FILARC welder guide book No.

1
PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Welder Guide Book No. 1

Index page 1

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FILARC PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

A new generation of basic cored wires with excellent welding characteristics for positional work on high quality fabrication

FILARC welder guide book No.1

PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Due to its policy of continual improvements in its welding consumables, FILARC reserves the right to change data in this guide without notice.

Introduction
FILARC PZ 6125 represents a new generation of basic fluxcored wires, with much improved weldability. PZ 6125 yields excellent mechanical properties, including satisfactory CTOD values, both as-welded and stress relieved, with hydrogen content dependably below 3ml /100g. PZ 6125 and related types provide good all-position weldability, with useful tolerance in welding parameter setting; they are far easier to use than conventional basic cored wires. However, due to the new flux formulation, weldability has distinctive, but not difficult, characteristics. This Guide Book provides all the information you need to ensure fully satisfactory use of these new basic cored wires.

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FILARC Welder Guide Books provide practical information on the use of specific FILARC flux and metal-cored wires. The contents will assist welders to apply correct welding parameters and use the FILARC cored wire effectively, to achieve optimum productivity and avoid faults. The information provided will be helpful to welders both qualified or still to qualify for cored wire welding. There is also helpful information for welding engineers establishing appropriate welding procedures, also training instructors and welding foremen. Overall the guide will enhance results from the FILARC flux or metal-cored wire(s) described.

Index
Correct use of equipment...........................................Page 2 Torch, liners and cable assembly ...........................................2 Wire drive unit.........................................................................2 Gas regulation ........................................................................2 Gas cup and contact tip combination ....................................4 Correct stickout length ...........................................................4 Gas cup sizes .........................................................................4

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FILARC PZ6125 is decribed in this guide, together with related types, listed below, having identical welding performance. All types come in diameter size 1.0, 1.2 and 1.6mm and are developed for use in Ar/CO2 mixed gas. Low alloyed types AWS A5.29 E71T5-G FILARC PZ 6125 High tensile types FILARC PZ6145 FILARC PZ6146 FILARC PZ6147 FILARC PZ6148 FILARC PZ6149 Creep resistant types FILARC PZ6201 FILARC PZ6202 FILARC PZ6203 FILARC PZ6204 FILARC PZ6205
E81T5-G E91T5-K2 E101T5-K3 E111T5-K4 E121T5-G

Power source facilities............................................................6 Welding parameter setting......................................................8 Choice of wire size ...............................................................10 Recommended average parameter setting ..........................12

EN 758
T 42 6 1Ni B M 1 H5

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T 50 5 Mn1Ni B M 1 H5

ASME and EN welding positions..........................................15 Welding advice .....................................................................16 Torch positions for positional welding ..................................18 Weaving technique ...............................................................22

AWS A5. .. / DIN 8575

DIN: SGCrMo1 29:E71T5-A1 DIN: SGCrMo2 22:E502T-1 29:E81T5-B2

Grinding ................................................................................24 Trouble shooting ...................................................................26 Causes of weld defects ........................................................27

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FILARC welder guide book No.1

Correct use of equipment
PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels
FILARC PZ 6125 and other cored wires will always perform well when welding sets are used correctly and maintained according to the makers instructions. Following are some simple guidelines for preventive inspection and maintenance. When carried out regularly, the most common causes of malfunctioning are avoided.

Replace worn contact tip.

concentric hole

worn hole

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Torch, liners and cable assembly

Ensure that the contact tip has the right size and is mounted tight. Ideally, contact tips are checked for wear upon wire spool change and replaced when necessary. Check gas cups for spatter built-up and clean if necessary. -im peded gas flow from clogged cups may cause porosity. Blowing-out the liner into the direction of wire delivery should be a regularly recurring routine. Check liners for damage at least weekly, and replace when necessary. Spiral steel liners are recommended. Check gas and water connections for leaks. When fitted, ensure water cooler is filled and pump operates satisfactorily. Inspect torch connections and clean liner weekly.

Exit to torch

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Wire drive unit

Wire guide tubes must be as close to the rollers as possible to prevent kinking of a cored wire. Proper alignment is essential to avoid unnecessary friction. A substantial amount of fine metallic swarf underneath the drive wheels indicates misalignment (or excessively worn drive wheels). Use drive wheels with a V-groove and, by preference, flat pressure wheels. Check that the groove of the drive wheel is correctly selected for the wire diameter, and that the pressure wheel is correctly tensioned. Too much pressure may flatten the cored wire, giving increased wear of liner and contact tip. Insufficient pressure may result in slip, causing erratic wire feed and burn-back. Limit the use of knurled wheels to situations where friction in the liner causes wheels with a V-groove to slip. This is only likely to happen with long, extremely curved cable assemblies, and/or with units with one set of rolls. Knurled wheels cause increased wear of liner and contact tip. Test wire delivery at the torch; this must be regular.

Correct location of wire guide tubes. Minimal space between guide tubes and rollers. Proper alignment is essential.

Exit to torch

Excessive space between wire guide tubes and rollers can cause kinking of wire. Misalignment, also in the plane perpendicular to the one shown here, causes friction.

Check gas pressure and flow rate.

Gas regulation
Check that Ar/CO 2 (80/20) gas is used. Adjust the flow rate between 15 and 20 l /min to suit wire and joint configuration. Outdoors, use 20l. Make a short test run to assure no porosity arises from incorrect gas flow. Always check gas flow with a flow meter which fits on the nozzle, to be sure that required gas flow is available.
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FILARC welder guide book No.1

PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Gas cup and contact tip combination

It is essential to mount the gas cup and contact tip at the right distance relative to each other. The ideal 2mm distance is shown right. A larger distance increases stickout length, causing slag traps and lack of fusion, mainly in narrow joints.
2mm 10mm

Correct positioning of contact tip.

Correct stickout length

Incorrect. Left: increased stickout causes slag traps and fusion faults, mainly in narrow joints. Right: contact tip extends beyond gas cup. Risk of insufficient shielding gas protection.

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The stand-off, here and in other FILARC sales literature referred to as stickout, is the distance between the tip of the contact tip and the workpiece. It must be held constant at 10 to 15mm for PZ 6125 and related types in 1.0 and 1.2mm sizes and 15 to 20mm for 1.6mm size. Correct, constant stickout length must be maintained, as far as joint preparation will allow. Variations will cause arc voltage and welding current to fluctuate and in turn adversely influence droplet transfer. Overlong stickout results in larger droplets, causing spatter, also reducing gas protection, so bringing weld porosity.

Ideal stickout length for 1.0 and 1.2mm wire sizes.

10 -1

5m

Gas cup sizes

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Various cup diameters must be available, to allow satisfactory access to the joint, and maintain the stickout length recommended above, according to wire size. Small diameter gas cups are used for first layers only. Revert to the standard gas cup diameter when access to the weld joint allows this, so full gas protection can be assured. Check gas flow after a change of gas cup size.

10-

15m

>10

-15

mm

Trouble shooting Porosity is normally the result of draught, the presence of condense water, rust or paint on the plate material or an overlong stickout length. Also insufficient gas flow, due to clogged gas nozzles is a common cause. Check the above, if porosity occurs. Unstable arc or large droplets are a sign of excessive stickout, possibly due to gas cup size not allowing suitable access to the joint; replace gas cup with smaller size. Also refer to the checklist of process faults and weld defects as from page 26.

Correct. Smaller gas cup diameter for 1st layers of joints with limited access.

Incorrect. Too large gas cup diameter restricts access to narrow joints, resulting in too long stickout length.

Correct gas cup for filling ensures good gas protection and correct stickout.

Incorrect. Too small gas cup diameter for filling reduces gas protection and brings porosity.
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PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Power source facilities

Power source rating must be suitable for the basic cored wire size at 60% duty cycle. These should have selectable choke settings; automatic chokes are not recommended. Power sources fall into the following categories for setting welding parameters (arc voltage, wire feed speed/welding current, choke setting). Manual selection, with or without Voltage and Ampre meters.

Use negative polarity for PZ6125 and related types (straight polarity).

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Pre-programmed with variable selection of wire feed speed. Available programs for flux-cored wires may not necessarily suit FILARC PZ 6125 and related wires. Test these carefully, and if not fully satisfactory check with equipment supplier for program revisions. Programmable, select the parameters recommended for FILARC PZ 6125 in preference to any already installed program(s) for flux-cored wires. Polarity negative It is essential to weld FILARC PZ 6125 and related types on negative polarity, to avoid slag inclusions and lack of fusion, also to obtain deeper penetration, especially when welding in position. Choke setting A welder often has a preference for a particular setting, so will adjust this until arriving at what is considered to be satisfactory. Due to the variety of welding equipment available, it is impractical to define the exact setting. However, a minimum choke value is best suited for FILARC PZ 6125, in all positions. Advice Start with a minimum value and adjust the arc voltage and wire feed speed to recommended values, and trim these for smoothest weldability in the welding position required. Only if spatter is excessive, use the next higher choke setting.

polarity

Choke setting values may be indicated by various symbols. Typical examples are shown here.

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1 minimum

3 maximum

A minimum

C maximum

A minimum

C maximum

Recommended setting for PZ6125 and related types.

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FILARC welder guide book No.1

PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Welding parameter setting

Arc voltage is related to welding current, which is established by the wire feed speed adjustment on the wire drive unit. Note, the arc voltage setting for FILARC PZ6125 is higher than usually required for normal basic cored wires. Advice After selecting the minimum choke value, set the recommended arc voltage (V) and wire feed settings/current values, see following pages for examples. Test weldability in the required welding position. Power sources fitted with voltage and current meters allow settings to be monitored. Correct parameter setting will bring the arc over the weld pool, delivering either a smooth, fine droplet transfer at lower wire feed speeds, or spray arc at higher speeds. Too short or long arcs can arise from incorrect setting of parameters for the welding position. To obtain correct results: adjust the wire feed speed slightly. If the arc length remains unsatisfactory, or weldability unsmooth, Correct arc length. Arc is just over weldpool, with smooth droplets or spray arc.

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adjust arc voltage in steps of 1 or 2V. Results may be further improved by slight adjustment of wire feed speed/welding current. In case of continuing difficulty, especially at lower arc voltage/welding currents, use a higher choke value and repeat the above adjustments. Note, irregular wire feeding due to incorrect wire drive roller adjustment, a damaged torch cable liner, or a worn contact tip can cause difficulties. Check these if weldability fluctuates; adjustment of welding parameters will not overcome these equipment faults. Arc Voltage and Welding Current Meters Usually fitted to power sources, these are helpful for training or monitoring purposes. They are not a substitute for correct adjustment of welding parameters to suit the best combination of wire size and welding position.

Arc length too short. Stubbing. Wire dips into weldpool, caused by too high a wire speed or too low an arc voltage.

Arc length too long. Wire speed too low, or arc voltage too high.
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PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Choice of wire size

FILARC PZ 6125 and related types are all available in 1.0, 1.2 and 1.6mm diameters, so allowing optimal productivity for various combinations of plate thicknesses and welding positions. The chart opposite shows recommended use. The 1.2mm size is recommended for general all-positional use. Diameter 1.6mm is a more productive choice when the majority of welding takes place in the downhand position. Although it is not recommended by FILARC, the 1.2mm size is also an option when fabricators wish to weld root passes without ceramic weld metal support. The 1.0mm size is advantageous for pipe work and tubular constructions with minimal 10-12mm wall thickness and minimal 4inch diameter, bringing excellent control of the weld pool in the 3 to 9 o'clock positions. Use with ceramic backing High quality root runs can be deposited economically when using ceramic weld metal support. Both the 1.2mm as well as the 1.6mm size are very suited. Consult the special FILARC brochure on ceramic backing materials. The 1.6mm size is very productive for root passes in the 1G and 2G positions. The thick root pass layer allows filling at higher welding currents. Chart recommendations are for average situations. There will be exceptions for plate size, application area, etc. where the versatility of PZ 6125 will still provide excellent results. For additional advice contact your FILARC welding engineer or nearest sales office. A guide to ASME and EN welding positions is given on page 15.

Wire Welding position Root Fill Root Fill Root Fill Root Fill Root Fill Root Fill
1 2

1.0mm

1.2mm

1.6mm

Suitability for average application not recomm. not recomm. not recomm. not recomm. not recomm. yes not recomm. yes not recomm. yes not recomm. yes possible2 possible2 not recomm. not recomm. on backing yes on backing yes on backing yes on backing yes on backing yes not recomm. not recomm.

1G/PA 1G/PA 2G/PC 2G/PC 3G/PF 3G/PF 4G/PE 4G/PE 5G/PF 5G/PF 6G HL045 6G HL045 1F/PA 2F/PB 3F/PF 4F/PD

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not recomm. not recomm. not recomm. yes1 not recomm. not recomm. not recomm. possible1 not recomm. not recomm. possible1 yes yes yes yes not recomm. yes yes not recomm. not recomm.

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For thicknesses below 20mm, 1.0mm size is recommended 1.2 or 1.6mm sizes will improve productivity.

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PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Recommended average parameter settings

FILARC PZ 6125, 1.0mm , negative () polarity.

FILARC PZ 6125, 1.2mm , negative () polarity.

1G/PA

Root*: 180-230A /8.0-11.0m/min 22-28V (spray arc) Fill : 240-320A/12.5-19.0m/min 28-34V

1G/PA

Not recommended. Diameters 1.2 and 1.6mm are best suited. 2G/PC Not recommended. Diameters 1.2 and 1.6mm are best suited. Root : not recommended Fill : 140-160A/8.5-9.8m/min 18-21V 3G/PF Root*: 150-180A /6.5-8.0m/min 19-22V (spray arc) Fill : 180-200A /8.0-9.5m/min 22-25V Root*: 170-230A/7.0-11.0m/min 21-28V (spray arc) Fill : 190-280A /9.0-16.0m/min 23-33V

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2G/PC

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3G/PF

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3F/4F/PF/PD

Fill

: not recommended

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4G/PE 4G/PE Root : not recommended Fill : 130-150A/7.8-9.2m/min 18-19V 5G+6G/H-L000+H-L045 5G/PF Root : not recommended Fill : 130-160A/7.8-9.8m/min 18-19V

Root : not recommended Fill : 130-150A /4.0-6.5m/min 18-19V

Root : not recommended Fill : 130-180A /4.0-8.0m/min 18-22V

6G/HL045

Root : not recommended Fill : 140-150A/8.5-9.2m/min 18-20V

1F/2F/PA/PB
240-320A/ 12.5-19.0m/min 28-34V

3F/4F/PF/PD
3F: 180-200A/ 8.0-9.5m/min 22-25V 4F: 160-230A/ 6.5-11.0m/min/18-28V

* One-sided root pass on ceramic backing (round groove)

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FILARC welder guide book No.1

PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

ASME and EN Welding Positions

FILARC PZ 6125, 1.6mm , negative () polarity. Generally used for plate thickness of 20mm and higher. Also used with ceramic backing for plate thicknesses down to 16mm. With ceramic backing

1G /PA

2G /PC

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1G/PA

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2G/PC

Root*: 220-260A /4.0-5.0m/min 26-28V (spray arc) Fill : 220-380A /4.5-12.0m/min 27-36V

Root*: 200-240A /3.5-4.5m/min 24-26V (spray arc) Fill : 240-270A /4.5-5.5m/min 26-30V

3G / PF & PG

4G /PE

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Plate thickness 20mm 1F/PA Fill : 240-380A/4.5-12.0m/min 27-36V

5G / PF & PG-H-L000

6G / H-L045

1F/ PA
2F/PB Fill : 240-320A/4.5-8.0m/min 30-35V

2F/ PB

3F / PF & PG

4F / PD

* One-sided root pass on ceramic backing (round groove)

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PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Welding advice
Following pages provide advice on welding techniques for typical applications, followed by troubleshooting for typical faults. Welding characteristics FILARC PZ 6125 has distinctive, but not difficult welding characteristics. These differ from conventional basic cored wires, by way of: Higher arc voltage with smoother droplet transfer. Semi-spray arc operation aids positional work. Greater tolerance for arc voltage/welding current setting. Warmer, more fluid weldpool for higher penetration. Flatter weld beads. Less risk of fusion faults and slag traps. Less slag. Grinding requirements considerably reduced. Figure A Correct backhand welding (trailing) with torch at 70-90. direction of travel 70-90

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These impressive advantages, including welder comfort, will bring improved results when the welding guidelines are correctly followed. Some training is obviously needed to gain familiarity with the welding characteristics of the PZ 6125, also to avoid using methods associated with rutile cored wires, or conventional basic types where colder weld pools and short arc dip transfer lead to less favourable weldability. Positive penetration To ensure positive penetration, and so avoid the most common cause of weld defects: Always try to weld backhand This ensures good penetration and prevents slag running ahead of the weldpool. See figure A. Forehand welding can deliver a reasonable appearance, but penetration is often poor, due to the slag running ahead of the weldpool. There is also the chance of overflowing the weldpool, causing slag traps and lack of fusion, see figure B. Correct torch angle is 70-90 as shown figure A. At lower angles, see figure C, insufficient penetration and lack of fusion can be expected. direction of travel

direction of travel

Figure B Forehand welding (pushing). Risk of insufficient penetration, lack of fusion and slag traps.

Figure C Backhand welding with too small a torch angle, causing insufficient penetration and lack of fusion.
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PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Torch positions for positional welding

PZ 6125 and related types are well suited for all-position welding. Following are typical situations where correct torch positioning plays an important role in avoiding weld defects. 2G/PC Torch position depends on plate thickness and bevel angle of the joint. If the torch positions shown cannot be used, it is recommended that the bevel angle is enlarged. Always maintain the torch angle of 70-90 relative to the weld bead and direction of travel as advised on page 17. Maintain a steady travel speed to achieve a regular bead thickness, without sagging. See page 22 for guidance on weaving. A. Root pass. Without backing: grind opposite side. With backing: use round ceramic. Avoid overthick bead.

C. Third layer builds up weld thickness.

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D. Fourth layer creates favourable angle for following pass.

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E. Fifth layer. Note how layers are always built up from bottom side of joint as weld thickness increases.

Avoid sagging Slag traps and fusion faults arise from sagging (rollover), typically caused by: B. Second layer, using flatter bead. Wrong travel speed. Incorrect torch angle. Too high welding current. Wrong weld bead sequence.

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Sagging requires grinding to eliminate weld defects. This can be avoided by keeping weld beads as flat as possible as shown by the diagrams, so reducing repair rates and unproductive grinding.

wrong

right

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Weaving advice is given on page 22.

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PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Torch positions, continued

3G/3F/PF Note the torch positions shown below for root run and filling layers. Joint bevelling must allow good access to the root area. If necessary use a narrower gas cup. ceramic backing

4G/PE Use basic electrode or TIG-welding for root pass. Use FILARC PZ 6125 and related types for filling. Figures A and B give ideal torch positioning. A B

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10

90 80-90

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2F/PB Figures A and B show the ideal torch positioning, using the backhand method recommended. A B

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A. Root pass

70 - 90

Trouble shooting Figures C and D show possible undercut and sagging faults, and possible causes. C 10 D

B. Filling layers C Undercut: Welding current too high. Arc voltage too high. Travel speed too high. Arc too close to vertical plane. Torch angle () too small. D Sagging: Welding current too high. Arc voltage too high. Torch angle () too big. Layer too thick.

Weaving advice is given on page 22.

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PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Weaving technique
Use of correct weaving, in conjunction with the torch positions described on previous pages, will avoid weld defects and reduce grinding requirements. 1G/PA Position Restrict weaving width; try to weld stringer beads as far as possible. For K joints, shown, restricted weaving and correct torch position are important. The arc must point into the corner between plate material and weld as illustrated below. A. Correct Apply stringer beads as far as possible. Correct torch position. Weave as little as possible. Backhand welding.

3G/PF Position Correct weaving technique is very important when welding PZ 6125 in the 3G position. Incorrect weaving can lead to weld defects. Apply a little weaving; stop at the plate edges for approx. 2 seconds to allow weld metal to solidify. Always ensure satisfactory side plate wetting, as shown figure A. A. Correct Weave width 1.5-2.0cm. Use an upward triangle towards the joint centre. Remain approximately 2 seconds at the plate edges. Assure good side plate wetting.

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B. Incorrect Excessive weaving. Wrong torch position. Forehand welding.

B. Incorrect Weave width correct but wrong technique. Downward triangle causes convex weld with risk of slag traps and fusion faults.

2G/PC Position A. Correct Torch pointed onto plate. Correct weaving width. Good wetting onto plate edges and weld. C. Incorrect Insufficient weaving, giving a convex weld, slag traps and fusion faults.

B. Incorrect Torch not pointed onto plate. Excessive weaving.

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PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Grinding
Grinding requirements for PZ 6125 welds are not excessive when the recommended welding techniques are applied. Avoid overgrinding, this can cause defects. Also do not create sharp edges, leading to slag traps and lack of fusion when filling. Remove only the most obvious irregularities, like sagging, starts, stops and undercut, always leaving smooth bead contours.

Sealing runs Grind before welding, as shown figure D, to create a smooth, slightly concave groove, giving easy access for the welding torch. D Correct.

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A Correct. B Incorrect.

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E Incorrect. Grinding wheel pushed into root, bringing deep groove. The narrow joint is almost inaccessible to the torch.

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C Always grind starts and stops.

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PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Trouble shooting/process faults

Although good equipment maintenance and proper welder training will help preventing process faults and weld defects, they can never be avoided completely. In such cases, understanding of the most common causes will lead the welder to quickly solving the problem encountered. Listed below are the most common process faults and their likely causes. For faults that result from incorrect setting or wrong welding techniques, we refer to previous chapters where correct handling of FILARC PZ 6125 and related types is described in detail. Weld defects and their origins are discussed on next pages. Process faults 1. wire stubbing 2. wire burn-back Likely causes - parameter settings wire reel brake too tight parameter settings damaged/worn contact tip burn-back time too long

Trouble shooting/weld defects

Lack of fusion defects. There are several types of lack of fusion defects, but all share the same feature that weld metal and parent metal have not fused at one or more places. Below, typical forms of lack of fusion are shown in a V-butt weld. They can equally occur in other butt-weld types. Also shown is a typical defect in fillet welds, where the weld metal fails to fuse with, normally, the standing leg.

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cold lap lack of interrun fusion lack of side wall fusion lack of root fusion

3. spatter

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- parameter settings - wrong shielding gas/gas flow rate too high, too low or irregular - irregular wire feed - worn contact tip - paint, rust or dirt in joint area

lack of fusion

4. irregular wire feed/ - roll pressure too low unstable arc/wire jam - damaged/worn contact tip - wrong contact tip size - overheated contact tip - damaged/worn/bent liner - dirty or rusty wire/wire kinks - misalignment of rolls and guide tubes/worn rolls - wire reel brake too tight - wire crossed on reel (brake too loose) - irregular gas flow

Possible causes General travel speed too high wrong parameter setting forehand welding Lack of root fusion root gap too small

Remedies - reduce travel speed/allow more dwell time at edges - adjust parameters - backhand welding, 70-90 torch angle - enlarge gap

Fillet: lack of fusion at standing leg torch too much pointed at - change torch orientation horizontal leg

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PZ6125 basic flux-cored wire and related types for high tensile and creep resistant steels

Lack of weld penetration Lack of penetration occurs when the weld metal fails to extend into the complete root of a joint. Shown below are three typical cases.

Porosity. Possible causes draught /wind paint, grease or dirt in the weld area gas cup clogged gas cup distorted gas cup too small or too big gas flow too high or too low gas leaks in system aspirate air

Remedies - close doors or windows/ place wind screens - clean plates - clean/replace - replace - replace with one suiting the joint geometry - adjust flow rate

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Examples of lack of root penetration

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Possible causes General welding current too low arc voltage too high travel speed too high travel speed too low forehand welding torch angle too small Remedies increase wire feed/arc voltage reduce arc voltage reduce travel speed increase travel speed; avoid slag running ahead of weld pool - backhand welding - use 70-90 torch angle; aim the arc at the leading edge of the pool - increase gap/reduce face - increase angle

- check by blocking gas cup; continued gas flow indicates leaks water leaks in cooled guns - check connections gas cup to workpiece - check positioning of contact tip distance too long relative to gas cup; readjust parameters Undercutting

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Butt welds root gap too small/ face too big joint included angle

Slag inclusions Slag inclusions occur when molten slag is not allowed to escape to the surface of the weld pool, when the weld pool overrides slag running ahead of it, or when slag remainders at the toe of beads are not sufficiently remolten. Possible causes welding current too low travel speed too low forehand welding torch angle too small convex beads too much weaving Remedies - increase wire feed/arc voltage - increase travel speed; avoid slag running ahead of weld pool - backhand welding - use 70-90 torch angle; keep slag behind arc - increase arc voltage - reduce travel speed; when possible use split-weave technique, otherwise reduce weaving width. Avoid thick layers.

Undercutting is generally caused by an excessive welding current or arc voltage, or may be the result of a too high travel speed. To avoid this, lower wire feed speed and/or travel speed until satisfactory bead appearance is obtained. If undercutting appears at one leg of a fillet weld, the torch position may be wrong; try increasing the angle between torch and opposite leg.

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FILARC Welding Industries B.V. P.O. Box 8086 NL-3503 RB Utrecht The Netherlands
Tel : + 31 30 248 59 11 Fax : + 31 30 241 15 35

FILARC Welding Sales Organisations

Belgium & Luxembourg S.A. Esab N.V. Avenue Jules Bordetlaan 15 B-1140 Brussels Tel : +32 2 726 84 00 Fax : +32 2 726 80 05 Czech Republic ESAB VAMBERK a.s. Smetanovo nbr ez 334 517 54 Vamberk Tel : +42 445 50 11 11 Fax : +45 445 50 14 64 Denmark V. Lwener Smedeland 2, P.O. Box 1330 DK-2600 Glostrup Tel : +45 43 20 03 00 Fax : +45 43 43 03 59 Finland FILARC Hitsaustuotteet Yliopistonkatu 37C SF-20100 Turku Tel : +358 2 251 3880 Fax : +358 2 251 3940 France Esab France S.A. Rue du Petit Albi ZAC du Moulin Vent Batiment D, Porte 402 F-95800 Cergy St. Christophe Tel : 33 1 30 75 55 00 Fax : 33 1 30 75 55 25 Germany Esab GmbH Beethovenstrasse 135 Postfach 100763 D-42648 Solingen Tel : +49 212 298 0 Fax : +49 212 298 415 Great Britain Esab Group (UK) Ltd Hertford Road, Waltham Cross Hertfordshire EN8 7RP Tel : +44 1992 76 85 15 Fax : +44 1992 71 58 03 Italy Esab Saldatura SpA Via E Mattei 24, I-20010 Mesero (MI) Tel : +39 297 96 81 Fax : +39 297 289 300 The Netherlands FILARC Lastechniek B.V. Kernkade 8, P.O. Box 8035 NL-3503 RA Utrecht Tel : +31 30 248 59 11 Fax : +31 30 241 15 34 Norway AS Esab Frankendalsvn 97, P.O.Box 2050 N-3255 Larvik Tel : + 47 331 210 00 Fax : + 47 331 152 03 Poland Esab Sp. z o.o. ul. St. Augusta 75, lok. 47 03-846 Warszawa Tel : + 48 22 612 59 61 Fax : + 48 22 612 59 57 Portugal Esab LdA Av. Infante D.Henrique Lote 332 - 2 Esq. P-1800 Lisbon Tel : +35 118 371 527 Fax : +35 118 591 277 Slovakia Esab Slovakia s.r.o. Rybnicn 40 835 54 Bratislava - Vajnory Tel : + 42 728 87 41 Fax : + 42 728 87 41 Spain Esab Ibrica SA Calle Aragoneses, 17 E-28100 Alcobendas (Madrid) Z.I. de Alcobendas Tel : +34 1 661 55 80 Fax : +34 1 661 71 36 Sweden Esab Sverige AB Marknad Tillsatsmaterial Herkulesgatan 72 P.O. Box 8004 S-402 77 Gteborg Tel : +46 31 50 95 00 Fax : +46 31 50 92 22 Switzerland Hulftegger & AG Bahnhofstrasse 52 CH-8712 Stfa Tel : +41 1 928 81 11 Fax : +41 1 926 67 55 For countries not listed here: FILARC Lastechniek B.V. International Division Utrecht, The Netherlands

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