized mode.
• Even though the flux in SAW can be used for alloying element tranfer,the process
is having limitation of positional limitation i.e most suitable for Flat/ Horizontal
position welding.
• Extensively used in industries for welding of Long/Circumferential seams of
pressure vessels.
Mechanised SAW Welding - Single Wire

                                                                                            
SAW TRAINING UNIT
Welding consumable standards

• IS (Indian)
• AWS/ASME (American)
• DIN (German)
• EN (British)
• National/International
Inspection/licenser
Specification
 CONSUMABLE SELECTION

The Welding consumables for welding of CS, LAS & SS are selected based on
guidelines provided in ASME II C. The relevant specification for the same are indicated
here below:

SFA 5.1 Carbon Steel Electrodes for Shielded Metal Arc Welding
SFA 5.4 Stainless Steel Electrodes for Shielded Metal Arc Welding
SFA 5.5 Low-Alloy Steel Electrodes for Shielded Metal Arc Welding
SFA 5.9 Bare Stainless Steel Welding Electrodes and Rods
SFA 5.17 Carbon Steel Electrodes and Fluxes for Submerged Arc Welding
SFA 5.18 Carbon Steel Electrodes and Rods for Gas Shielding Arc Welding
SFA 5.20 Carbon Steel Electrodes for Flux Cored Arc Welding
SFA 5.22 Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless
Steel Flux Cored Rods for Gas Tungsten Arc Welding
SFA 5.23 Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding
SFA 5.29 Low Alloy Electrodes for Flux Cored Arc Welding
SFA 5.01 Filler Metal Procurement Guidelines
 TESTING OF ELECTRODES

• PHYSICAL TEST

• CHEMICAL TEST

• MECHNICAL TESTS
 PHYSICAL TEST

• UNIFORMITY OF COATING
• PROPER BRUSHING OF HOLDING &
STRIKING ENDS
• CONCENTRIC COATING
• STRIKING END FREE OF FLUX & RUST
• ELECTRODES NOT DEFORMED
• NO DAMAGE TO COATING IN TRANSIT

• FOR COTINUOUS WIRE CHECK SPOOL DAMAGE

• UNIFORMITY OF WIRE-LAYER WINDING
• CAST & HELIX
 PERFORMANCE CHARACTERS

• UNIFORM COVERING
• CONCENTRICITY
• GRIP END/ARC END TRIMMING
• CUP FORMATION
• ARC INTENSITY/STABILITY
• SMOOTH ARC
• FLUIDITY/VISCOSITY
• SLAG/OXIDE INCLUSIONS
• MOISTURE ABSORPTION
• LOW SPATTER
• COVERING THICKNESS
• CRATER CRACKING
• IDENTIFICATION
• SLAG DETATCHABILITY
 FACTORS TO BE EVALUATED

• CHEMICAL COMPOSITION

• MECHANICAL PROPERTIES

• NOTCH TOUGHNESS

• ELCTRICAL CHARECTERISTICS

• TYPE OF COVERING
 OPTIONAL PARAMETERS

• NOTCH TOUGHNESS REQUIREMENTS

• MOISTURE CONTENT

• DIFFUSIBLE HYDROGEN
 SUPPLEMENTARY PARAMETERS

• HARDNESS

• CORROSION RESISTANCE

• FERRITE CONTENT

• HOT TENSILE TEST

• WEAR RESISTANCE

• HOT CRACKING TEST

SPECIFIC TESTS FOR WELDING CONSUMABLES
(CS&LAS)
CARBON STEEL CONSUMABLES

• WELDMETAL CHEMISTRY
• CVN IMPACT VALUE AT-SPECIFIED LOW TEMP.
• TENSILE/YIELD AFTER PWHT
• HARDNESS REQUIREMENT

LOW ALLOY STEEL CONSUMABLES

• WELDMETAL CHEMISTRY
• TENSILE/YIELD AFTER PWHT
• HARDNESS REQUIREMENT
• DIFFUSIBLE HYDROGEN CONTENT
• CVN IMPACT AS SPECIFIED
 SPECIFIC TESTS FOR WELDING
CONSUMABLES(SS&NF)
STAINLESS STEELCONSUMABLES

• FERRITE CONTENT
• WELDMETAL CHEMISTRY
• CORROSION RESISTANCE
• CVN IMPACT VALUE AT -196 DEG C

NON FERROUS CONSUMABLES

• WELDMETAL CHEMISTRY
• CORROSION RESISTANCE
• WELDABILITY
AWS SFA 5.1 CLASSIFICATION FOR CARBON
STEEL ELECTRODE

E X X Y Y -1* HZ R

 E DESIGNATES AN ELECTRODE
 XX TENSILE STRENGH IN KSI
 YY WELDING POSITION& TYPE OF COVERING
 1 IMPROVED TOUGHNESS
 HZ DIFFUSIBLE HYDROZEN 4/8/16
 R MOISTURE RESISTANCE

 *M MILITARY SPEC. AS AGREED TO

 MOISURE RESISTANT ELECTRODES

• THE ELECTRODES THAT CAN RESIST PICK OF MOISURE ARE CLASSIFIED WITH
SUFFIX “R”
• THE CLASSIFICATION IS BASED ON EVALUATION OF MOISURE AS RECEIVED
CONDITION & AFTER EXPOSURE TO ATMOSPHRE AT 80%RH /27 C FOR 9hrs
» MAX. MOISURE CONTENT % BY WEIGHT
DESIGNATION AS RECD. AFTER EXPOSURE
E7016R
E7016-1R
E7018R 0.30 0.40
E7018-1R
E7028-R
E7048-R
E7018-M 0.10 0.40
 AWS CLASSIFICATION FOR
CARBON STEEL ELECTRODE

E.G. E 70 1 8
E-Manual Metal Arc Welding Electrode

70- Minimum UTS of 70 Ksi(70000psi)

1- Usability of electrode in all positions

8- Basic type of covering with Iron powder

 TYPES OF COVERING

• 0-HIGH CELLULOSE SODIUM

• 1-HIGH CELLULOSE POTASSIUM
• 2-HIGH TITANIA SODIUM
• 3-HIGH TITANIA POTASSIUM
• 4-IRON POWDER,TITANIA
• 5-LOW HYDROGEN SODIUM
• 6-LOW HYDROGEN POTASSIUM
• 7-HIGH IRON OXIDE,IRON POWDER
• 8-LOW HYDROGEN POTASSIUM,
• IRON POWDER
• 9-IRON OXIDE TITANIA POTASSIUM
 RUTILE Vs BASIC
• GOOD PERFORMANCE
• OPERATES ON AC/DC
• GOOD OPERATOR APPEAL
• IMPACT AT SUBZERO LOW
• REBAKING NOT REQD
• .
• H2 LEVEL HIGH
• POSITIONAL WELDING EASY
• SATISFACTORY PERFORMANCE
• NOT WELL ON AC
• SATISFACTORY
• GOOD IMPACT PROPERTIES
• CAN NOT BE USED WITHOUT
REBAKING
• H2 CAN BE CONTROLLED
• POSSIBLE.HIGHER SKILL LEVEL
REQUIRED
 AWS SFA 5.5 2007 CLASSIFICATION FOR
ALLOY STEEL ELECTRODE

E XX XX –X* HZ R
 E DESIGNATES AN ELECTRODE
 XX TENSILE STRENGH IN KSI
 X WELDING POSITIONX
 X TYPE OF COVERING
 X CHEMICAL COMP. OF WELD METAL
 HZ DIFFUSIBLE HYDROZEN
 R MOISTURE RESISTANCE

 *M MILITARY SPEC. AS AGREED TO

 SUFFIX ALPHABETS INDICATIONS

• A C-Mo STEELS

• B Cr-Mo STEELS

• Ni Ni STEELS
•
• D Mn-Mo STEELS

• K Mn-Ni-Cr-Mo STEELS
AWS CLASSIFICATION OF LOW ALLOY STEEL
ELECTRODE

E.G. E 80 1 8 B2
• E-MANUAL METAL ARC WELDING ELECTRODE

• 80-MINIMUM UTS OF 80KSI(80000 psi)

• 1-USABILITY OF ELECTRODE IN ALL POSITIONS

• 8-BASIC TYPE OF COVERING WITH IRON POWDER

• B2-CHEMICAL COMPOSITION OF 1CHROME - 1/2 MOLY STEEL

AWS CLASSIFICATION OF LOW ALLOY STEEL
ELECTRODE

E.G. E 8016 G
• E-MANUAL METAL ARC WELDING ELECTRODE

• 80-MINIMUM UTS OF 80KSI(80000 psi)

• 1-USABILITY OF ELECTRODE IN ALL POSITIONS

• 6-BASIC TYPE OF COVERING

• G-CHEMICAL COMPOSITION -Ni,Cr &Mo

AWS CLASSIFICATION OF LOW ALLOY STEEL
ELECTRODE

E.G. E 80 1 8 D3
• E-MANUAL METAL ARC WELDING ELECTRODE

• 80-MINIMUM UTS OF 80KSI(80000 psi)

• 1-USABILITY OF ELECTRODE IN ALL POSITIONS

• 8-BASIC TYPE OF COVERING WITH IRON POWDER

• D3-CHEMICAL COMPOSITION OF ½ MOLY STEEL

AWS CLASSIFICATION OF LOW ALLOY STEEL
ELECTRODE

E.G. E 80 1 8 C2
• E-MANUAL METAL ARC WELDING ELECTRODE

• 80-MINIMUM UTS OF 80KSI(80000 psi)

• 1-USABILITY OF ELECTRODE IN ALL POSITIONS

• 8-BASIC TYPE OF COVERING WITH IRON POWDER

• C2-CHEMICAL COMPOSITION OF 2%NICKEL STEEL

 SELECTION OF CONSUMABLES FOR SS

FOR JOINING OF SIMILAR MATERIAL

 SELECTION BASED ON MATCHING OF MAJOR ALLOYNG

ELEMENTS.

 CORBON MATCHING ;L OR H TYPE

 STABILISED GRADES FOR STABILISED TYPES.

 CORROSION &CRYOGENIC APPLICATION IF SPECIFIED

TESTED CONSUMABLES FOR SPECIAL APPLICATION
 AWS SFA 5.4 2007 CLASSIFICATION FOR
STAINLESS STEEL ELECTRODE
E XXX XX X-XX

 E DESIGNATES AN ELECTRODE
 X XX ALLOY COMPOSITION
 XX ALLOY ADDITION
 X L-LOW CORBON H-HIGH CORBON
 XX 15-DCRP ( ALL POSITION )
16-AC/DCRP ( ALL POSITION )
17-AC/DCRP ( ALL POSITION )
25-DCRP(H & F)
26-AC/DCRP(H & F )
AWS CLASSIFICATION OF STAINLESS STEEL
ELECTRODE

E.G. E 316 L
• E-Manual metal arc welding electrode

• 316-Chemical composition of 17 to 20 Chrome,11 to14 Nickel,2

to 3 Moly

• L-low carbon variety

AWS CLASSIFICATION OF STAINLESS STEEL
ELECTRODE

E.G. E 309MOL-16
• E-Manual metal arc welding electrode

• 309Mo-Chemical composition of 22 to 25 Chrome,12 to14 Nickel,2 to 3

Moly

• L-low carbon variety

F
 AWS SFA 5.9 2007 CLASSIFICATION FOR
BARE STAINLESS STEEL RODS
ER XXX XX X

 ER DESIGNATES AN BARE ROD

 X XX ALLOY COMPOSITION

 XX ALLOY ADDITION

 X L-LOW CORBON H-HIGH CORBON

 AWS CLASSIFICATION OF STAINLESS
STEEL FILLER ROD

E.g. ER 308 L
• ER-ELECTRODE ROD

• 308-CHEMICAL COMPOSITION OF 19 TO22 CHROME,9

TO 11 NICKEL,0.75 MOLY

• L-LOW CARBON VARIETY

 AWS CLASSIFICATION OF STAINLESS
STEEL FILLER ROD

E.g. ER 309 L Mo
• ER-ELECTRODE ROD

• 309-CHEMICAL COMPOSITION OF 22%-25%

CHROME,12%-14% NICKEL,2%-3% MOLY

• L-LOW CARBON VARIETY

AWSSFA 5.11-2007 CLASSIFICATION
OF NON FERROUS ELECTRODE

E.G. E XXXX

• E-MANUAL METAL ARC WELDING ELECTRODE

• XXXX- ALLOY SPECIFICATION

AWSSFA 5.11-2007 CLASSIFICATION
OF NON FERROUS ELECTRODE

E.G. E Ni Cu 7

• E-MANUAL METAL ARC WELDING ELECTRODE

• NICU7-CHEMICAL COMPOSITION OF
MONEL(70%NICKEL&BALANCE COPPER)
AWSSFA 5.11-2007 CLASSIFICATION
OF NON FERROUS ELECTRODE

E.G. E Ni Cr Fe3

• E-MANUAL METAL ARC WELDING ELECTRODE

• NI Cr Fe3-CHEMICAL COMPOSITION OF
INCONEL(60%NICKEL& 13-17% Cr, BALANCE FE)
 ELECTRODES FOR CAST IRON

GENERALLY FOLLOWING TYPES ARE USED

• LOW HYDROGEN TYPE

• CAST IRON DEP.

• NICKEL BASED

• FERRO NICKEL BASED

• MONEL BASED
 CI CONSUMABLES

PROPERTY LH/CI NI DEP. FeNi DEP MONEL DEP

MACHINABILITY NO GOOD GOOD GOOD
COLOUR MATCHING NO MATCH OK NO MATCH
STRENGH GOOD LOW SATISFACTORY LOW
TOLERANCE GOOD NOT GOOD SATISFACTORY NOT GOOD
TO IMPURITY
RECOMMENDED FOR SMALL BEST FOR FOR SMALL
SUITABILITY WHERE REPAIR ALL JOBS REPAIR
MACHINING WORK REQUIRING WORK
IS NOT REQD. MACHINING
AWS SFA 5.15-2007 CLASSIFICATION OF
ELECTRODES &RODS FOR CAST IRON

E.G. E Ni - CI

• E ELECTRODE

• NI CHEMICAL COMPOSITION OF NICKEL

BASED

• CI CAST IRON
 AWS SFA 5.15-2007 CLASSIFICATION OF
ELECTRODES &RODS FOR CAST IRON

E.G. E Ni Fe - CI

• E MANUAL METAL ARC WELDING ELECTRODE

• NI Fe CHEMICAL COMPOSITION OF
FERRO NICKEL BASED

• CI CAST IRON
 AWS SFA 5.15-2007 CLASSIFICATION OF
ELECTRODES & RODS FOR CAST IRON

E.G. E Ni Fe T3- CI

• E ELECTRODE

• NI Fe CHEMICAL COMPOSITION FERRO NICKEL BASED

• T TUBULAR/FCAW

• 3 SELF SHIELDING

• CI CAST IRON
 AWS SPECIFICATION FOR
BARE RODS
• A5.7-COPPER AND ALLOYS
• A5.9-CHROMIUM AND CHROMIUM NICKEL STEELS
• A5.10-ALUMINIUM AND ALLOYS
• A5.13-SURFACING
• A5.14-NICKEL AND ALLOYS
• A5.15-CAST IRONS
• A5.16-TITANIUM AND ALLOYS
• A5.17-CARBON STEEL(SAW)
• A5.18-CARBON STEEL(GTAW)
• A5.23-LOW ALLOY STEEL(SAW)
• A5.28-LOW ALLOY STEEL(GTAW)
 CLASSIFICATION SFA 5.18 FOR
CORBON STEELBARE WIRE

ER XX S* –X Y N HZ

 ER INDICATES BARE WIRE

 XX TESILE STRENGH IN KSI
 S SOLID WIRE
 *C COMPOSITE WIRE
 X CHEMICAL COMP.(GS SINGLE)
 Y TYPE OF GAS C-CO2/M-MIXED
 N SPECIAL APPLICATION
 HZ HYDROGEN LEVEL AT 4/8/16
 AWS CLASSIFICATION OF
CARBON STEEL FILLER ROD

E.g. ER 70 S 2
• ER-Electrode Rod
• 70-minimum UTS of 70 Ksi
• S-solid Rod
• 2-minimum CVN Impact Value of 20
Ftlb at Minus 20 Deg Fahrenheit
 CLASSIFICATION FOR LAS SFA 5.28
FOR BARE WIRE GMAW

ER XX S* –X HZ

 ER INDICATES BARE WIRE

 XX TESILE STRENGH IN KSI

 S SOLID WIRE

 *C COMPOSITE WIRE

 X CHEMICAL COMP.(G FOR MULTI PASS &GS SINGLE)

 HZ HYDROGEN LEVEL AT 4/8/16

AWS Classification of Low Alloy Steel Filler
Rod

E.g. ER 90 S B3 L
• ER-ELECTRODE ROD

• 90-MINIMUM UTS OF 90KSI

• S-SOLID ROD

• B3-CHEMICAL COMPOSITION OF 2.25 CHROME-1 MOLY STEEL

• L-LOW CARBON VARIETY

AWS SFA 5.14-2007 CLASSIFICATION
OF NON FERROUS ELECTRODE

E.G. ER XXXX

• ER- ELECTRODE BARE ROD

• XXXX-ALLOY SPECIFICATION
AWS SFA 5.14-2007 CLASSIFICATION
OF NON FERROUS FILLER RODS

E.G. ER Ni Cu 7

• ER- ELECTRODE BARE ROD

• NICU7-CHEMICAL COMPOSITION OF
MONEL(70%NICKEL&BALANCE COPPER)
 AWS CLASSIFICATION OF NON FERROUS
FILLER ROD

E.g. ER NiCr - 3
• ER-Electrode Bare Rod

• NiCr-3-Chemical composition of 70%Nickel and

20%Chromium
 CARBON STEEL ELECTRODES FOR
FLUX CORED ARC WELDING
AWS A5.20-2007

E X X T – XX-JXHX
• E-ELECTRODE
• X-TENSILE IN KSI
• X-POSITION DESIGNATOR
• T-FCAW/TUBULAR
• X-USABILITY DESIGNATOR
• X-SHIELDING GAS C-CO2/M-MIXED
• J-20 ftlb AT -40 C
• X-D/Q INDICATES SPECIAL MECH.PROPERTIES
• HX-HYDROGEN DESIGNATOR
 CARBON STEEL ELECTRODES FOR
FLUX CORED ARC WELDING
AWS A5.20-2007

E71 T – 1C
• E-ELECTRODE

• 7-TENSILE IN KSI(70)

• 1-ALL POSITION

• T-FCAW/TUBULAR

• 1-USABILITY AS PER TABLE 2(MULTIPASS)

• C-SHIELDING GAS C-CO2

 CARBON STEEL ELECTRODES FOR
FLUX CORED ARC WELDING
AWS A5.20-2007
E70 T – 3C
• E-ELECTRODE

• 7-TENSILE IN KSI(70)

• 0-FLAT/HORIZONTAL POSITION

• T-FCAW/TUBULAR

• 3-USABILITY AS PER TABLE 2(SINGLE PASS)

• X-SHIELDING GAS C-CO2

 CARBON STEEL ELECTRODES FOR
FLUX CORED ARC WELDING
AWS A5.20-2007
E70 T – 8
• E-ELECTRODE

• 7-TENSILE IN KSI(70)

• 0-FLAT/HORIZONTAL POSITION

• T-FCAW/TUBULAR

• 8-USABILITY AS PER TABLE 2(MUTI PASS-SELF SHIELDING)

 LOW ALLOY STEEL ELECTRODES FOR
FLUX CORED ARC WELDING
AWS A5.29-2007

E X X TX – XX-JHX
• E-ELECTRODE
• X-TENSILE IN KSI
• X-POSITION DESIGNATOR
• T-FCAW/TUBULAR
• X-USABILITY DESIGNATOR
• X-CHEMICAL COMPOSITION
• X-SHIELDING GAS C-CO2/M-MIXED
• J-IMPROVED TOUGHNESS -27JAT 10 C
• HX-HYDROGEN DESIGNATOR
 LOW ALLOY STEEL ELECTRODES FOR
FLUX CORED ARC WELDING
AWS A5.29-2007

E 8 X T1 – Ni1C/M
• E-ELECTRODE
• 8-TENSILE IN KSI(80)
• X-POSITION DESIGNATOR
• T-FCAW/TUBULAR
• 1-RUTILE TYPE
• Ni1-CHEMICAL COMPOSITION-1%Ni
• C-CO2 SHIELDING GAS
• M-MIXED GAS
 LOW ALLOY STEEL ELECTRODES FOR
FLUX CORED ARC WELDING
AWS A5.29-2007

E 8X T5 – B2CJH4
• E-ELECTRODE
• 8-TENSILE IN KSI(80)
• X-POSITION DESIGNATOR
• T-FCAW/TUBULAR
• 5-BASIC TYPE
• B2-CHEMICAL COMPOSITION- 2 Cr-1 Mo
• C-CO2 SHIELDING GAS
• J-IMPROVED TOUGHNESS - 27J AT 10 C
• HX-HYDROGEN DESIGNATOR-4ml/100gms OF WELD METAL
 STAILESS STEEL ELECTRODES FOR
FLUX CORED ARC WELDING
AWS A5.22-2007

E X X XTX-X
 E-ELECTRODE
 XXX-COMPOSITION OF WELD METAL

 T-FCAW/TUBULAR

 X-POSITIONAL WELDING DESIGNATOR 0-F/H;1-ALL POSITION

 X-SHIELDING GAS 1-CO2/ 3-SELF SHIELDING/ 4-80-20 Ar-CO2/ 5-Ar

 STAINLESS STEEL ELECTRODES FOR
FLUX CORED ARC WELDING
AWS A5.22-2007

E 308T1-1
 E-ELECTRODE
 308-COMPOSITION OF WELD METAL-18%Cr/8%Ni

 T-FCAW/TUBULAR

 1-ALL POSITION

 1-SHIELDING GAS 1-CO2

 STAILESS STEEL ELECTRODES FOR
FLUX CORED ARC WELDING
AWS A5.22-2007

E 308T0-3
 E-ELECTRODE
 308-COMPOSITION OF WELD METAL-18%Cr/8%Ni

 T-FCAW/TUBULAR

 0-FLAT/HORIZONTAL

 3-SELF SHIELDING
 STAILESS STEEL
FLUX CORED RODS FOR GTAW WELDING
AWS A5.22-2007

R X X XT1-5
 R-WELDING ROD
 XXX-COMPOSITION OF WELD METAL

 T-FCAW/TUBULAR

 1- ALL POSITION

 5-100% ARGON
 STAILESS STEEL
FLUX CORED RODS FOR GTAW WELDING
AWS A5.22-2007

R 308LT1-5
 R-WELDING ROD
 308L-COMPOSITION OF WELD METAL

 T-FCAW/TUBULAR

 1- ALL POSITION

 5-100% ARGON
 SAW

E.g. F S7 P 4 EXXX HX
• F-SAW FLUX
• S- INDICATES FLUX BEING CRUSHED
SLAG/SLAG +VIRGIN FLUX
• 7-MINIMUM UTS OF 70 KSI(70000psi)
• P- HEAT TREATMENT P-PWHT/A-AS WELDED
• 4-MINIMUM CVN IMPACT ENERGY OF 20 Ft Lb
AT MINUS 40°F
• EXXX-ELECTRODE WIRE
• HX- HYDROGEN DESIGNATOR
 SAW

E.g. F 7 A6 EM12K
• F-SAW FLUX

• 7-MINIMUM UTS OF 70 KSI(70000psi)

• A- AS WELDED

• 6-MINIMUM CVN IMPACT ENERGY OF 20 Ft Lb AT MINUS 60°F

• EM12K-ELECTRODE SPECIFICATION

• HX- NOT SPECIFIED

• S-ABSENCE INDICATES VIRGIN FLUX

 SHIELDING GASES

• SELECTION OF SHIELDING GAS IS VITAL FOR GMAW/FCAW

• GAS SELECTION CAN AFFECT ARC CHARACTERISTICS & ALSO

AFFECT MECHANICAL PROPERTIES.

• THE GAS PLAYS IMPORTANT ROLE IN MODE OF METAL

TRANFER,BEAD PROFILE &PENETRATION.

• THE COMMEN GASES USED ARE CO2,ARGON,HELIUM & MIXED

GASES.
 COMPARISON OF INERT GASES Ar &He
ARGON
• 1.4 TIMES HEAVIER THAN AIR
• QUANTUM OF SHIEDING GAS
REQD. IS LOW
• DUE TO LOWER THERMAL
CONDUCTIVITY FINGER TYPE
PENETRATION
• PRODUCES SPRAY TRANFER
• USED COMMENLY FOR WIDE
RANGE OF MATERIAL MOSTLY AS
MIXED GAS WITH CO2
HELIUM
• 0.14TIMES HEAVIER THAN AIR
• QUAMTUM OF SHIELDING GAS REQD.
IS VERY HIGH
• DUE TO HIGHER THERMAL
CONDUCTIVITY DEEP BROAD
PARABOLIC TYPE PENETRATION
• CAN PRODUCE SPRAY TRANFER
ONLY WHEN MIXED WITH ARGON
• USED FOR HIGH CONDUCTIVITY
MATERIAL LIKE Cu ,Al etc
 ACTIVE GAS-CO2

• USED FOR CORBON & LAS

• USED ALSO FOR SS IN FCAW
• HIGHER SPED,ADEQUATE PENETRATION AT LOWER COST
ARE ITS SALIENT FEATURES.
• FOR SOLID WIRE TRANFER MODE IS EITHER SHORT
CIRCUITING OR GLOBULAR
• TRANFER TYPE LEADS TO HIGHER SPATTER & ROUGH BEAD
PROFILE
• FOR FCAW SPRAY TRANFER IS ACHIVED HENCE MOST
COMMENLY USED GAS
 GAS MIXTURES
• Ar+CO2

• Ar+O2

• Ar+O2+CO2

• Ar+He

• AR+He+O2

• Ar+He+O2+CO2
 SHIELDING GASES
 Arc Characteristics
 Penetration Profile
 Mode Of Transfer
 Spatter Level
 Alloy Recovery
 Material Types
 SHIELDING GAS COMPARISON
E 81T-1-Ni1 VERTICAL UP @21 KJ/CM

95Ar/5CO2 75Ar/25CO2 50Ar/50CO2 100CO2

TYPICAL C .059 .055 .042 .041
CHEMICAL Mn 1.29. 1.29 1.24 1.16
ANALYSIS Si .44 .44 .39 .31
TYPICAL YS 540 531 502 457
MECH.
PROP(Mpa) UTS 603 586 568 565
TYPICAL 0 Deg C 123 125 109 104
IMPACT
PROP(J) -40Deg C 91 84 48 40

BEAD FLAT FLAT CONVEX CONVEX

SHAPE
 IMPORTANT

Making a Gas Decision

Deciding on a particular shielding gas
should be based on the specific
manufacturer’s recommendation. Failure
to do so may result in weld metal defects
or in an deterioration in Mechanical
properties.The manufacture’s guaranteed
values are obtainable only when specified
technical parameters are followed in full .
 STORAGE OF CONSUMABLES

• SHELF LIFE OF WELDING CONSUMABLES DEPENDS ON THE

WAY THEY ARE STORED

• IF THE ELECTRODES ARE STORED IN A DRY HUMIDITY

CONTROLLED ROOM WITHOUT OPENING THE ORIGINAL
PACKING,THEY CAN BE UTILISED EVEN UPTO 2 YEARS FROM
DATE OF PACKING.
 STORAGE & RECONDITIONING FOR
SMAW /FCAW
SMAW
• Low Hydrogen Store 100-150 Deg C
Recondition at 400 Deg C- 1Hr
• Stainless Recondition at 200 Deg C- 1Hr
FCAW
• Plastic Recondition at 50 Deg C- 48Hr Min
• Coils Store 100-125 Deg C
Recondition at 150 Deg C- 6-8Hrs
• Wire Spool Store 150 Deg C
Basket Recondition at 250 Deg C- 2-3Hrs
Higher Rebake Temperature , Faster Reconditioning
STORAGE AND DRYING OF CS&LAS
CONSUMABLES

• CELLULOSIC TYPE-REDRYING TEMP-70 TO 80

DEG C/HR

• BASIC TYPE-REDRYING TEMP- 260 TO 420 DEG C /

2HR ,HOLDING TEMP-30 TO 140 DEG C
 REBAKING SCHDULE FOR LH ELECTRODES

• REBAKE CONSUMABLES AT 250-300 C FOR ONE HOUR

• TRANFER THEM TO HOLDING OVEN AT 100 C

• TRANPORT HOLDING OVEN TO WORKING AREA &USE THE SAME FOR

FABRICATION

• USE DIFFERENT COMPARTMENTS OF OVEN TO BAKE OTHER

SPECIFICATION OF CONSUMABLES.

• CLEAN THE OVEN AT LEAST ONCE A WEEK.

 STORAGE&DRYING OF SS&NF
CONSUMABLES

• RUTILE TYPE- REDRYING TEMP-120TO150 DEG C /2HR

• SEMI BASIC TYPE-REDRYING TEMP-180 TO 200 DEG C/2HR

• BASIC TYPE-REDRYING TEMP-200 TO 250 DEG C/2HR

 VACCUM PACKING

• SPECIAL PURPOSE MACHINES ARE AVILALE FOR VACUUME PACKING

ELECTRODES AS WELL AS WIRE SPOOLS.

• IN THIS TYPE OF PACKING AS ALL AIR INSIDE THE PACKING ARE

REMOVED,THE CONSUMABLES DO NOT ABSORB ANY MOISTURE

• THEY CAN BE USED WITHOUT REBAKING

• THE PACKING QUANTUM CAN BE VARIED BASED ON SPECIFIC

APPLICATION

• HIGHLY RECOMMENDED WHEN REBAKING IS NOT FEASIBLE

SOME COMMENLY ASKED
QUESTIONS
The E7018 welding rods I've been buying are now marked E7018 H4R. What
does the H4R mean? Are these rods different than the E7018 rods I've used
before?

H4R is an optional supplementary designator, as defined in AWS A5.1-91 (Specification for

shielded metal arc welding electrodes). Basically, the number after the "H" tells you the
hydrogen level and the "R" means it's moisture resistant.
"H4" identifies electrodes meeting the requirements of 4ml average diffusible hydrogen
content in 100g of deposited weld metal when tested in the "as-received" condition.
"R" identifies electrodes passing the absorbed moisture test after exposure to an environment
of 80ºF(26.7ºC) and 80% relative humidity for a period of not less than 9 hours.
The H4R suffix is basically just additional information printed on the rod, and does not
necessarily mean a change in an electrode previously marked E7018.
Why is hydrogen a concern in welding?

Hydrogen contributes to delayed weld and/or heat affected zone

cracking. Hydrogen combined with high residual stresses and crack-
sensitive steel may result in cracking hours or days after the welding has
been completed.
High strength steels, thick sections, and heavily restrained parts are
more susceptible to hydrogen cracking. On these materials, we
recommend using a low hydrogen process and consumable, and
following proper preheat, interpass, and postheat procedures. Also, it is
important to keep the weld joint free of oil, rust, paint, and moisture as
they are sources of hydrogen
What consumables are better for welding over rusty, dirty steel?

Steel should be cleaned of any oil, grease, paint, and rust before using any
arc welding process. However, if complete cleaning cannot be performed,
consumables that form a slag, have deeper penetration, are slower freezing,
or have higher Silicon and Manganese are recommended for dirty steels

Why are the Charpy impact values from my test welds

lower than that printed on your Certificate of
Conformance?

The test results on our Certificate of Conformance were obtained from

welding an AWS filler metal test plate. Any change in welding procedure
will affect Charpy impact values. Below are common practices for
welding test plates when Charpy impact specimens are required:
• Controlled heat input
• Controlled preheat and interpass temperature
• Even number of passes per layer
• Build-up cap pass to maximum allowed in specification
I'm using E71T-1 flux-cored wire with 75Ar/25CO2. Why am I
getting gas marks on the weld surface?

The fast freezing rutile slag on an E71T-1 wire gives it excellent out-of-position
characteristics, but can also trap gases under the slag as the weld solidifies,
resulting in gas marks. Gas marks are more commonly observed welding at
high procedures under a high Argon blend shielding gas. Gas marking and/or
can be minimized by:
1. Switching to 100% CO2 shielding gas
2. Lowering the welding current
3. Cleaning the weld joint of paint, rust, and moisture
4. Minimize any wind disturbance
5. Cleaning spatter from inside gas nozzle
6. Increasing the shielding gas flow rate
Why is preheat sometimes required before welding?

Preheating the steel to be welded slows the cooling rate in the weld area. This
may be necessary to avoid cracking of the weld metal or heat affected zone. The
need for preheat increases with steel thickness, weld restraint, the carbon/alloy
content of the steel, and the diffusible hydrogen of the weld metal. Preheat is
commonly applied with fuel gas torches or electrical resistance heaters
 Preheat Temperature
Tp = 350 ( C ) - 0.25

( C ) = CE ( 1 + 0.005 x t )
CE - Carbon Equivalent
t - Thickness in mm

Carbon Equivalent
Mn Ni Cr+Mo+V
CE =C+ + +
20 15 10
How should uniformity of preheat be measured?

AWS D1.1 Structural Steel Welding Code, Section 5.6 states: Preheat and all
subsequent minimum interpass temperatures shall be maintained during the
welding operation for a distance at least equal to the thickness of the thickest
welded part, but not less than 3 in. [75mm] in all directions from the point of
welding.
In general, when preheat is specified, the entire part should be thoroughly
heated so the minimum temperature found anywhere on that part will meet or
exceed the specified preheat temperature.
What is interpass temperature?

Interpass temperature refers to the temperature of the steel just prior to the
depositing of an additional weld pass. It is identical to preheat, except that preheating
is performed prior to any welding.
When a minimum interpass temperature is specified, welding should not be
performed when the base plate is below this temperature. The steel must be heated
back up before welding continues.
A maximum interpass temperature may be specified to prevent deterioration of the
weld metal and heat affected zone properties. In this case, the steel must be below
this temperature before welding continues.
Do I need an oven to store low hydrogen electrodes?

All low-hydrogen consumables must be dry to perform properly. Unopened hermetically

sealed containers provide excellent protection in good storage conditions. Once cans are
opened, they should be stored in a cabinet at 120º-150ºC.
When the electrodes are exposed to the air, they will pickup moisture and should be redried.
Electrodes exposed to the air for less than 1 week with no direct contact with water should
be redried as follows:

1 hour at 650º-750ºF
E7018:
E8018, E9018, E10018,
1 hour at 700º-800ºF
E11018:

1. If the electrodes come in direct contact with water or have been exposed to high humidity,
they should be predried for 1-2 hours at 180º-220ºF first before following the above
redrying procedure.
2. Standard EXX18 electrodes should be supplied to welders twice per shift.
3. Low hydrogen electrodes with the suffix "R" have a moisture resistant coating and may be
left out up to 9 hours or as specified by code requirements.
What precautions should I take when welding T-1 steels?

T-1 is a quenched and tempered steel. Welding quenched & tempered steels may be
difficult due its high strength and hardenability. The base steel around the weld is
rapidly being heated and cooled during welding, resulting in a heat affected zone
(HAZ) with high hardness. Hydrogen in the weld metal may diffuse into HAZ and cause
hydrogen embrittlement, resulting in delayed underbead or toe cracking outside of the
weld. To minimize heat affected zone cracking:
1. Use a low hydrogen consumable, like a -H4 or -H2.
2. Preheat. This slows the cooling rate. Note that excessive preheat may anneal the base
material.
3. Slow cool. More time at elevated temperatures allows the dissolved hydrogen to
escape.
4. Peen the weld beads to minimize residual weld stresses.
5. Use the lowest strength filler metal meeting design requirements. If making fillet welds,
the weld can be oversized to give the specified strength
6. Minimize weld restraint.
What electrode can I use to join mild steel to stainless steel?

Electrode selection is determined from the base metal chemistries and the percent weld
admixture. The electrode should produce a weld deposit with a small amount of ferrite (3-
5 FN) needed to prevent cracking. When the chemistries are not known, E 312 type
electrode, which produces a high ferrite number, is commonly used.

What consumable should be used to weld cast iron?

Cast irons are alloys which typically have over 2% carbon plus 1-3% silicon and are
difficult to weld. Electrodes with a high percentage of nickel are commonly used to repair
cast iron. Nickel is very ductile, making it a good choice to weld on cast iron, which is very
brittle. welding with Nickel(99%)l/Ferro Nickel(55%) are the recommended electrodes
designed for welding cast iron.
CASE STUDIES & FAILURE ANALYSIS

WITH STICK WELDING(SMAW) PROCESS

ON DIFFERENT TYPES OF MATERIAL

 FAILURE OF TEST COUPENS OF DISHED END

PETAL HOT PRESSED/

TYPE COLD SPINNING

THE WPS/PQR ESTABLISHED USING E7018 ELETRODES FOR SA515Gr70

MATERIAL GAVE SATIASFACTORY RESULTS FOR PETAL D.E
THE SAME WPS FOUND TO VARIATION IN RESULT WHEN USED FOR
COLD SPUN /HOT PRESSED D.E. WITH WELD JOINT.

ANALYSIS

THE HOT PRESSED ./COLD SPUN D.E.UNDERGOES NORMALISING

OPERATION WHICH IS NOT ACCOUNTED IN WPS

WHEN USING E7018 ELECTRODES ,UTS DROPS BY 50-70 N/mm sq WITH

NORMALISING OPERATION
FAILURE OF TEST COUPENS OF DISHED END(CONTD)
SOLUTION
• IT IS RECOMMENDED TO USE E7018A1 WELDING
CONSUMABLES.

PROPERTIES OF CONSUMABLES WITH TYPICAL H.T. CYCLES.

Sl.No CONSUMALE AS SR NORMALISED

TYPE WELDED
1 E7018 530 525 480
2 E7018A1 540 535 530
FAILURE OF 5Cr-1/2 Mo SPIRAL HEAT EXCHANGER

PROBLEM:
THE SPIRAL COIL WELD JOINTS WERE FOUND TO BE LEAKING
AFTER SHORT SEVICE OF SIX MONTHS

ANALYSIS:

THE WELD JOINTS EXAMINED USING DP INDICATED SEVERE MICRO

FISSURING ON ALL THE JOINTS.

THE EXAMINATION OF WPS/PQR INDICATED ROOT RUN BY GTAW &

BALANCE BY SMAW OF E 8018-B6 CONSUMABLES.
 FAILURE OF 5Cr-1/2 Mo SPIRAL HEAT EXCHANGER(CONTD)
• ON EXAMINATION OF CONSUMABLE RECORDS ,BEING 2.5MM
IN SIZE ,NO MECHANICAL TEST RESULS WERE CALLED FOR &
HENCE NOT PROVIDED.
REVIEW
• TAKING INTO CONSIDERATION TYPE OF BASE MATERIAL
WHICH IS PRONE FOR INTERMEDIATE HARDANABLE MICRO
STRUCTURE & MICRO FISSURING UNDER RESTRAIANT, IT
WAS RECOMMENDED TO USE E8018-B6 DULY QUALIFIED
WITH TEKKAN Y-GROOVE TEST

TEKKEN Y-GROOVE ASSEMBLY

20mm
 CROYOGENIC APPLICATION

TYPICAL REQUIREMENT 15 mil LE AT MINUS 196 Deg.C

• LOW CORBON(<0.04),NITROGEN(<0.05),

• FERRITE(2%)

• BASIC SLAG

 SMAW “15 “ COATING TYPE

 FCAW LIME/FLUORIDE COATING

E308L 15/16 FOR CRYOGENIC APPLICATION(CONTD)
 PROBLEM
• SELECTION OF PROPER CONSUMABLE FOR CRYOGENIC
APPLICATION
 ANALYSIS
• THE CONVENTIONAL E308L-16 ELECTRODES GAVE ERRATIC
RESULTS.
• EVENTHOUGH THE E308L-15 ELECTRODES FOUND TO GIVE GOOD
RESULTS, RADIOGRAPHIC RESULTS WERE NOT CONSISTANT
• IT WAS POSSIBLE TO OBTAIN GOOD PERFORMANCE AS WELL AS
CONSISTANT RESULT BY MODIFYING THE PRODUCT E308L-16 WITH
CONTROLLED FERRITE(<2%)
RESULTS OF E308L-16 BATCH TEST
BATCH CVN AT -196 C LE mil UTS %E FN
mpa %

A 32.3 17 536 45.4 2

B 40 19.2 543 49 1.5
C 35.3 19 564 47 1

THE RESULTS WITH MODIFIED PRODUCT FOUND SATISFACTORY

 CORROSION APPLICATION

• TYPICAL REQUIREMENTS 24 mpy PRAC.B/15MPY

ASTM A 262 PRAC. C

• BASIC SLAG,LOW FERRITE(NIL)

• HIGH NICKEL&/OR HIGH MANGANESE

 E316LF WITH NIL FERRITE
 PROBLEM
 THE E316LF ELETRODES QUALIFIED FOR JOB GAVE MICRO
FISSURING IN ACTUAL FABRICATION PARTICULARLY ON
RESTRAIANT JOINTS.
 ANALYSIS:
 THE QUALIFIED CONSUMABLE ,EVENTHOUGH GAVE
SATISFACTORY RESULTS IN L-SEAMS,FOUND TO GIVE MICRO
FISSURING IN C-SEAM& NOZZLE JOINTS.
 THE CRATER GRINDING THOUGH CONTROLLED THE
PROBLEM, IT WAS NOT DESIRED SOLUTION
 SOLUTION:
 BASED ON OBSERVATION & STUDIES ,IT WAS DECIDED
DEVELOP THE E316LF CONSUMABLE CAPABLE ON
WITHSTADING HEAVY RESTRAINANT. TO EVALUATE THE
CONSUMABLE ,THE THOMAS-SCHFFLER TEST WAS TAKEN
AS BASIS
 E316LF WITH NIL FERRITE
 TEST RESULTS OF CORROSION ON MOD.E316LF
BATCH TEST CORR.RATE REMARKS NO OF FERRITE
DURATION mpy NO.
NO . CRACKS

A 48X5 14 FAIL 5 NIL

B 48X5 10.5 REVIEW 1 NIL
C 48X5 5.5 ACCPT. - NIL

THOMAS SCHFLLER TEST ASSEMBLY

WELDING OF DISSIMILAR STEELS
 WELDING OF DISSIMILAR METALS

PROBLEM:
 FOR WELDING OF CS &LAS TO SS THE COMMON
CONSUMABLES SELECTED LIKE E309/309L/309Mo GAVE
PROBLEMS WITH REGARD TO DUCTILITY
ANALYSIS
 THE COMMONLY AVILABLE CONSUMABLES IN ABOVE
GRADES COMMONLY HAD FERRITE 8-16%
 THESE CONSUMABLES EVEN THOUGH SUITABLE FOR THIN
SECTIONS,GAVE VERY LOW %E WHEN USED ON THICKER
JOINTS/SR APPLICATION
 THE REASON FOR ABOVE WAS DUE TO FORMATION OF
INTERMEDIATE BAINITE(SIGMA) PHASE
SOLUTION
 USE MODIFIED CONSUMABLES WITH CONTROLLED FERRITE
OF 6-9% & QUALIFY THE SAME WITH SR AT 680deg C FOR
1HOUR
 WHEN WELDING JOINTS THICKER THAN 20mm ,BUTTER THE
CS/LAS WITH E309&WELD WITH SUITABLE SSCONSUMABLES.
EFFECT OF POST WELD HEAT TREATMENT ON E309 TYPE CONSUMABLES

% AGE ELONG. WITH REF

TO ORIGINAL%E 4
8
16

POST WELD HT TEMP

POST WELD HT FOR 10 HOURS

A 550 °C
C 600 °C

B 500 °C
D 700 °C
 TYPICAL MECHANICAL PROPERTIES OF WELDING CONSUABLES
STEEL WELDING USED FOR DISSIMILAR
Sl. Type T Mech. Prop Mech. Prop
e (ASME Specified (Actual)
No
c
h
n As Welded PWHT As Welded PWHT
I
c
a UTS % UTS % UTS % Ferrite UTS % Ferri
l N/mm2 E N/mm2 E N/mm2 E N/mm2 E te
C
o
1 E309/E309MO 550 30 - - 550-650 30 16 650- 750 10 4
n
d
2 E310 i 550 30 - - 550-650 30 - 550- 650 30 -
t
3 ENiCrFe3 I 550 30 - - 550-650 30 - 550- 6O0 30 -
4 E309/E309MO o 550 30 - - 550-650 30 8 580- 680 25 6
(Modified) n

Undiluted E309 deposit SS18/8 TYPE

E309 BUTTERING WELD METAL
40
20 10

CS TO SS WELDING WITH CS TO SS WIELDING

E309 TYPECONSUMABLES WITH CS SIDE BUTTERING
 PROBLEMS RELATED

TO CLAD STEEL WELDING

MISMATCH OF 1.2MM-CONVENTIONAL EDGE PREPARATION
Barrier layer location

1-2MM

NOZZLE TO SHELL WELD STRIP BACK

Contamination of high & HIGH ALLOY WELD
alloy steel With CS/LAS
5mm

SEQUENCE OF WELDING
FIRST SIDE FIRST LAYER
BG &SECOND SIDE
BASE METAL WELDING BASE MEATL WELDING
BARRIER LAYER
 COMMON TYPES OF EDGE PREPARATIONS
3mm
5mm 3mm

REPAIR WELDING
CS/LAS WELDING TO BE RESTRITED LEVEL OF BARRIER LAYER
1MM BELOW ORIGINAL BARRIER LAYER 5mm DEPTH

REPAIR FROM CS/LAS SIDE T-Thickness

a-Clad thickness

b-High alloy steel

dep. Depth

c-Balance CS/LAS
BALANCE CS/LAS} t- (d+b) weld metal
WELD METAL }
d-Gouging depth
THANK YOU