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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
BASIC
WELDING FILLER METAL
TECHNOLOGY
Go T
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A Correspondence Course
Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
LESSON I
THE BASICS OF ARC WELDING
!
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
An Introduction to Metals
! Electricity for Welding
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ESAB
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON I
THE BASICS OF ARC WELDING
Lesson 2
Common Electric
Arc Welding
Processes
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
PART A.
Section Nr.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
AN INTRODUCTION TO METALS
Section Title
Page
1.1
1.1.1
1.1.2
1.1.3
1.1.4
Semi-Killed Steel...............................................................................
1.1.5
1.2
Classification of Steels...................................................................
1.2.1
1.2.2
1.2.3
1.3
Specifications .................................................................................
1.4
1.4.1
1.5
1.5.1
Preheat .............................................................................................
1.5.2
1.5.3
Hardening .........................................................................................
1.5.4
Tempering .........................................................................................
1.5.5
Annealing ..........................................................................................
1.5.6
Normalizing .......................................................................................
10
1.5.7
10
1.6
Properties of Metals........................................................................
10
1.6.1
10
1.6.2
Yield Strength....................................................................................
11
1.6.3
11
1.6.4
11
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
Glo
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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
TABLE OF CONTENTS
LESSON I - Con't.
Section Nr.
Lesson 10
Reliability of Welding
Filler Metals
Section Title
Page
1.6.5
1.6.6
11
1.6.7
12
1.6.8
Creep Strength..................................................................................
13
1.6.9
13
1.6.10
13
1.6.11
14
1.6.12
14
11
1.7
14
1.7.1
Carbon ..............................................................................................
14
1.7.2
Sulphur .............................................................................................
14
1.7.3
Manganese .......................................................................................
15
1.7.4
Chromium .........................................................................................
15
1.7.5
Nickel ................................................................................................
15
1.7.6
Molybdenum .....................................................................................
15
1.7.7
Silicon ...............................................................................................
15
1.7.8
Phosphorus.......................................................................................
15
1.7.9
Aluminum ..........................................................................................
15
1.7.10
Copper ..............................................................................................
15
1.7.11
Columbium........................................................................................
16
1.7.12
Tungsten ...........................................................................................
16
1.7.13
Vanadium ..........................................................................................
16
1.7.14
Nitrogen ............................................................................................
16
1.7.15
16
PART B.
Section Nr.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
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Section Title
Page
1.8
17
1.8.1
17
1.8.2
18
1.8.3
19
1.8.4
20
Go T
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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Cu
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Tab
Con
TABLE OF CONTENTS
LESSON I - Con't.
Section Nr.
Section Title
Page
1.8.5
Transformers ....................................................................................
22
1.8.6
24
1.8.7
Rectifying AC to DC ..........................................................................
25
1.9
26
1.9.1
26
1.9.2
26
1.9.3
27
1.9.4
28
Appendix A
29
Go T
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Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
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Lesson 8
Hardsurfacing
Electrodes
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Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
AN INTRODUCTION TO METALS
Lesson 2
Common Electric
Arc Welding
Processes
1.1
Metals come from natural deposits of ore in the earths crust. Most ores are contaminated
with impurities that must be removed by mechanical and chemical means. Metal extracted
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
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from the purified ore is known as primary or virgin metal, and metal that comes from scrap
is called secondary metal. Most mining of metal bearing ores is done by either open pit or
underground methods. The two methods of mining employed are known as selective in
which small veins or beds of high grade ore are worked, and bulk in which large quantities
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
There are two types of ores, ferrous and nonferrous. The term ferrous comes
from the Latin word ferrum meaning iron, and a ferrous metal is one that has a high iron
content. Nonferrous metals, such as copper and aluminum, are those that contain little or
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
no iron. There is approximately 20 times the tonnage of iron in the earths crust compared
to all other nonferrous products combined; therefore, it is the most important and widely
used metal.
1.1.0.2
during the welding operation and an understanding of welding metallurgy can be gained by
imagining the welding arc as a miniature steel mill.
1.1.0.4
The largest percentage of commercially produced iron comes from the blast
furnace process. A typical blast furnace is a circular shaft approximately 90 to 100 feet in
Lesson 8
Hardsurfacing
Electrodes
height with an internal diameter of approximately 28 feet. The steel shell of the furnace is
The iron blast furnace utilizes the chemical reaction between a solid fuel charge
and the resulting rising column of gas in the furnace. The three different materials used for
the charge are ore, flux and coke. The ore consists of iron oxide about four inches in
diameter. The flux is limestone that decomposes into calcium oxide and carbon dioxide.
The lime reacts with impurities in the ore and floats them to the surface in the form of a
slag. Coke, which is primarily carbon, is the ideal fuel for blast furnaces because it
Lesson 10
Reliability of Welding
Filler Metals
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Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
next most widely used metal. Commercial aluminum ore, known as bauxite, is a residual
1.1.0.3
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Aluminum, because of its attractive appearance, light weight and strength, is the
produces carbon monoxide gas, the main agent for reducing iron ore into iron metal.
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Lesson 1
The Basics of Arc
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LESSON I, PART A
1.1.0.6
The basic operation of the blast furnace is to reduce iron oxide to iron metal and
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to remove impurities from the metal. Reduced elements pass into the iron and oxidized
Lesson 2
Common Electric
Arc Welding
Processes
elements dissolve into the slag. The metal that comes from the blast furnace is called pig
iron and is used as a starting material for further purification processes.
1.1.0.7
Pig iron contains excessive amounts of elements that must be reduced before
steel can be produced. Different types of furnaces, most notably the open hearth, electric
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
and basic oxygen, are used to continue this refining process. Each furnace performs the
task of removing or reducing elements such as carbon, silicon, phosphorus, sulfur and
nitrogen by saturating the molten metal with oxygen and slag forming ingredients. The
oxygen reduces elements by forming gases that are blown away and the slag attracts
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Depending upon the type of slag that is used, refining furnaces are classed as
either acid or basic. Large amounts of lime are contained in basic slags and high quantities
of silica are present in acid slags. This differential between acid and basic slags is also
Lesson 5
Welding Filler Metals
for Stainless Steels
present in welding electrodes for much of the same refining process occurs in the welding
operation.
1.1.0.9
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
After passing through the refining furnace, the metal is poured into cast iron ingot
Turn
molds. The ingot produced is a rather large square column of steel. At this point, the metal
is saturated with oxygen. To avoid the formation of large gas pockets in the cast metal, a
substantial portion of the oxygen must be removed. This process is known as deoxidation,
and it is accomplished through additives that tie up the oxygen either through gases or in
slag. There are various degrees of oxidation, and the common ingots resulting from each
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
are as follows:
1.1.1
Rimmed Steel - The making of rimmed steels involves the least deoxidation. As
the ingots solidify, a layer of nearly pure iron is formed on the walls and bottom of the mold,
and practically all the carbon, phosphorus, and sulfur segregate to the central core. The
Lesson 8
Hardsurfacing
Electrodes
oxygen forms carbon monoxide gas and it is trapped in the solidifying metal as blow holes
that disappear in the hot rolling process. The chief advantage of rimmed steel is the excellent defect-free surface that can be produced with the aide of the pure iron skin. Most
rimmed steels are low carbon steels containing less than .1% carbon.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
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1.1.2
Capped Steel - Capped steel regulates the amount of oxygen in the molten
metal through the use of a heavy cap that is locked on top of the mold after the metal is
allowed to reach a slight level of rimming. Capped steels contain a more uniform core
composition than the rimmed steels. Capped steels are, therefore, used in applications
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
that require excellent surfaces, a more homogenous composition, and better mechanical
Cu
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Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
1.1.3
Killed Steel - Unlike rimmed or capped steel, killed steel is made by completely
removing or tying up the oxygen before the ingot solidifies to prevent the rimming action.
This removal is accomplished by adding a ferro-silicon alloy that combines with oxygen to
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Lesson 3
Covered Electrodes
for Welding
Mild Steels
1.1.4
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
1.1.5
Glo
oxygen from the molten steel without adding an element that forms nonmetallic inclusions.
This is done by increasing the carbon content of the steel and then subjecting the molten
metal to vacuum pouring or steam degassing. The carbon reacts with the oxygen to form
Lesson 5
Welding Filler Metals
for Stainless Steels
carbon monoxide, and as a result, the carbon and oxygen levels fall within specified limits.
Because no deoxidizing elements that form solid oxides are used, the steel produced by
this process is quite clean.
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
1.2
CLASSIFICATIONS OF STEEL
The three commonly used classifications for steel are: carbon, low alloy, and high alloy.
These are referred to as the type of steel.
1.2.1
Carbon Steel - Steel is basically an alloy of iron and carbon, and it attains its
strength and hardness levels primarily through the addition of carbon. Carbon steels are
classed into four groups, depending on their carbon levels.
Low Carbon
Mild Carbon Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Up to 0.15% carbon
.15% to 0.29% carbon
The largest tonnage of steel produced falls into the low and mild carbon steel
groups. They are popular because of their relative strength and ease with which they can
be welded.
1.2.2
Lesson 10
Reliability of Welding
Filler Metals
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Low Alloy Steel - Low alloy steel, as the name implies, contains small amounts
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
elements are added to improve strength and toughness, to decrease or increase the
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response to heat treatment, and to retard rusting and corrosion. Low alloy steel is gener-
Lesson 2
Common Electric
Arc Welding
Processes
ally defined as having a 1.5% to 5% total alloy content. Common alloying elements are
manganese, silicon, chromium, nickel, molybdenum, and vanadium. Low alloy steels may
contain as many as four or five of these alloys in varying amounts.
1.2.2.1
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
structural steel. Since they have high strength-to-weight ratios, they reduce dead weight in
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Low alloy steels have higher tensile and yield strengths than mild steel or carbon
Ordinary carbon steels, that exhibit brittleness at low temperatures, are unreliable
in critical applications. Therefore, low alloy steels with nickel additions are often used for
Glo
Steels lose much of their strength at high temperatures. To provide for this loss
Lesson 5
Welding Filler Metals
for Stainless Steels
added.
1.2.3
High Alloy Steel - This group of expensive and specialized steels contain alloy
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
1.2.3.1
give it two exceptional qualities, the ability to harden while undergoing cold work and great
toughness. The term austenitic refers to the crystalline structure of these steels.
1.2.3.2
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Austenitic manganese steel contains high carbon and manganese levels, that
Stainless steels are high alloy steels that have the ability to resist corrosion. This
characteristic is mainly due to the high chromium content, i.e., 10% or greater. Nickel is
also used in substantial quantities in some stainless steels.
1.2.3.3
Tool steels are used for cutting and forming operations. They are high quality
steels used in making tools, punches, forming dies, extruding dies, forgings and so forth.
Lesson 8
Hardsurfacing
Electrodes
Depending upon their properties and usage, they are sometimes referred to as water
hardening, shock resisting, oil hardening, air hardening, and hot work tool steel.
1.2.3.4
Lesson 9
Estimating &
Comparing Weld
Metal Costs
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Because of the high levels of alloying elements, special care and practices are
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON I, PART A
1.3
SPECIFICATIONS
Many steel producers have developed steels that they market under a trade name such as
Cor-Ten, HY-80, T-1, NA-XTRA, or SS-100, but usually a type of steel is referred to by its
specification. A variety of technical, governmental and industrial associations issue
specifications for the purpose of classifying materials by their chemical composition,
properties or usage. The specification agencies most closely related to the steel industry
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Cu
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are the American Iron and Steel Institute (AISI), Society of Automotive Engineers (SAE),
American Society for Testing and Materials (ASTM), and the American Society of
Mechanical Engineers (ASME).
1.3.0.1
The American Iron and Steel Institute (AISI) and the Society of Automobile
Engineers (SAE) have collaborated in providing identical numerical designations for their
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specifications. The first two digits of a four digit index number refer to a series of steels
classified by their composition or alloy combination. While the last two digits, which can
change within the same series, give an approximate average of the carbon range. For
Lesson 5
Welding Filler Metals
for Stainless Steels
example, the first two digits of a type 1010 or 1020 steel indicate a 10 series that has
carbon as its main alloy. The last two digits indicate an approximate average content of
.10% or .20% carbon, respectively. Likewise, the 41 of a 4130 type steel refers to a group
that has chromium and molybdenum as their main alloy combination with approximately
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
The AISI classifications for certain alloys, such as stainless steel, are somewhat
different. They follow a three digit classification with the first digit designating the main
alloy composition or series. The last two digits will change within a series, but are of an
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
arbitrary nature being agreed upon by industry as a designation for certain compositions
within the series. For example, the 3 in a 300 series of stainless steel indicates chromium
and nickel as the main alloys, but a 308 stainless has a different overall composition than a
347 type. The 4 of a 400 series indicates the main alloy as chromium, but there are
Lesson 8
Hardsurfacing
Electrodes
different types such as 410, 420, 430, and so forth within the series.
1.3.0.3
The American Society for Testing and Materials (ASTM) is the largest
organization of its kind in the world. It has compiled some 48 volumes of standards for
materials, specifications, testing methods and recommended practices for a variety of
Lesson 9
Estimating &
Comparing Weld
Metal Costs
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Two ASTM designated steels commonly specified for construction are A36-77
and A242-79. The prefix letter indicates the class of a material. In this case, the letter A
indicates a ferrous metal, the class of widest interest in welding. The numbers 36 and 242
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
are index numbers. The 77 and 79 refer to the year that the standards for these steels
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Lesson 2
Common Electric
Arc Welding
Processes
1.3.0.5
The ASTM designation may be further subdivided into Grades or Classes. Since
many standards for ferrous metals are written to cover forms of steel (i.e., sheet, bar, plate,
etc.) or particular products fabricated from steel (i.e., steel rail, pipe, chain, etc.), the user
may select from a number of different types of steel under the same classification. The
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
different types are than placed under grades or classes as a way of indicating the
ASME Boiler and Pressure Vessel Code. The material specification as adopted by the
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ASME is identified with a prefix letter S, while the remainder is identical with ASTM with
the exception that the date of adoption or revision by ASTM is not shown. Therefore, a
common example of an ASME classification is SA 387 Grade 11, Class 1.
Lesson 5
Welding Filler Metals
for Stainless Steels
1.4
When a liquid metal is cooled, its atoms will assemble into a regular crystal pattern and we
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
say the liquid has solidified or crystallized. All metals solidify as a crystalline material. In a
crystal the atoms or molecules are held in a fixed position and are not free to move about
as are the molecules of a liquid or gas. This fixed position is called a crystal lattice. As the
temperature of a crystal is raised, more thermal energy is absorbed by the atoms or
molecules and their movement increases. As the distance
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
4000
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
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2000
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1000
SOLID
TIME
SOLID-LIQUID TRANSFORMATION, PURE IRON
Lesson 10
Reliability of Welding
Filler Metals
FIGURE 1
Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
1.4.0.1
Lesson 2
Common Electric
Arc Welding
Processes
Liquid
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
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Solid
1.4.0.2
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
TIME
FIGURE 2
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
form as the temperature is changed. This is known as phase transformation. For example,
pure iron solidifies at 2795F, the delta structure transforms into a structure referred to as
gamma iron. Gamma iron is commonly known as austenite and is a nonmagnetic
structure. At a temperature of 1670F., the pure iron structure transforms back to the delta
iron form, but at this temperature, the metal is known as alpha iron. These two phases are
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
given different names to differentiate between the high temperature phase (delta) and the
low temperature phase (alpha). The capability of the atoms of a material to transform into
two or more crystalline structures at different temperatures is defined as allotropic. Steels
and iron are allotropic metals.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
1.4.1
Grains and Grain Boundaries - As the metal is cooled to its freezing point, a
small group of atoms begin to assemble into crystalline form (refer to Figure 3). These
small crystals scattered throughout the body of the liquid are oriented in all directions and
as solidification continues, more crystals are formed from the surrounding liquid. Often,
Lesson 8
Hardsurfacing
Electrodes
they take the form of dendrites, or a treelike structure. As crystallization continues, the
crystals begin to touch one another, their free growth hampered, and the remaining liquid
freezes to the adjacent crystals until solidification is complete. The solid is now composed
of individual crystals that usually meet at different orientations. Where these crystals meet
Lesson 9
Estimating &
Comparing Weld
Metal Costs
A number of conditions influence the initial grain size. It is important to know that
cooling rate and temperature has an important influence on the newly solidified grain
structure and grain size. To illustrate differences in grain formation, let's look at the cooling
Lesson 10
Reliability of Welding
Filler Metals
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phases in a weld.
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LESSON I, PART A
Lesson 1
The Basics of Arc
Welding
GRAIN
BOUNDARIES
Lesson 2
Common Electric
Arc Welding
Processes
BASE
METAL
DENDRITE
FORMATION
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
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INITIAL
CRYSTAL FORMATION
COMPLETE
SOLIDIFICATION
Go T
FIGURE 3
1.4.1.3
Initial crystal formation begins at the coolest spot in the weld. That spot is at the
point where the molten metal and the unmelted base metal meet. As the metal continues
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
to solidify, you will note that the grains in the center are smaller and finer in texture than the
Glo
grains at the outer boundaries of the weld deposit. This is explained by the fact that as the
weld metal cools, the heat from the center of the weld deposit will dissipate into the base
metal through the outer grains that solidified first. Consequently, the grains that solidified
first were at high temperatures for a longer time while in the solid state and this is a
situation that encourages grain growth. Grain size can have an effect on the soundness of
the weld. The smaller grains are stronger and more ductile than the larger grains. If a
crack occurs, the tendency is for it to start in the area where the grains are largest.
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
1.4.1.4
To summarize this section, it should be understood that all metals are composed
of crystals of grains. The shape and characteristics of crystals are determined by the
arrangement of their atoms. The atomic pattern of a single element can change its
arrangement at different temperatures, and that this atomic pattern or microstructure
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
1.5
HEAT TREATMENT
The temperature that metal is heated, the length of time it is held at that temperature, and
Lesson 8
Hardsurfacing
Electrodes
the rate that it is cooled, all have an effect on a metal's crystalline structure. This crystalline
structure, commonly referred to as "microstructure," determines the specific properties of
metals. There are various ways of manipulating the microstructure, either at the steel mill
or in the welding procedure. Some of the more common ways are as follows:
Lesson 9
Estimating &
Comparing Weld
Metal Costs
1.5.1
Preheat - Most metals are rather good conductors of heat. As a result, the heat
in the weld area is rapidly dispersed through the whole weldment to all surfaces where it is
radiated to the atmosphere causing comparatively rapid cooling. In some metals, this rapid
cooling may contribute to the formation of microstructures in the weld zone that are detri-
Lesson 10
Reliability of Welding
Filler Metals
Se
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mental. Preheating the weldment before it is welded is a method of slowing the cooling
Se
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
rate of the metal. The preheat temperature may vary from 150F to 1000F, but more
Cu
Ch
Tab
Con
commonly it is held in the 300F to 400F range. The thicker the weld metal, the more
Lesson 2
Common Electric
Arc Welding
Processes
likely will it be necessary to preheat, because the heat will be conducted away from the
weld zone more rapidly as the mass increases.
1.5.2
Stress Relieving - Metals expand when heated and contract when cooled. The
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
the metal closest to the weld is subjected to the highest temperature, and as the distance
from the weld zone increases, the maximum temperature reached decreases. This nonuni-
form heating causes nonuniform expansion and contraction and can cause distortion and
internal stresses within the weldment. Depending on its composition and usage, the metal
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
may not be able to resist these stresses and cracking or early failure of the part may occur.
Lesson 5
Welding Filler Metals
for Stainless Steels
1.5.3
after it has been welded. The metal is heated to temperatures just below the point where a
microstructure change would occur and then it is cooled at a slow rate.
Hardening - The hardness of steel may be increased by heating it to 50F to
100F above the temperature that a microstructure change occurs, and then placing the
metal in a liquid solution that rapidly cools it. This rapid cooling, known as "quenching,"
locks in place microstructures known as "martensite" that contribute to a metal's hardness
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Glo
One way to minimize these stresses or to relieve them is by uniformly heating the structure
Turn
characteristic. The quenching solutions used in this process are rated according to the
speed that they cool the metal, i.e., Oil (fast), Water (faster), Salt Brine (fastest).
1.5.4
a process where the metal is reheated to somewhere below 1335F, held at that tempera-
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
ture for a length of time, and then cooled to room temperature. Tempering reduces the
brittleness that is characteristic in hardened steels, thereby producing a good balance
between high strength and toughness. The term toughness, as it applies to metals, usually
refers to resistance to brittle fracture or notch toughness under certain environmental
conditions. More information on these properties will be covered later in this lesson and in
Lesson 8
Hardsurfacing
Electrodes
subsequent lessons. Steels that respond to this type of treatment are known as "quenched
and tempered steels."
1.5.5
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Se
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above where a microstructure change occurs, held at that temperature for a sufficient time
for a uniform change to take place, and then cooled at a very slow rate, usually in a furnace. The principal reason for annealing is to soften steel and create a uniform fine grain
structure. Welded parts are seldom annealed for the high temperatures would cause
distortion.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
1.5.6
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
where the microstructure transforms and then cooled in still air rather than in a furnace.
1.5.7
Heat Treatment Trade-Off - It must be noted that these various ways of control-
ling the heating and cooling of metals can produce a desired property, but sometimes at the
Go T
expense of another desirable property. An example of this trade-off is evident in the fact
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
that certain heat treatments can increase the strength or hardness of metal, but the same
treatments will also make the metal less ductile or more brittle, and therefore, susceptible
to welding problems.
1.6
PROPERTIES OF METALS
Glo
The usefulness of a particular metal is determined by the climate and conditions in which it
will be used. A metal that is stamped into an automobile fender must be softer and more
pliable than armor plate that must withstand an explosive force, or the material used for an
Lesson 5
Welding Filler Metals
for Stainless Steels
oil rig on the Alaska North Slope must perform in a quite different climate than a steam
boiler. It becomes obvious that before a material is recommended for a specific use, the
physical and mechanical properties of that metal and the weld metal designed to join it
Turn
must be evaluated. Some of the more important properties of metals and the means of
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
machined to exact standard dimensions and clamped into the testing apparatus at both
ends. The specimen is then
RECORDING
DIAL
Lesson 8
Hardsurfacing
Electrodes
TEST
SPECIMEN
1.6.1.2
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Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
FORCE
Se
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FIGURE 4
Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
1.6.2
Cu
Ch
Tab
Con
rubberband. When a load of limited magnitude is applied, the metal stretches, and when
Lesson 2
Common Electric
Arc Welding
Processes
the load is released, the metal returns to its original shape. This is the elastic characteristic
of metal and is represented by letter A in Figure 5. As a greater load is applied, the metal
will reach a point where it will no longer return to its original shape but will continue to
stretch. Yield strength is the point where the metal reaches the limit of its elastic character-
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
Ultimate Tensile Strength - Once a metal has exceeded its yield point, it will
continue to stretch or deform, and if the load is suddenly released, the metal will not return
to its original shape, but will remain in its elongated form. This is called the plastic region of
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
the metal and is represented by the letter B in Figure 5. As this plastic deformation inagainst further elongation, and
Ultimate Strength
Reduction
of Area
Elongation
Lesson 5
Welding Filler Metals
for Stainless Steels
Yield Strength
Fracture
STRAIN - INCHES
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Glo
FIGURE 5
Turn
withstood or resisted the maximum applied load is its ultimate tensile strength. This information is usually recorded in pounds per square inch (psi).
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
1.6.4
tester, two marks at a measured distance are placed on the opposing ends of the circular
shaft. After the specimen is fractured, the distance between the marks is measured and
recorded as a percentage of the original distance. See Figure 5. This is the percentage of
Lesson 8
Hardsurfacing
Electrodes
elongation and it gives an indication of the ductility of the metal at room temperature.
1.6.5
area of its midpoint cross-section is a known figure. As the specimen is loaded to the point
Lesson 9
Estimating &
Comparing Weld
Metal Costs
of fracture, the area where it breaks is reduced in size. See Figure 5. This reduced area is
calculated and recorded as a percentage of the original cross-sectional area. This information reflects the relative ductility or brittleness of the metal.
1.6.6
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Charpy Impacts - Metal that is normally strong and ductile at room temperature
may become very brittle at much lower temperatures, and thus, is susceptible to fracture if
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
Se
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
a sharp abrupt load is applied to it. An impact tester measures the degree of susceptibility
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
1.6.6.1
notched on one side. Quite often, the notch is in the form of a "V" and the test in this case
is referred to as a Charpy V-Notch Impact Test. The specimen is cooled to a
predetermined temperature and then placed in a stationary clamp at the base of the testing
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
ENERGY
IN FT/LBS
FRACTURES
Lesson 5
Welding Filler Metals
for Stainless Steels
CRACKS
DEFORMS
CHARPY V-NOTCH
SPECIMEN
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
FIGURE 6
1.6.6.2
The hammer is released from a fixed height and the energy required to fracture
the specimen is recorded in ft-lbs. A specimen that is cooled to -60F and absorbs 40 ft-lbs
of energy is more ductile, and therefore, more suitable for low temperature service than a
specimen that withstands only 10 ft-lbs at the same temperature. The specimen that
Lesson 8
Hardsurfacing
Electrodes
1.6.7
Fatigue Strength - A metal will withstand a load less than its ultimate tensile
strength but may break if that load is removed and then reapplied several times. For ex-
Lesson 9
Estimating &
Comparing Weld
Metal Costs
ample, if a thin wire is bent once, but if it is bent back and forth repeatedly, it will eventually
fracture and it is said to have exceeded its fatigue strength. A common test for this
strength is to place a specimen in a machine that repeatedly applies the same load first in
tension and then in compression. The fatigue strength is calculated from the number of
cycles the metal withstands before the point of failure is reached.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
Se
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Se
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
1.6.8
Cu
Ch
Tab
Con
temperature (72F), it will cause some initial elongation, but there will be no further measur-
Lesson 2
Common Electric
Arc Welding
Processes
able elongation if the load is kept at a constant level. If that same load were applied to a
metal heated to a high temperature, the situation would change. Although the load is held
at a constant level, the metal will gradually continue to elongate. This characteristic is
called creep. Eventually, the material may rupture depending on the temperature of the
Lesson 3
Covered Electrodes
for Welding
Mild Steels
metal, the degree of load applied and the length of time that it is applied. All three of these
Go T
factors determine a metal's ability to resist creep, and therefore, its creep strength.
P
1.6.9
Oxidation Resistance - The atoms of metal have a tendency to unite with oxy-
gen in the air to form oxide compounds, the most visible being rust and scale. In some
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
metals, these oxides will adhere very tightly to the skin of the metal and effectively seal it
Glo
from further oxidation as is evident in stainless steel. These materials have high oxidation
resistance. In other metals, the bond is very loose, creating a situation where the oxides
will flake off, and the metal gradually deteriorates as the time of exposure is extended.
Lesson 5
Welding Filler Metals
for Stainless Steels
1.6.10
hardness and an indication of the materials's strength. To test for hardness, a fixed load
forces an indenter into the test material (Figure 7). The depth of the penetration or the size
of the impression is measured. The measurement is converted into a hardness number
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Vickers, Knoop and Rockwell. The Rockwell is further divided into different scales, and
HARDNESS TEST
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
SHAPE OF INDENTER
A
C
D
B
}
}
Diamond
Cone
1/16 in. Diameter
Steel Sphere
1/8 in. Diameter
Steel Sphere
10 mm Sphere of Steel
or Tungsten Carbide
BRINNELL
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
INDENTER DESCRIPTION
ROCKWELL
F
G
Lesson 8
Hardsurfacing
Electrodes
Turn
through the use of a variety of established tables. The most common tables are the Brinell,
VICKERS
Diamond Pyramid
KNOOP
Diamond Pyramid
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
depending on the material being tested, the shape of the indenter and the load applied, the
Cu
Ch
Tab
Con
conversion tables may differ. For example, a material listed as having a hardness of Rb or
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Rc means its hardness has been determined from the Rockwell "B" scale or the Rockwell
"C" scale.
1.6.11
Coefficient of Expansion - All metals expand when heated and contract when
cooled. This dimensional change is related to the crystalline structure and will vary with
Go T
different materials. The different expansion and contraction rates are expressed numerically by a coefficient of thermal expansion. When two different metals are heated to the
same temperature and cooled at the same rate, the one with the higher numerical coefficient will expand and contract more than the one with the lesser coefficient.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
1.6.12
Thermal Conductivity - Some metals will absorb and transmit heat more readily
Glo
than others. They are categorized as having high thermal conductivity. This characteristic
contributes to the fact that some metals will melt or undergo transformations at much lower
temperatures than others.
Lesson 5
Welding Filler Metals
for Stainless Steels
1.7
Alloying is the process of adding a metal or a nonmetal to pure metals such as copper,
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
aluminum or iron. From the time it was discovered that the properties of pure metals could
be improved by adding other elements, alloy steel has increased by popularity. In fact,
metals that are welded are rarely in their pure state. The major properties that can be
improved by adding small amounts of alloying elements are hardness, tensile strength,
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
ductility and corrosion resistance. Common alloying elements and their effect on the
properties of metals are as follows:
1.7.1
Carbon - Carbon is the most effective, most widely used and lowest in cost
alloying element available for increasing the hardness and strength of metal. An alloy
Lesson 8
Hardsurfacing
Electrodes
containing up to 1.7% carbon in combination with iron is known as steel, whereas the
combination above 1.7% carbon is known as cast iron. Although carbon is a desirable
alloying element, high levels of it can cause problems; therefore, special care is required
when welding high carbon steels and cast iron.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Se
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1.7.2
brittleness. It may be deliberately added to improve the machinability of the steel. The
sulphur causes the
machine chips to break rather than form long curls and clog the machine. Normally, every
effort is made to reduce the sulphur content to the lowest possible level because it can
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
Se
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
Lesson 2
Common Electric
Arc Welding
Processes
1.7.3
Lesson 3
Covered Electrodes
for Welding
Mild Steels
1.7.4
Cu
Ch
Tab
Con
steels as a deoxidizer and desulphurizer. That is to say, it readily combines with oxygen
and sulphur to help negate the undesirable effect these elements have when in their natural state. Manganese also increases the tensile strength and hardenability of steel.
Go T
Chromium - Chromium, in combination with carbon, is a powerful hardening
resistance and the strength of steel at high temperatures. Chromium is the primary alloying
element in stainless steel.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
1.7.5
Nickel - The greatest single property of steel that is improved by the presence of
Glo
nickel is its ductility or notch toughness. In this respect, it is the most effective of all alloying elements in improving a steel's resistance to impact at low temperatures. Electrodes
with high nickel content are used to weld cast iron materials. Nickel is also used in combi-
Lesson 5
Welding Filler Metals
for Stainless Steels
characteristic of steel. It is quite often used in combination with chromium to improve the
strength of the steel at high temperatures. This group of steels is usually referred to as
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
chrome-moly steels.
1.7.7
strength to steel but excessive amounts can reduce the ductility. Additional amounts of
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
silicon are sometimes added to welding electrodes to increase the fluid flow of weld metal.
1.7.8
because it greatly reduces ductility and toughness. Efforts are made to reduce it to its very
lowest levels; however, phosphorus is added in very small amounts to some steels to
Lesson 8
Hardsurfacing
Electrodes
increase strength.
1.7.9
Lesson 9
Estimating &
Comparing Weld
Metal Costs
1.7.10
Se
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by retarding the rate of rusting at room temperature, but high levels of copper can cause
welding difficulties.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
Se
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART A
1.7.11
Cu
Ch
Tab
Con
lizer. Since the carbon in the stainless steel decreases the corrosion resistance, a means
Lesson 2
Common Electric
Arc Welding
Processes
of making carbon ineffective must be found. Columbium has a greater affinity for carbon
than chromium, leaving the chromium free for corrosion protection.
1.7.12
Tungsten also joins with carbon to form carbides that are exceptionally hard, and therefore
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
Vanadium - Vanadium helps keep steel in the desirable fine grain condition after
heat treatment. It also helps increase the depth of hardening and resists softening of the
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
1.7.14
Nitrogen - Usually, efforts are made to eliminate hydrogen, oxygen and nitrogen
from steel because their presence can cause brittleness. Nitrogen has the ability to form
austenitic structures; therefore, it is sometimes added to austenitic stainless steel to reduce
Lesson 5
Welding Filler Metals
for Stainless Steels
the amount of nickel needed, and therefore, the production costs of that steel.
1.7.15
elements to a pure metal may influence the crystalline form of the resultant alloy. If a pure
metal has allotropic characteristics (the ability of a metal to change its crystal structure) at a
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
specific temperature, then that characteristic will occur over a range of temperatures with
the alloyed metal. The range in which the change takes place may be wide or narrow,
depending on the alloys and the quantities in which they are added. The alloying element
may also effect the crystalline changes by either suppressing the appearance of certain
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
crystalline forms or even by creating entirely new forms. All these transformations induced
by alloying elements are dependent on heat input and cooling rates. These factors are
closely controlled at the steel mill, but since the welding operation involves a nonuniform
heating and cooling of metal, special care is often needed in the welding of low and high
alloy steel.
Lesson 8
Hardsurfacing
Electrodes
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Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON I, PART B
1.8
1.8.1
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
Ch
Tab
Con
Go T
solid state. All arc welding utilizes the transfer of electrical energy to heat energy, and to
understand this principle, a basic knowledge of electricity and welding power sources is
necessary.
1.8.1.1
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
1.8.1.2
Science has established that all matter is made up of atoms and each atom
contains fundamental particles. One of these particles is the electron, which has the ability
to move from one place to another. The electron is classified as a negative electrical
charge. Another particle, about 1800 times as heavy as the electron, is the proton and
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
equal number of positive charges (protons) and negative charges (electrons). This balance
is upset when pressure forces the electrons to move from atom to atom. This pressure,
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
1.8.1.4
Since we know that like charges repel and unlike charges attract, the tendency is
for the electrons to move from a position of over-supply (negative charge) to an atom that
lacks electrons (positive charge). This tendency becomes reality when a suitable path is
provided for the movement of the electrons. The transfer of electrons from a negative to a
Lesson 9
Estimating &
Comparing Weld
Metal Costs
positive charge throughout the length of a conductor constitutes an electrical current. The
rate that current flows through a conductor is measured in amperes and the word ampere
is often used synonymously with the term current. To give an idea of the quantities of
electrons that flow through a circuit, it has been theoretically established that one ampere
equals 6.3 quintillion (6,300,000,000,000,000,000) electrons flowing past a fixed point in a
Lesson 10
Reliability of Welding
Filler Metals
Se
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Se
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART B
1.8.1.5
Cu
Ch
Tab
Con
wood and rubber, have what is called a tight electron bond and their atoms greatly resist
Lesson 2
Common Electric
Arc Welding
Processes
the free movement of electrons. Such materials are considered poor electrical conductors.
Metals, on the other hand, have large amounts of electrons that transfer freely. Their
comparatively low electrical resistance classifies them as good electrical conductors.
1.8.1.6
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
P
1.8.1.7
the closed water system with the electrical diagram shown in Figure 8. You can see that as
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
the pump is running, the water will move in the direction of the arrows. It moves because
Glo
pressure has been produced and that pressure can be likened to voltage in an electrical
circuit. The pump can be compared to a battery or a DC generator. The water flows
VALVE
SWITCH
Lesson 5
Welding Filler Metals
for Stainless Steels
RESISTOR
10 OHM
LARGE
PIPE
SMALL PIPE
PUMP
Turn
BATTERY
12 VOLT
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
ELECTRICAL DIAGRAM
FIGURE 8
through the system at a certain rate. This flow rate in an electrical circuit is a unit of
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
measure known as the ampere. The small pipe in the fluid circuit restricts the flow rate and
can be likened to a resistor. This unit resistance is known as the ohm. If we close the
valve in the fluid circuit, we stop the flow, and this can be compared to opening a switch in
an electrical circuit.
Lesson 8
Hardsurfacing
Electrodes
1.8.2
principle, we must know the Ohm's Law, which is stated as follows: In any electrical circuit,
the current flow in amperes is directly proportional to the circuit voltage applied and inversely proportional to the circuit resistance. Directly proportional means that even though
Lesson 9
Estimating &
Comparing Weld
Metal Costs
the voltage and amperage may change, the ratio of their relationship will not. For example,
if we have a circuit of one volt and three amps, we say the ratio is one to three. Now if we
increase the volts to three, our amperage will increase proportionately to nine amps. As
can be seen, even though the voltage and amperage changed in numerical value, their
Lesson 10
Reliability of Welding
Filler Metals
Se
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ratio did not. The term "inversely proportional" simply means that if the resistance is
Se
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART B
doubled, the current will be reduced to one-half. Ohm's Law can be stated mathematically
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
I=ER
1)
or
R=EI
Go T
12 10 = 1.2 amps
2)
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
E=IR
1.8.2.1
Lesson 3
Covered Electrodes
for Welding
Mild Steels
or
Glo
15 5 = 75 volts
3)
When the voltage is 80 and the circuit is limited to 250 amps, what is the value
of the resistor?
80 250 = .32 ohms
Lesson 5
Welding Filler Metals
for Stainless Steels
1.8.2.2
process for it is this resistance in the air space between the electrode and the base metal
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
that contributes to the transfer of electrical energy to heat energy. As voltage forces the
electrons to move faster, the energy they generate is partially used to overcome the
resistance created by the arc gap. This energy becomes evident as heat. In the welding
process, the temperature increases to the point where it brings metals to a molten state.
1.8.3
electrical terminology. When we pay our electrical bills, we are actually paying for the
power to run our electrical appliances, and the watt is a unit of power. It is defined as the
amount of power required to maintain a current of one ampere at a pressure of one volt.
The circuit voltage that comes into your home is a constant factor, but the amperage drawn
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
from the utility company depends on the number of watts required to run the electrical
Se
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appliance. The watt is figured as a product of volts times amperes and is stated mathematically with the following equation:
W =E I
=W I
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=W E
watts rating of the device by the primary voltage for which it is designed.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON I, PART B
1.8.3.2
Cu
Ch
Tab
Con
voltage of 115 and the wattage stamped on the appliance faceplate is 5, then the
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
metric designation that means 1,000 units of something; therefore, one kilowatt is 1,000
watts of power.
1.8.4
alternating current (AC). With direct current, the electron movement within the conductor is
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
in one direction only. With alternating current, the electron flow reverses periodically. Although some types of electrical generators will produce current directly (such as batteries,
dry cells, or DC generators), most direct current is developed from alternating current.
1.8.4.1
magnetic field, an electrical current is induced into the wire, and the current is at its
maximum when the motion of the conductor is at right
angles to the magnetic lines of force. The sketch
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Glo
GALVANOMETER
Turn
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
ELECTRO-MAGNETIC
INDUCTION
Lesson 8
Hardsurfacing
Electrodes
1.8.4.3
FIGURE 9
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Se
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From 0to 90rotation, the coil wire cuts an increasing number of magnetic lines
of force and reaches the maximum number at 90rotation. The current increases to the
maximum because the wire is now at right angles to the lines of force.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
Cu
Ch
Tab
Con
LESSON I, PART B
ROTATING COIL
OR ARMATURE
Lesson 2
Common Electric
Arc Welding
Processes
90
N
180
Lesson 3
Covered Electrodes
for Welding
Mild Steels
270
Go T
P
PERMANENT MAGNETS
OR FIELD COILS
CONTACTS
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
FIGURE 10
1.8.4.5
From 90to 180rotation, the coil wire cuts a diminishing number of lines of
Lesson 5
Welding Filler Metals
for Stainless Steels
1.8.4.6
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
From 180to 270, the current begins to rise again but in the opposite direction
Turn
One cycle is completed as the coil wire moves from 270to 0and the current
With the aid of a graph, we can visualize the rate at which the lines of force are
cut throughout the cycle. If we plot the current versus degree of rotation, we get the
familiar sine wave as seen in Figure 11.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
1.8.4.9
(+)
MAXIMUM (+)
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Se
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MAXIMUM ()
()
0
START
90
1/4 TURN
180
1/2 TURN
270
3/4 TURN
360
FULL TURN
North America.
FIGURE 11
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART B
1.8.4.10
Cu
Ch
Tab
Con
sources of AC power as identical voltages brought in by three wires, the three voltages or
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
120
Go T
1 CYCLE
THREE PHASE AC
1.8.4.12
FIGURE 12
Glo
Since all shops do not have three-phase power, welding machines for both
Lesson 5
Welding Filler Metals
for Stainless Steels
to a safe value as the conditions demand. Common household voltage is usually 115 or
230 volts, whereas industrial power requirements may be 208, 230, 380, or 460 volts.
Transmitting such relatively low voltages over long distances would require a conductor of
enormous and impractical size. Therefore, power transmitted from a power plant must be
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
240
the sine wave for the three phases are plotted on one
Turn
stepped up for long distance transmission and then stepped down for final use
1.8.5.1
As can be seen in Figure 13, the voltage is generated at the power plant at
13,800 volts. It is increased, transmitted over long distances, and then reduced in steps for
the end user. If power supplied to a transformer circuit is held steady, then secondary
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
current (amperes) decreases as the primary voltage increases, and conversely, secondary
current increases as primary voltage decreases. Since the current flow (amperes)
determines the wire or conductor size, the high voltage line may be of a relatively small
Se
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diameter.
Lesson 8
Hardsurfacing
Electrodes
4,600
V
HIGH VOLTAGE
34,000 V
13,800 V
POWER
Lesson 9
Estimating &
Comparing Weld
Metal Costs
PLANT
132,000 V
287,000
V
STEP
UP
STEP
DOWN
208V
230V
460V
FINAL
USE
300 MILES
POWER TRANSMISSION
FIGURE 13
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART B
1.8.5.2
The transformer in a welding machine performs much the same as a large power
Cu
Ch
Tab
Con
plant transformer. The primary voltage coming into the machine is too high for safe
Lesson 2
Common Electric
Arc Welding
Processes
welding. Therefore, it is stepped down to a useable voltage. This is best illustrated with an
explanation of how a single transformer works.
1.8.5.3
Go T
induced into a conductor when that conductor is moved through a magnetic field to
Lesson 3
Covered Electrodes
for Welding
Mild Steels
pulsating magnetic field will surround the exterior of that conductor, that is the magnetic
field will build in intensity through the first 90 electrical degrees, or the first cycle. From that
point, the magnetic field will decay during the next quarter cycle until the voltage or current
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
reaches zero at 180 electrical degrees. Immediately, the current direction reverses and the
Lesson 5
Welding Filler Metals
for Stainless Steels
1.8.5.4
in the cycle. From that point the current and the magnetic field again begin to decay until
they reach zero at 360 electrical degrees, where the cycle begins again.
If that conductor is wound around a material with high magnetic permeability
(magnetic permeability is the ability to accept large amounts of magnetic lines of force)
such as steel, the magnetic field permeates that core. See
STEEL CORE
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
PRIMARY
COIL
Turn
SECONDARY
COIL
460 V
80 V
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Glo
magnetic field will begin to build again until it reaches a maximum at 270 electrical degrees
80
TURNS
460
TURNS
1.8.5.5
FIGURE 14
transformer. This causes an electrical current of the same frequency as the primary coil to
Lesson 8
Hardsurfacing
Electrodes
flow when the secondary circuit is completed by striking the welding arc. Remember that
all transformers operate only on alternating current.
1.8.5.6
This welder would operate on 230 volts input power and the primary winding has 230 turns
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Se
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(Fa
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of wire on the core. We need 80 volts for initiating the arc in the secondary or welding
circuit, thus we have 80 turns of wire in the secondary winding of the core. Before the arc
is struck, the voltage between the electrode and the work piece is 80 volts. Remember that
no current (amperage) flows until the welding circuit is completed by striking the arc.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART B
1.8.5.7
9600 WATTS
9600 WATTS
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
230 TURNS
41.74
AMPS
230
VOLTS
PRIMARY
80 TURNS
Lesson 3
Covered Electrodes
for Welding
Mild Steels
32 VOLTS
300 AMPS
80
SECONDARY OCV
OUTPUT
CONTROL
Go T
FIGURE 15
inversely proportional to
resistance as we saw when studying Ohm's Law. Ohm's Law also stated that the
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
amperage is directly proportional to the voltage. This being so, you can see that adjusting
the output control will also adjust the amperage or welding current.
1.8.5.8
Lesson 5
Welding Filler Metals
for Stainless Steels
After the arc is initiated and current begins to flow through the secondary or
welding circuit, the voltage in that circuit will be 32 volts because it is then being controlled
by the output control.
1.8.6
Figure 15, and that is power consumption. Earlier, we explained that the watt was the unit
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
circuit is:
Watts = 32 300
Watts = 9600 Watts
1.8.6.2
Lesson 8
Hardsurfacing
Electrodes
The primary side of our transformer must be capable of supplying 9600 watts
also (disregarding losses due to heating, power factor, etc.), so by rearranging the formula,
Se
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Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
1.8.6.1
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Glo
1.8.6.3
This information establishes the approximate power requirements for the welder,
and helps to determine the input cable and fuse size necessary.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART B
1.8.7
Cu
Ch
Tab
Con
power sources, the majority of industrial welding is done with machines that produce a
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
SILICON RECTIFIER
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
SELENIUM RECTIFIER
FIGURE 16
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
The negative half-wave is simply cut off and a pulsating DC is produced. During
second.
By using four rectifiers connected in a
Se
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Se
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1 CYCLE
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
half-cycle, the current is blocked. This produces a DC composed of 60 positive pulses per
Lesson 8
Hardsurfacing
Electrodes
FIGURE 17
the positive half-cycle, current is allowed to flow through the rectifier. During the negative
1.8.7.3
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON I, PART B
1.9
Welding power sources are designed in many sizes and shapes. They may supply either
AC or DC, or both, and they may have various means of controlling their voltage and
amperage output. The reasons for this is that the power source must be capable of
producing the proper arc characteristics for the welding process being used. A power
Go T
source that produces a satisfactory arc when welding with coated electrodes will be less
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
Ch
Tab
Con
than satisfactory for welding with solid and flux cored wires.
1.9.1
primarily with coated electrodes. This type of power source has a relatively small change in
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
amperage and arc power for a corresponding relatively large change in arc voltage or arc
illustrated by observing a graph that plots the voltampere curve. As can be seen in Figure 20, the
80
Lesson 5
Welding Filler Metals
for Stainless Steels
O
L
T
S
50
34V - 290
A
40
30
20
10
100
200
300
AMPERES
CONSTANT CURRENT VOLT / AMPERE CURVE
FIGURE 20
known as constant potential, are used in welding with solid and flux cored electrodes, and
source, the voltage is set at the machine and amperage is determined by the speed that
Arc length plays an important part in welding with solid and flux cored electrodes,
just as it does in welding with a coated electrode. However, when using a constant voltage
power source and a wire feeder that delivers the wire at a constant speed, arc length
Lesson 10
Reliability of Welding
Filler Metals
Se
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as the name implies, the voltage output remains relatively constant. On this type of power
the wire is fed to the welding gun. Increasing the wire feed speed increases the amperage.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
32V - 300 A
30V - 308 A
1.9.2
Lesson 8
Hardsurfacing
Electrodes
60
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
70
1.9.1.1
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Glo
length, thus the name constant current. The characteristics of this power source are best
caused by operator error, plate irregularities, and puddle movement are automatically
Se
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART B
compensated for by the characteristics of this process. To understand this, keep in mind
Cu
Ch
Tab
Con
that with the proper voltage setting, amperage setting, and arc length, the rate that the wire
Lesson 2
Common Electric
Arc Welding
Processes
melts is dependent upon the amperage. If the amperage decreases, this melt-off rate
decreases and if the amperage increases, so does the melt-off rate.
1.9.2.2
In Figure 21, we see that condition #2 produces the desired arc length, voltage,
Go T
and amperage. If the arc length is increased as in #1, the voltage increases slightly; the
Lesson 3
Covered Electrodes
for Welding
Mild Steels
amperage decreases considerably, and therefore, the melt-off rate of the wire decreases.
The wire is now feeding faster than it is melting
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
40
30
V
O
L
T
S
20
10
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
100
200
300
AMPERES
400
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
1.9.2.3
There are a variety of different welding machines, each with its own unique
internal design. Our purpose is not to detail the function of each part of the machine, but to
emphasize that their main difference is in the way they control the voltage and amperage
output.
Lesson 8
Hardsurfacing
Electrodes
1.9.3
are being built today for electric arc welding and we shall mention some of the major types
briefly. Welding power sources can be divided into two main categories: static types and
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Se
Ch
(Fa
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rotating types.
1.9.3.1
Static Types - Static type power sources are all of those that use commercially
generated electrical power to energize a transformer that, in turn, steps the line voltage
down to useable welding voltages. The two major categories of static power sources are
the transformer type and the rectifier type.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON I, PART B
1.9.3.1.1 The transformer type produce only alternating current. They are commonly
Cu
Ch
Tab
Con
called "Welding Transformers." All AC types utilize single-phase primary power and are of
Lesson 2
Common Electric
Arc Welding
Processes
Go T
power. They contain a transformer, but rectify the AC or DC by the use of selenium
Lesson 3
Covered Electrodes
for Welding
Mild Steels
rectifiers, silicon diodes or silicon controlled rectifiers. Available in either the constant
current or the constant voltage type, some manufacturers offer units that are a combination
of both and can be used for coated electrode welding, non-consumable electrode welding
and for welding with solid or flux cored wires.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
1.9.3.2
Rotating Types - Rotating type power sources may be divided into two classifi-
Glo
cations:
1.
Motor-Generators
2.
Engine Driven
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
1.9.3.2.2 Engine driven types consist of a gasoline or diesel engine coupled to a generator
or alternator that produces the desired welding power. They are used extensively on jobs
beyond commercial power lines and also as mobile repair units. Both rotating types can
deliver either AC or DC welding power, or a combination of both. Both types are available
as constant current or constant voltage models.
1.9.4
Power Source Controls - Welding power sources differ also in the method of
Lesson 8
Hardsurfacing
Electrodes
trical types of controls, such as magnetic amplifiers or saturable reactors, are also utilized
and the most modern types, containing silicon controlled rectifiers, give precise electronic
control.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
1.9.4.1
A detailed discussion of the many types of welding power sources on the market
today is much too lengthy a subject for this course, although additional information on the
type of power sources for the various welding processes will be covered in Lesson II.
1.9.4.2
Lesson 10
Reliability of Welding
Filler Metals
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Lesson 1
The Basics of Arc
Welding
LESSON I, GLOSSARY
APPENDIX A
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
AISI
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Allotropic
Lesson 5
Welding Filler Metals
for Stainless Steels
Alternating
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Current
Glo
used in the U.S.A., the current direction reverses 120 times every
second.
Ampere
ASME
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
ASTM
Atom
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
and electrons.
Carbon Steel
Lesson 8
Hardsurfacing
Electrodes
Conductor
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Se
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(Fa
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Constant Current
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON I, GLOSSARY
Constant Voltage
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
Direct Current
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
all DC devices are usually marked (+) or (-). Reversing the leads
Electron
Glo
Hertz
Hertz (Hz) is the symbol which has replaced the term cycles per
second. Today, rather than saying 60 cycles per second or simply
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Go T
Ferrous
Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Induced Current or
Induction
Lesson 8
Hardsurfacing
Electrodes
field.
Ingot
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Insulator
Se
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A material which has a tight electron bond, that is, relatively few
electrons which will move when voltage (electrical pressure) is
applied. Wood, glass, ceramics and most plastics are good
insulators.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
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Doc
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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
LESSON I, GLOSSARY
Kilowatt
1,000 watts
Non-Ferrous
Go T
P
Ohm
Glo
Phase
Transformation
Proton
Rectifier
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Cu
Ch
Tab
Con
Turn
SAE
Transformer
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Volt
Se
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(Fa
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Watt
Se
Doc
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Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1999 THE ESAB GROUP, INC.
Cu
Ch
Tab
Con
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
BASIC
WELDING FILLER METAL
TECHNOLOGY
Go T
Glo
A Correspondence Course
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
LESSON II
COMMON ELECTRIC ARC
WELDING PROCESSES
Se
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Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Turn
Se
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ESAB
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON II
COMMON ELECTRIC ARC WELDING
PROCESSES
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Cu
Ch
Tab
Con
Section Nr.
Section Title
Page
Go T
P
2.1
INTRODUCTION ..............................................................................
2.2
2.2.1
2.2.2
2.2.3
Electrode Holder................................................................................
2.2.4
2.2.5
2.2.6
2.3
2.3.1
2.3.2
2.3.3
Torches..............................................................................................
10
2.3.4
11
2.3.5
Electrodes .........................................................................................
12
2.3.6
Summary ...........................................................................................
13
2.4
13
2.4.1
14
2.4.2
15
2.4.3
17
2.4.4
Power Source....................................................................................
18
2.4.5
19
2.4.6
20
2.4.7
21
2.4.7.1
22
2.4.7.2
23
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Glo
Turn
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Se
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(Sl
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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Cu
Ch
Tab
Con
TABLE OF CONTENTS
LESSON II - Con't.
Section Nr.
Section Title
Page
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.4.7.3
23
2.4.8
Electrodes .........................................................................................
23
2.5
24
2.5.1
24
2.5.2
25
2.5.3
26
2.5.4
Equipment .........................................................................................
26
2.5.5
Power Source....................................................................................
26
2.5.6
26
2.5.7
26
2.5.8
27
2.6
27
2.6.1
28
2.6.2
28
2.6.3
28
2.6.4
Equipment .........................................................................................
28
2.6.5
Electrodes .........................................................................................
29
2.6.6
Summary ...........................................................................................
29
2.7
30
2.7.1
Electroslag Welding...........................................................................
30
2.7.2
Flux ...................................................................................................
30
2.7.3
Process .............................................................................................
30
2.7.4
Equipment.........................................................................................
31
2.7.5
Summary ..........................................................................................
31
32
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Glo
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Lesson 1
The Basics of Arc
Welding
LESSON II
Cu
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2.1
INTRODUCTION
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
After much experimentation by others in the early 1800's, an Englishman named Wilde
obtained the first electric welding patent in 1865. He successfully joined two small pieces of
iron by passing an electric current through both pieces producing a fusion weld. Approximately
twenty years later, Bernado, a Russian, was granted a patent for an electric arc welding
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
process in which he maintained an arc between a carbon electrode and the pieces to be
joined, fusing the metals together as the arc was manually passed over the joint to be welded.
2.1.0.1
Glo
During the 1890's, arc welding was accomplished with bare metal electrodes that
were consumed in the molten puddle and became part of the weld metal. The welds were of
Lesson 5
Welding Filler Metals
for Stainless Steels
poor quality due to the nitrogen and oxygen in the atmosphere forming harmful oxides and
nitrides in the weld metal. Early in the Twentieth Century, the importance of shielding the arc
from the atmosphere was realized. Covering the electrode with a material that decomposed in
the heat of the arc to form a gaseous shield appeared to be the best method to accomplish
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
were tried. These efforts culminated in the extruded coated electrode in the mid-1920's,
greatly improving the quality of the weld metal and providing what many consider the most
significant advance in electric arc welding.
2.1.0.2
Since welding with coated electrodes is a rather slow procedure, more rapid
welding processes were developed. This lesson will cover the more commonly used electric
arc welding processes in use today.
2.2
Shielded Metal Arc Welding* , also known as manual metal arc welding, stick welding, or
electric arc welding, is the most widely used of the various arc welding processes. Welding is
performed with the heat of an electric arc that is maintained between the end of a coated metal
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
this end. As a result, various methods of covering electrodes, such as wrapping and dipping,
electrode and the work piece (See Figure 1). The heat produced by the arc melts the base
metal, the electrode core rod, and the coating. As the molten metal droplets are transferred
across the arc and into the molten weld puddle, they are shielded from the atmosphere by the
gases produced from the decomposition of the flux coating. The molten slag floats to the top
of the weld puddle where it protects the weld metal from the atmosphere during solidification.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
Other functions of the coating are to provide
arc stability and control bead shape. More
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
COATING
SHIELDING
GASES
2.2.1
WORK PIECE
SHIELDED METAL ARC WELDING
FIGURE 1
Glo
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
1.
2.
Electrode holder
3.
Ground clamp
4.
5.
6.
2.2.2
AC OR DC
POWER
SOURCE
ELECTRODE
CABLE
ELECTRODE
HOLDER
ELECTRODE
GROUND
WORK
FIGURE 2
Welding Power Sources - Shielded metal arc welding may utilize either
alternating current (AC) or direct current (DC), but in either case, the power source selected
must be of the constant current type. This type of power source will deliver a relatively constant
amperage or welding current regardless of arc length variations by the operator (See Lesson I,
2.2.2.1
Whether to use an AC, DC, or AC/DC power source depends on the type of welding
to be done and the electrodes used. The following factors should be considered:
Lesson 10
Reliability of Welding
Filler Metals
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Section 1.9). The amperage determines the amount of heat at the arc and since it will remain
1. Electrode Selection - Using a DC power source allows the use of a greater range
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
CABLE
SHIELDED METAL ARC WELDING CIRCUIT
relatively constant, the weld beads produced will be uniform in size and shape.
Lesson 8
Hardsurfacing
Electrodes
Go T
WELD METAL
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
SOLIDIFIED
SLAG
MOLTEN
POOL
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Cu
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Lesson 1
The Basics of Arc
Welding
LESSON II
3. Distance from Work - If the distance from the work to the power source is great,
Cu
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AC is the best choice since the voltage drop through the cables is lower than with
Lesson 2
Common Electric
Arc Welding
Processes
DC. Even though welding cables are made of copper or aluminum (both good
conductors), the resistance in the cables becomes greater as the cable length
increases. In other words, a voltage reading taken between the electrode and the
work will be somewhat lower than a reading taken at the output terminals of the
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
welding than AC. AC can successfully be used for out-of-position work if proper
electrodes are selected.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
5. Arc Blow - When welding with DC, magnetic fields are set up throughout the
weldment. In weldments that have varying thickness and protrusions, this magnetic
field can affect the arc by making it stray or fluctuate in direction. This condition is
especially troublesome when welding in corners. AC seldom causes this problem
Lesson 5
Welding Filler Metals
for Stainless Steels
Combination power sources that produce both AC and DC are available and
provide the versatility necessary to select the proper welding current for the application.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
2.2.2.3
Turn
When using a DC power source, the question of whether to use electrode negative
or positive polarity arises. Some electrodes operate on both DC straight and reverse polarity,
and others on DC negative or DC positive polarity only. Direct current flows in one direction in
an electrical circuit and the direction of current flow and the composition of the electrode
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
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coating will have a definite effect on the welding arc and weld bead. Figure 3 shows the
connections and effects of straight and reverse polarity.
2.2.2.4
Electrode negative (-) produces welds with shallow penetration; however, the
electrode melt-off rate is high. The weld bead is rather wide and shallow as shown at "A" in
Lesson 8
Hardsurfacing
Electrodes
Figure 3. Electrode
positive (+)
produces welds with
deep penetration
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
DC
POWER SOURCE
DC
POWER SOURCE
DEEP PENETRATION,
LOW BURN-OFF RATE
ELECTRODE
ELECTRODE
bead as shown at
"B" in Figure 3.
WORK PIECE
STRAIGHT POLARITY
WORK PIECE
REVERSE POLARITY
FIGURE 3
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Lesson 1
The Basics of Arc
Welding
LESSON II
2.2.2.5
While polarity affects the penetration and burn-off rate, the electrode coating also
Cu
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Lesson 2
Common Electric
Arc Welding
Processes
2.2.3
Electrode Holder - The electrode holder connects to the welding cable and con-
ducts the welding current to the electrode. The insulated handle is used to guide the electrode
Go T
over the weld joint and feed the electrode over the weld joint and feed the electrode into the
Lesson 3
Covered Electrodes
for Welding
Mild Steels
weld puddle as it is consumed. Electrode holders are available in different sizes and are rated
2.2.4
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Ground Clamp - The ground clamp is used to connect the ground cable to the work
piece. It may be connected directly to the work or to the table or fixture upon which the work is
Glo
positioned. Being a part of the welding circuit, the ground clamp must be capable of carrying
the welding current without overheating due to electrical resistance.
2.2.5
Lesson 5
Welding Filler Metals
for Stainless Steels
Welding Cables - The electrode cable and the ground cable are important parts of
the welding circuit. They must be very flexible and have a tough heat-resistant insulation.
Connections at the electrode holder, the ground clamp, and at the power source lugs must be
soldered or well crimped to assure low electrical resistance. The cross-sectional area of the
cable must be sufficient size to carry the welding current with a minimum of voltage drop.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
Increasing the cable length necessitates increasing the cable diameter to lessen resistance
and voltage drop. The table in Figure 4 lists the suggested American Wire Gauge (AWG)
cable size to be used for various welding currents and cable lengths.
Welding
Service
Range
(Amperes)
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
20 to 180
30 to 250
60 to 375
80 to 500
100 to 600
Lesson 8
Hardsurfacing
Electrodes
1.8
1.8
1.7
1.8
2.0
Up to 100 ft.
Cable
Voltage
Size
Drop
Up to 250 ft.
Cable
Voltage
Size
Drop
Up to 500 ft.
Cable
Voltage
Size
Drop
#2
#1
#0
#000
#0000
#1
#0
#00
#0000
...
#0
#0
#000
#0000
...
2.9
2.5
3.0
2.5
2.5
5.7
5.0
5.9
5.0
...
9.1
9.9
9.3
9.9
Voltage
Drop
Figured
At
180
200
300
400
500
Amps
Amps
Amps
Amps
Amps
Voltage drops indicated do not include any drop caused by poor connection, electrode holder, or work metal
FIGURE 4
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.2.6
metal arc welding. Electrodes used for welding mild or carbon steels are quite different than
those used for welding the low alloys and stainless steels. Details on the specific types will be
covered in subsequent lessons.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON II
2.3
Gas Tungsten Arc Welding* is a welding process performed using the heat of an arc
established between a nonconsumable tungsten electrode and the work piece. See Figure 5.
The electrode, the arc, and the area surrounding the molten weld puddle are protected from
the atmosphere by an inert gas shield. The electrode is not consumed in the weld puddle as in
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
TORCH
Glo
SHIELDING GAS
NOZZLE
ARC
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
TRAVEL
DIRECTION
Lesson 5
Welding Filler Metals
for Stainless Steels
INERT GAS
SHIELD
FILLER
METAL
FIGURE 5
Gas tungsten arc welding may be used for welding almost all metals mild steel,
low alloys, stainless steel, copper and copper alloys, aluminum and aluminum alloys, nickel
most extensively used for welding aluminum and stainless steel alloys where weld integrity is of
the utmost importance. Another use is for the root pass (initial pass) in pipe welding, which
requires a weld of the highest quality. Full penetration without an excessively high inside bead
is important in the root pass, and due to the ease of current control of this process, it lends
Lesson 9
Estimating &
Comparing Weld
Metal Costs
itself to control of back-bead size. For high quality welds, it is usually necessary to provide an
inert shielding gas inside the pipe to prevent oxidation of the inside weld bead.
Lesson 10
Reliability of Welding
Filler Metals
Turn
WORK PIECE
and nickel alloys, magnesium and magnesium alloys, titanium, and others. This process is
Lesson 8
Hardsurfacing
Electrodes
Cu
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Tab
Con
Gas Tungsten Arc Welding (GTAW ) is the current terminology approved by the American Welding Society,
formerly known as "TIG" (Tungsten Inert Gas) welding.
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Lesson 1
The Basics of Arc
Welding
LESSON II
2.3.0.3
Gas tungsten arc welding lends itself to both manual and automatic operation. In
Cu
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manual operation, the welder holds the torch in one hand and directs the arc into the weld joint.
Lesson 2
Common Electric
Arc Welding
Processes
The filler metal is fed manually into the leading edge of the puddle. In automatic applications,
the torch may be automatically moved over a stationary work piece or the torch may be
stationary with the work moved or rotated in relation to the torch. Filler metal, if required, is
also fed automatically.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
2.3.1
with relatively simple equipment, or it may require some highly sophisticated components.
Choice of equipment depends upon the type of metal being joined, the position of the weld
being made, and the quality of the weld metal necessary for the application. The basic equip-
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Glo
1.
2.
3.
Shielding gas
4.
Tungsten electrode
5.
6.
Ground cable
7.
Protective equipment
Turn
REGULATOR
FLOW METER
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
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Lesson 8
Hardsurfacing
Electrodes
WORK
POWER
SOURCE
Lesson 9
Estimating &
Comparing Weld
Metal Costs
* COMPOSITE CABLE
GAS COOLED TORCH.
CURRENT IN & GAS IN.
WATER
TO
TORCH
WATER
FROM
TORCH
GROUND CABLE
SHIELDING
GAS SUPPLY
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
Power Sources - Both AC and DC power sources are used in gas tungsten arc
2.3.2
Cu
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welding. They are the constant current type with a drooping volt-ampere curve. This type of
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
power source produces very slight changes in the arc current when the arc length (voltage) is
varied. Refer to Lesson I, Section 1.9.
2.3.2.1
The choice between an AC or DC welder depends on the type and thickness of the
Go T
metal to be welded. Distinct differences exist between AC and DC arc characteristics, and if
DC is chosen, the polarity also becomes an important factor. The effects of polarity in GTAW
are directly opposite the effects of polarity in SMAW as described in paragraphs 2.2.2.3
through 2.2.2.5. In SMAW, the distribution of heat between the electrode and work, which
determines the penetration and weld bead width, is controlled mainly by the ingredients in the
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
flux coating on the electrode. In GTAW where no flux coating exists, heat distribution between
Glo
the electrode and the work is controlled solely by the polarity. The choice of the proper welding
current will be better understood by analyzing each type separately. The chart in Figure 7 lists
current recommendations.
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
WELDING CURRENT
Material &
Thickness
DCEN
Aluminum
Under 1/8"
Over 1/8"
2
2&3
Magnesium
Under 1/16"
Over 1/16"
DCEP
SHIELDING GAS
AC
High Freq.
Argon
Helium
Ar/He
1
1
1
1
2
3
1
1
1
1
Carbon Steel
Under 1/8"
Over 1/8"
1
1
1
1
Stainless Steel
Under 1/8"
Over 1/8"
1
1
Copper
Under 1/8"
Over 1/8"
1
1
Nickel Alloys
Under 1/8"
Over 1/8"
1
1
Titanium
Under 1/8"
Over 1/8"
Turn
2
2
1
1.
2.
3.
3
2
2
1
2
1
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
Direct current electrode negative (DCEN) is produced when the electrode is
2.3.2.2
Cu
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Tab
Con
connected to the negative terminal of the power source. Since the electrons flow from the
Lesson 2
Common Electric
Arc Welding
Processes
electrode to the plate, approximately 70% of the heat of the arc is concentrated at the work,
and approximately 30% at the electrode end. This allows the use of smaller tungsten electrodes that produce a relatively narrow concentrated arc. The weld shape has deep penetration and is quite narrow. See Figure 8. Direct current electrode negative is suitable for weld-
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
ing most metals. Magnesium and aluminum have a refractory oxide coating on the surface that
must be physically removed immediately prior to welding if DCSP is to be used.
P
Direct current electrode positive (DCEP) is produced when the electrode is
2.3.2.3
connected to the positive terminal of the welding power source. In this condition, the electrons
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
flow from the work to the electrode tip, concentrating approximately 70% of the heat of the arc
Glo
at the electrode and 30% at the work. This higher heat at the electrode necessitates using
larger diameter tungsten to prevent it from melting and contaminating the weld metal. Since
the electrode diameter is larger and the heat is less concentrated at the work, the resultant
Lesson 5
Welding Filler Metals
for Stainless Steels
Electrode
Polarity
_
GAS IONS
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
ELECTRON
FLOW
Direct Current
Straight Polarity
Electrode Negative
Penetration
Deep
Penetration
Narrow
Bead
Medium Penetration
Alternating Current
+ _
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Direct Current
Reverse Polarity
Electrode Positive
Medium Width
Bead
Shallow Penetration
Oxide
Cleaning
Heat
Concentration
None
At
Work
Good
Cleans Oxide
on Each Half
Cycle
Alternates Between
Electrode and Work
Maximum
Wide Bead
At
Electrode
Lesson 8
Hardsurfacing
Electrodes
FIGURE 8
2.3.2.4
Aluminum and magnesium are two metals that have a heavy oxide coating that acts
as an insulator and must be removed before successful welding can take place. Welding with
Lesson 9
Estimating &
Comparing Weld
Metal Costs
electrode positive provides a good oxide cleaning action in the arc. If we were to study the
physics of the welding arc, we find that the electric current causes the shielding gas atoms to
lose some of their electrons. Since electrons are negatively charged, these gas atoms now
are unbalanced and have an excessive positive charge. As we learned in Lesson I, unlike
Lesson 10
Reliability of Welding
Filler Metals
charges attract. These positively charged atoms (or positive ions as they are known in
Turn
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Lesson 1
The Basics of Arc
Welding
LESSON II
chemical terminology) are attracted to the negative pole, in this case the work, at high velocity.
Cu
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Tab
Con
Upon striking the work surface, they dislodge the oxide coating permitting good electrical
Lesson 2
Common Electric
Arc Welding
Processes
conductivity for the maintenance of the arc, and eliminate the impurities in the weld metal that
could be caused by these oxides.
2.3.2.5
Direct current electrode positive is rarely used in gas-tungsten arc welding. Despite
the excellent oxide cleaning action, the lower heat input in the weld area makes it a slow
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
process, and in metals having higher thermal conductivity, the heat is rapidly conducted away
from the weld zone. When used, DCEP is restricted to welding thin sections (under 1/8") of
used for welding aluminum. In a sense, the advantages of both DC processes are combined,
Glo
and the weld bead produced is a compromise of the two. Remember that when welding with
60 Hz current, the electron flow from the electrode tip to the work reverses direction 120 times
every second. Thereby, the intense heat alternates from electrode to work piece, allowing the
Lesson 5
Welding Filler Metals
for Stainless Steels
use of an intermediate size electrode. The weld bead is a compromise having medium
penetration and bead width. The gas ions blast the oxides from the surface of aluminum and
magnesium during the positive half cycle. Figure 8 illustrates the effects of the different types
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
2.3.2.7
DC constant current power sources - Constant current power sources, used for
shielded metal arc welding, may also be used for gas-tungsten arc welding. In applications
where weld integrity is not of utmost importance, these power sources will suffice. With
machines of this type, the arc must be initiated by touching the tungsten electrode to the work
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
and quickly withdrawing it to maintain the proper arc length. This starting method
contaminates the electrode and blunts the point which has been grounded on the electrode
end. These conditions can cause weld metal inclusions and poor arc direction. Using a
power source designed for gas tungsten arc welding with a high frequency stabilizer will
Lesson 8
Hardsurfacing
Electrodes
eliminate this problem. The electrode need not be touched to the work for arc initiation.
Instead, the high frequency voltage, at very low current, is superimposed onto the welding
current. When the electrode is brought to within approximately 1/8 inch of the base metal, the
high frequency ionizes the gas path, making it conductive and a welding arc is established.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
The high frequency is automatically turned off immediately after arc initiation when using direct
current.
2.3.2.8
AC Constant Current Power Source - Designed for gas tungsten arc welding,
always incorporates high frequency, and it is turned on throughout the weld cycle to maintain a
stable arc. When welding with AC, the current passes through 0 twice in every cycle and the
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
arc must be reestablished each time it does so. The oxide coating on metals, such as
Cu
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aluminum and magnesium, can act much like a rectifier as discussed in Lesson I. The positive
Lesson 2
Common Electric
Arc Welding
Processes
half-cycle will be eliminated if the arc does not reignite, causing an unstable condition.
Continuous high frequency maintains an ionized path for the welding arc, and assures arc reignition each time the current changes direction. AC is extensively used for welding aluminum
and magnesium.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
2.3.2.9
AC/DC Constant Current Power Sources - Designed for gas tungsten arc
welding, are available, and can be used for welding practically all metals. The gas tungsten
arc welding process is usually chosen because of the high quality welds it can produce. The
metals that are commonly welded with this process, such as stainless steel, aluminum and
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
some of the more exotic metals, cost many times the price of mild steel; and therefore, the
welds. Among these are:
1.
Lesson 5
Welding Filler Metals
for Stainless Steels
Remote current control, which allows the operator to control welding amperage
with a hand control on the torch, or a foot control at the welding station.
2.
Automatic soft-start, which prevents a high current surge when the arc is
initiated.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
3.
Turn
Shielding gas and cooling water solenoid valves, which automatically control
flow before, during and for an adjustable length of time after the weld is completed.
4.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
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Power sources for automatic welding with complete programmable output are also
available. Such units are used extensively for the automatic welding of pipe in position. The
Lesson 8
Hardsurfacing
Electrodes
welding current is automatically varied as the torch travels around the pipe. Some units
provide a pulsed welding current where the amperage is automatically varied between a low
and high several times per second. This produces welds with good penetration and improved
weld bead shape.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Glo
power sources designed for this process have many desirable features to insure high quality
2.3.3
Torches - The torch is actually an electrode holder that supplies welding current to
the tungsten electrode, and an inert gas shield to the arc zone. The electrode is held in a
collet-like clamping device that allows adjustment so that the proper length of electrode protrudes beyond the shielding gas cup. Manual torches are designed to accept electrodes of 3
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
inch or 7 inch lengths. Torches may be either air or water-cooled. The air-cooled types actu-
Cu
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Tab
Con
ally are cooled to a degree by the shielding gas that is fed to the torch head through a compos-
Lesson 2
Common Electric
Arc Welding
Processes
ite cable. The gas actually surrounds the copper welding cable, affording some degree of
cooling. Water-cooled torches are usually used for applications where the welding current
exceeds 200 amperes. The water inlet hose is connected to the torch head. Circulating
around the torch head, the water leaves the torch via the current-in hose and cable assembly.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cooling the welding cable in this manner allows the use of a smaller diameter cable that is
Go T
P
2.3.3.1
The gas nozzles are made of ceramic materials and are available in various sizes
and shapes. In some heavy duty, high current applications, metal water-cooled nozzles are
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
used.
2.3.3.2
Glo
A switch on the torch is used to energize the electrode with welding current and start
the shielding gas flow. High frequency current and water flow are also initiated by this switch if
the power source is so equipped. In many installations, these functions are initiated by a foot
Lesson 5
Welding Filler Metals
for Stainless Steels
control that also is capable of controlling the welding current. This method gives the operator
full control of the arc. The usual welding method is to start the arc at a low current, gradually
increase the current until a molten pool is achieved, and welding begins. At the end of the
weld, current is slowly decreases and the arc extinguished, preventing the crater that forms at
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
2.3.4
Shielding Gases - Argon and helium are the major shielding gases used in gas
tungsten arc welding. In some applications, mixtures of the two gases prove advantageous.
To a lesser extent, hydrogen is mixed with argon or helium for special applications.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.3.4.1
Argon and helium are colorless, odorless, tasteless and nontoxic gases. Both are
inert gases, which means that they do not readily combine with other elements. They will not
burn nor support combustion. Commercial grades used for welding are 99.99% pure. Argon
is .38% heavier than air and about 10 times heavier than helium. Both gases ionize when
Lesson 8
Hardsurfacing
Electrodes
present in an electric arc. This means that the gas atoms lose some of their electrons that
have a negative charge. These unbalanced gas atoms, properly called positive ions, now
have a positive charge and are attracted to the negative pole in the arc. When the arc is
positive and the work is negative, these positive ions impinge upon the work and remove
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
Argon is most commonly used of the shielding gases. Excellent arc starting and
ease of use make it most desirable for manual welding. Argon produces a better cleaning
action when welding aluminum and magnesium with alternating current. The arc produced is
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
relatively narrow. Argon is more suitable for welding thinner material. At equal amperage,
Cu
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Tab
Con
helium produces a higher arc voltage than argon. Since welding heat is the product of volts
Lesson 2
Common Electric
Arc Welding
Processes
times amperes, helium produces more available heat at the arc. This makes it more suitable
for welding heavy sections of metal that have high heat conductivity, or for automatic welding
operations where higher welding speeds are required.
2.3.4.3
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Argon-helium gas mixtures are used in applications where higher heat input and the
Go T
desirable characteristics of argon are required. Argon, being a relatively heavy gas, blankets
the weld area at lower flow rates. Argon is preferred for many applications because it costs
Helium, being approximately 10 times lighter than argon, requires flow rates of 2 to
Glo
Electrodes - Electrodes for gas tungsten arc welding are available in diameters
from .010" to 1/4" in diameter and standard lengths range from 3" to 24". The most commonly
Lesson 5
Welding Filler Metals
for Stainless Steels
used sizes, however, are the .040", 1/16", 3/32", and 1/8" diameters.
2.3.5.1
The shape of the tip of the electrode is an important factor in gas tungsten arc
welding. When welding with DCEN, the tip must be ground to a point. The included angle at
which the tip is ground varies with the application, the electrode diameter, and the welding
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
current. Narrow joints require a relatively small included angle. When welding very thin
material at low currents, a needlelike point ground onto the smallest available electrode may
be necessary to stabilize the arc. Properly ground electrodes will assure easy arc starting,
good arc stability, and proper bead width.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.3.5.2
When welding with AC, grinding the electrode tip is not necessary. When proper
welding current is used, the electrode will form a hemispherical end. If the proper welding
current is exceeded, the end will become bulbous in shape and possibly melt off to
contaminate the weld metal.
Lesson 8
Hardsurfacing
Electrodes
2.3.5.3
The American Welding Society has published Specification AWS A5.12-80 for
tungsten arc welding electrodes that classifies the electrodes on the basis of their chemical
composition, size and finish. Briefly, the types specified are listed below:
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
2) 1% Thoriated Tungsten (AWS EWTh-1) Color Code: Yellow
Cu
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Tab
Con
Good current carrying capacity, easy arc starting and provide a stable arc. Less
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
nonferrous materials.
P
4) .5% Thoriated Tungsten (AWS EWTh-3) Color Code: Blue
Sometimes called "striped" electrode because it has 1.0-2.0% Thoria inserted in a
wedge-shaped groove throughout its length. Combines the good properties of pure
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
easily than thoriam-tungsten when forming rounded or tapered tungsten end. Ideal for
applications where tungsten contamination must be minimized.
2.3.6
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Summary - Gas Tungsten Arc Welding is one of the major welding processes
Turn
today. The quality of the welds produced and the ability to weld very thin metals are the major
features. The weld metal quality is high since no flux is used, eliminating the problem of slag
inclusions in the weld metal. It is used extensively in the aircraft and aerospace industry, where
high quality welds are necessary and also for welding the more expensive metals where the
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
weld defects become very costly. Metals as thin as .005" can be welded due to the ease of
controlling the current.
2.3.6.1
The major disadvantages of the process are that it is slower than welding with
consumable electrodes and is little used on thicknesses over 1/4" for this reason. Shielding
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
gas and tungsten electrode costs make the process relatively expensive.
2.4
Gas Metal Arc Welding* is an arc welding process that uses the heat of an electric arc
established between a consumable metal electrode and the work to be welded. The electrode
is a bare metal wire that is transferred across the arc and into the molten weld puddle. The
*
Lesson 10
Reliability of Welding
Filler Metals
Gas Metal Arc Welding (GMAW) is the current technology approved by the American Welding Society.
Formerly known as "MIG" (Metal Inert Gas) Welding.
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Lesson 1
The Basics of Arc
Welding
LESSON II
wire, the weld puddle, and the area in the arc zone are protected from the atmosphere by a
Cu
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gaseous shield. Inert gases, reactive gases, and gas mixtures are used for shielding. The
Lesson 2
Common Electric
Arc Welding
Processes
metal transfer mode is dependent on shielding gas choice and welding current level. Figure 9
is a sketch of the process showing the basic features.
TRAVEL
DIRECTION
WELDING WIRE
WELDING CABLE
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
SHIELDING GAS
SOLID WIRE
ELECTRODE
P
GAS NOZZLE
GAS SHIELD
CONTACT TIP
ARC
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
WELD METAL
WORK PIECE
MOLTEN POOL
GAS METAL ARC WELDING
Lesson 5
Welding Filler Metals
for Stainless Steels
FIGURE 9
2.4.0.1
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Gas metal arc welding is a versatile process that may be used to weld a wide
Turn
variety of metals including carbon steels, low alloy steels, stainless steels, aluminum alloys,
magnesium, copper and copper alloys, and nickel alloys. It can be used to weld sheet metal or
relatively heavy sections. Welds may be made in all positions, and the process may be used
for semiautomatic welding or automatic welding. In semiautomatic welding, the wire feed
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
speed, voltage, amperage, and gas flow are all preset on the control equipment. The operator
needs merely to guide the welding gun along the joint at a uniform speed and hold a relatively
constant arc length. In automatic welding, the gun is mounted on a travel carriage that moves
along the joint, or the gun may be stationary with the work moving or revolving beneath it.
2.4.0.2
Practically all GMAW is done using DCEP (Electrode positive). This polarity
provides deep penetration, a stable arc and low spatter levels. A small amount of GMAW
welding is done with DCEN and although the melting rate of the electrode is high, the arc is
erratic. Alternating current is not used for gas metal arc welding.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.4.1
Current Density - To understand why gas metal arc welding can deposit weld
metal at a rapid rate, it is necessary that the term "current density" be understood. Figure 10
shows a 1/4" coated electrode and a 1/16" solid wire drawn to scale. Both are capable of
carrying 400 amperes. Notice that the area of the 1/16" wire is only 1/16 that of the core wire
Lesson 10
Reliability of Welding
Filler Metals
of the coated electrode. We can say that the current density of the 1/16" wire is 16 times
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Lesson 1
The Basics of Arc
Welding
LESSON II
AREA = .049 SQ. IN.
Cu
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Con
Lesson 2
Common Electric
Arc Welding
Processes
CORE WIRE
A
A 16
1/16"
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
SOLID WIRE
1/4"
COATED ELECTRODE
.049 .0031 = 16
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
FLUX
COATING
Glo
2.4.2.1
Spray transfer is a high current density process that rapidly deposits weld metal in
droplets smaller than the electrode diameter. They are propelled in a straight line from the
center of the electrode. A shielding gas mixture of Argon with 1% to 2% Oxygen is used for
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
welding mild and low alloy steel, and pure Argon or Argon-Helium mixtures are used for welding aluminum, magnesium, copper, and nickel alloys. Welding current at which spray transfer
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Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
SPRAY
TRANSFER
GLOBULAR
TRANSFER
PULSE
TRANSFER
1
2
3
SHORT CIRCUITING ARC METAL TRANSFER
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
takes place is relatively high and will vary with the metal being welded, electrode diameter, and
the shielding gas being used. Deposition rates are high and welding is usually limited to the
flat or horizontal fillet position. See Figure 11.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
2.4.2.2
Globular transfer takes place at lower welding currents than spray transfer. There
Cu
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is a transition current where the transfer changes to globular even when shielding gases using
Lesson 2
Common Electric
Arc Welding
Processes
a high percentage of argon are used. When carbon dioxide (CO ) is used as a shielding gas,
2
the transfer is always globular. In globular transfer, a molten drop larger than the electrode
diameter forms on the end of the electrode, moves to the outer edge of the electrode and falls
into the molten puddle. Occasionally, a large drop will "short circuit" across the arc, causing
Lesson 3
Covered Electrodes
for Welding
Mild Steels
the arc to extinguish momentarily, and then instantaneously reignite. As a result, the arc is
somewhat erratic, spatter level is high, and penetration shallow. Globular transfer is not
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
Short circuiting transfer is a much used method in gas metal arc welding. It is
produced by using the lowest current-voltage settings and the smaller wires, usually .030",
Glo
.035", and .045" diameters. The low heat input makes this process ideal for sheet metal, outof-position work, and poor fit-up applications. Often called "short arc welding" because metal
transfer is achieved each time the wire actually short circuits (makes contact) with the weld
Lesson 5
Welding Filler Metals
for Stainless Steels
puddle. This happens very rapidly. It is feasible for the short circuit frequency to be 20-200
times a second, but in practice, it occurs from 90-100 times a second. Each time the
electrode touches the puddle, the arc is extinguished. It happens so rapidly that it is visible
only on high speed films.
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
2.4.2.4
Pulse transfer is a mode of metal transfer somewhat between spray and short
circuiting. The specific power source has built into it two output levels: a steady background
level, and a high output (peak) level. The later permits the transfer of metal across the arc.
This peak output is controllable between high and low values up to several hundred cycles per
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
second. The result of such a peak output produces a spray arc below the typical transition
current.
2.4.2.4.1 Figure 11 shows the transfer method. The arc is initiated by touching the wire to the
work. Upon initial contact, a bit of the wire melts off to form a molten puddle. The wire feeds
Lesson 8
Hardsurfacing
Electrodes
forward until it actually contacts the work again, as at 1 in Figure 11, and the arc is
extinguished. The short circuiting current causes the wire to neck down, as shown in 1, until it
melts off, as shown at 2. As soon as the wire is free of the puddle, the arc is reignited and a
molten ball forms at the end of the electrode, as at 3. The wire continues to move forward until
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Gas metal arc spot welding is a variation of the process that allows spot welding
of thinner gauge metals, or of a thin gauge metal to a heavier section. The gun is placed
directly against the work and is equipped with a special nozzle to allow escape of the shielding
gas. When the trigger switch is actuated, the following sequence takes place. The shielding
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
gas flows for a short interval before wire feeding starts; wire feeding starts; the arc is initiated
Cu
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and continues for a preset time (usually a few seconds). The welding current and wire feeding
Lesson 2
Common Electric
Arc Welding
Processes
stops, and the shielding gas flows for a short interval before it automatically stops. The
process is also useful for tacking welding pieces in position prior to running the final weld
bead.
2.4.3
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
EQUIPMENT AND OPERATION - The equipment used for gas metal arc welding
Go T
is more complicated than that required for shielded metal arc welding. Initial cost is relatively
high, but the cost is rapidly amortized due to the savings in labor and overhead achieved by
The equipment necessary for gas metal arc welding is listed below:
Glo
1) Power source
2) Wire feeder
3) Welding gun
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.4.3.2
Turn
The basic equipment necessary for semiautomatic gas metal arc welding is shown
in Figure 12.
GAS HOSE
FLOWMETER
REGULATOR
TRIGGER
CONTROL LEAD
FEED ROLLS
WIRE SPOOL
WIRE FEEDER
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VALVE
Lesson 8
Hardsurfacing
Electrodes
MAGNETIC
Lesson 9
Estimating &
Comparing Weld
Metal Costs
WELD CABLE
115V
WELDING GUN
SHIELDING
GAS
CONTACTOR
_
+
POWER
SOURCE
GROUND CABLE
WORK
SCHEMATIC DIAGRAM SEMI-AUTOMATIC GMAW EQUIPMENT
Lesson 10
Reliability of Welding
Filler Metals
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FIGURE 12
Lesson 1
The Basics of Arc
Welding
LESSON II
2.4.4
Lesson 2
Common Electric
Arc Welding
Processes
for gas metal arc welding. It may be a transformer-rectifier or a rotary type unit. The lower
open circuit voltage and self-correcting arc length feature, as described in Lesson I, makes it
most suitable. Constant voltage power sources used for spray transfer welding and for flux
cored electrode welding (to be covered later) are the same. However, if the unit is to be used
for short-circuiting arc
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
OPERATING POINT
V
O
L
T
S
20
Glo
15
10
Lesson 5
Welding Filler Metals
for Stainless Steels
25
Slope control is a
means of limiting the
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
SHORT CIRCUITING
CURRENT NO SLOPE
circuiting current.
200
2.4.4.1
If we were
400
600
800
1000
1200
1400
short-arc welding at
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
FIGURE 13
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
slope components in the circuit, the short-circuiting current is in the neighborhood of 400
amperes, and the molten ball is sort of pinched off the end of the wire more gently. For those
with an electrical background, it might be added that in some machines, slope is achieved by
adding a reactor in the AC secondary of the power source. In others, a slope resistor is added
Lesson 8
Hardsurfacing
Electrodes
in the DC output portion of the circuit. Slope may be adjustable for varying wire diameters or it
may be fixed, giving a good average value for .035" and .045" diameter wires, the two most
popular sizes.
2.4.4.2
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Cu
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Tab
Con
Another factor influencing the arc in short-circuiting welding is the rate that the
amperage reaches the short-circuiting current level. Using the example in Figure 13, we know
that the current goes from 150 amperes to 400 amperes during each shorting period. If we
were to plot the current rise on a graph, as in Figure 14, we would see that the current rise if
very rapid, as shown by the broken line.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
This rapid current rise can be
Cu
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Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
WITH INDUCTANCE
Go T
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
150 AMPS
TIME - MILLISECONDS
EFFECT OF INDUCTANCE ON CURRENT RISE
FIGURE 14
Lesson 5
Welding Filler Metals
for Stainless Steels
becomes smoother,
spatter is reduced, and
bead shape and
appearance are
improved. Because the inductor influences the time function, its design determines arc on-off
time, and short-circuit frequency. Some power sources have a selector that can switch in
several different inductance values to finely tune the arc.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Glo
2.4.4.4
Turn
Welding power sources designed for gas metal arc welding have a 115 volt outlet to
provide power to operate the wire feeder. They also have a receptacle to receive the electrical
power required to close the main contactor in the power source, which turns on the welding
power to the welding gun when the gun trigger is actuated.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.4.4.5
models. Inverters, as well as microprocessor controls, have created the greatest attention. In
addition, multipurpose machines have provided the user with greater flexibility with a variety of
capabilities.
Lesson 8
Hardsurfacing
Electrodes
2.4.4.6
advancements in arc welding equipment. As energy prices rise, greater demands for more
efficient equipment will follow.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.4.5
Wire Feeder - When welding with a constant voltage power source, as is the case
in most gas metal arc welding applications, the prime function of the wire feeder is to deliver
the welding wire to the arc at a very constant speed. Since the wire feed speed determines
the amperage, and the amperage determines the amount of heat at the arc, inconsistent wire
Lesson 10
Reliability of Welding
Filler Metals
feed speed will produce welds of varying penetration and bead width. Advanced electronics
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The Basics of Arc
Welding
LESSON II
technology makes it possible to design motor speed controls that will produce the same
Cu
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speed, even though the load on the motor varies or the input voltage to the motor may fluctuate.
Lesson 2
Common Electric
Arc Welding
Processes
2.4.5.1
A limited amount of gas metal arc welding is performed with constant current type
power sources. In this case, the motor speed automatically varies to increase or decrease the
wire feed speed as the arc length varies to maintain a constant voltage.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
2.4.5.2
reasons. This assures that the welding wire will only be energized when the switch on the
welding gun is depressed.
2.4.5.3
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
The wire feeder also controls the main contactor in the power source for safety
The flow of shielding gas is controlled by a solenoid valve (magnetic valve) in the
wire feeder to turn the shielding gas on and off when the gun switch is actuated. Most feeders
Glo
utilize a dynamic breaking circuit to quickly stop the motor at the end of a weld to prevent a
long length of wire protruding from the gun when the weld is terminated. Most feeders have a
burn-back circuit that allows the welding current to stay on for a short period of time after wire
Lesson 5
Welding Filler Metals
for Stainless Steels
feeding has stopped, to allow the wire to burn back exactly the right amount for the next arc
initiation.
2.4.5.4
The feed rolls, sometimes called drive rolls, pull the wire off the spool or reel, and
push it through a feed cable or conduit to the welding gun. These rolls must usually be
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
changed to accommodate each different wire diameter, although some rolls are designed to
feed a combination of sizes.
2.4.6
Welding Gun - The function of the welding gun, sometimes referred to as a torch, is
to deliver the welding wire, welding current, and shielding gas to the welding arc. Guns are
available for semi-automatic operation and for automatic operation, where they are fixed in the
automatic welding head.
2.4.6.1
Guns for GMAW have several characteristics in common. All have a copper alloy
shielding gas nozzle, that delivers the gas to the arc area in a nonturbulent, angular pattern to
Lesson 8
Hardsurfacing
Electrodes
prevent aspiration of air. The nozzle may be water cooled for semiautomatic welding at high
amperage and for automatic welding where the arc time is of long duration. Welding current is
transferred to the welding wire as the wire travels through the contact tip or contact tube
located inside the gas nozzle (Refer to Figure 9). The hole in the contact tip through which the
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
wire passes is only a few thousandths of an inch larger than the wire diameter. A worn contact
tip will result in an erratic arc due to poor current transfer. Figure 15 shows a few different
semiautomatic gun configurations that are commonly used for GMAW.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
Lesson 2
Common Electric
Arc Welding
Processes
CURVED NECK
Cu
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PISTOL TYPE
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
SELF CONTAINED
PULL TYPE
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
FIGURE 15
2.4.6.2
The curved neck or "goose neck" type is probably the most commonly used. It
allows the best access to a variety of weld joints. The wire is pushed to this type of gun by the
Lesson 5
Welding Filler Metals
for Stainless Steels
feed rolls in the wire feeder through a feed cable or conduit that usually is 10 or 12 feet in
length. The shielding gas hose, welding current cable, and trigger switch leads are supplied
with the welding gun.
2.4.6.3
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
The self contained type has an electric motor in the handle and feed rolls that pull the
wire from a 1 or 2 pound spool mounted on the gun. The need for a long wire feed cable is
eliminated, and wire feed speed may be controlled by the gun. Guns of this type are often
used for aluminum wire up to .045" diameter, although they may also be used for feeding steel
or other hard wires.
The pull type gun has either an electric motor or an air motor mounted in the handle
that is coupled to a feeding mechanism in the gun. The spool of wire is located in the control
cabinet that may be located as far as fifty feet from the gun. When feeding such long
distances, a set of "push" rolls located in the control cabinet assist in feeding the wire. This
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
difficult to reach joints. The pistol type is also a "push" type gun and is more suitable for gas
2.4.6.5
Lesson 8
Hardsurfacing
Electrodes
The pistol type gun is similar to the curved neck type, but is less adaptable for
then becomes known as a push-pull feed system and is especially useful in feeding the softer
wires such as aluminum.
2.4.7
SHIELDING GASES - In gas metal arc welding, there are a variety of shielding
gases that can be used, either alone or in combinations of varying degrees. The choice is
dependent on the type of metal transfer employed, the type and thickness of metal, the bead
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
profile (See Figure 16), penetration, and speed of welding. In our discussion, we will deal with
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the more common choices used for the various transfer processes.
Lesson 2
Common Electric
Arc Welding
Processes
FERROUS METALS
NON-FERROUS METALS
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
CO2
ARGON + CO2
ARGON + O2
ARGON
HELIUM
P
BEAD PROFILE
FIGURE 16
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
2.4.7.1
Short Circuiting Transfer - Straight carbon dioxide (CO ) is often used for short
Glo
circuiting arc welding because of its low cost. The deep penetration usually associated with
CO is minimized because of the low amperage and voltage settings used with this process.
2
Compared to other gas mixes, CO will produce a harsher arc and therefore, greater spatter
2
Lesson 5
Welding Filler Metals
for Stainless Steels
levels. Usually, this is minimized by maintaining a short arc length and by careful adjustment of
the power supply inductance. The temperatures reached in welding will cause carbon dioxide
to decompose into carbon monoxide and oxygen. To reduce the possibility of porosity caused
by entrapped oxygen in the weld metal, it is wise to use electrodes that contain deoxidizing
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
elements, such as silicon and manganese. If the current is increased above the short circuiting
range, the use of carbon dioxide tends to produce a globular transfer.
2.4.7.1.1 Mixing argon in proportions of 50-75% with carbon dioxide will produce a smoother
arc and reduce spatter levels. It will also widen the bead profile, reduce penetration, and
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
encourage "wetting". Wetting, i.e., a uniform fusion, along with joining edges of the base metal
and the weld metal, minimizes the weld imperfection known as undercutting (See Figure 17).
UNDERCUT
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WETTING
FIGURE 17
2.4.7.1.2 The 75% Argon/25 CO mixture is often chosen for short circuit welding of thin
2
Lesson 10
Reliability of Welding
Filler Metals
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steel, but as the carbon dioxide breaks down, excessive carbon may be transferred into the
Lesson 1
The Basics of Arc
Welding
LESSON II
weld metal. Corrosion resistance in stainless steel is reduced as the carbon content
Cu
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increases. To counteract this possibility, a less reactive mixture of 90% helium - 7-1/2% argon
Lesson 2
Common Electric
Arc Welding
Processes
- 2-1/2% CO is sometimes chosen. This combination, known as a trimix, provides good arc
2
Spray Arc Transfer - Pure argon produces a deep constricted penetration at the
center of the bead with much shallower penetration at the edges (Figure 16). Argon performs
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
well on nonferrous metals, but when used on ferrous metals, the transfer is somewhat erratic
with the tendency for the weld metal to move away from the center line. To make argon suit-
able for spray transfer on ferrous metals, small additions of 1 to 5% oxygen have proven to
provide remarkable improvements. The arc stabilizes, becomes less spattery, and the weld
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
metal wets out nicely. If the percentage of argon falls below 80%, it is impossible to achieve
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
2.4.7.3
Pulse Spray Transfer - The selection of shielding gas must be adequate enough to
support a spray transfer. Material type, thickness, and welding position are essential variables
in selecting a particular shielding gas. The following is a list of recommended gases:
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.4.8
Lesson 8
Hardsurfacing
Electrodes
Turn
Carbon Steel
Alloy Steel
Stainless
Argon/Helium
Aluminum
Argon/Helium
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Electrodes - The solid electrodes used in GMAW are of high purity when they come
from the mill. Their chemistry must be closely controlled and some types purposely contain
high levels of deoxidizers for use with CO shielding.
2
2.4.8.1
The electrode manufacturer draws down the electrode to a finished diameter that,
with GMAW, is usually quite small. Diameters from .030" thru 1/16" are common.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
2.4.8.2
Most steel GMAW electrodes are copper plated as a means of protecting the
surface. The copper inhibits rusting, provides smooth feeding, and helps electrical
conductivity.
2.4.8.3
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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON II
2.5
Flux Cored Arc Welding (FCAW) is quite similar to GMAW as far as operation and
equipment are concerned. The major difference is that FCAW utilizes an electrode that is very
different from the solid electrode used in GMAW. The flux cored electrode is a fabricated
electrode and as the name implies, flux material is deposited into its core. The flux cored
Go T
electrode begins as a flat metal strip that is formed first into a "U" shape. Flux and alloying
Lesson 3
Covered Electrodes
for Welding
Mild Steels
elements are deposited into the "U" and then the shape is closed into a tubular configuration
by a series of forming rolls.
2.5.0.1
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Cu
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The flux cored electrode is a continuous electrode that is fed into the arc where it is
melted and transferred into the molten puddle. As in GMAW, the flux cored process depends
Glo
on a gas shield to protect the weld zone from detrimental atmospheric contamination. With
FCAW, there are two primary ways this is accomplished (See Figure 18). The gas is either
applied externally, in which case the electrode is referred to as a gas shielded flux cored
electrode, or it is generated from the decomposition of gas forming ingredients contained in
Lesson 5
Welding Filler Metals
for Stainless Steels
the electrode's core. In this instance, the electrode is known as a self-shielding flux cored
electrode. In addition to the gas shield, the flux cored electrode produces a slag covering for
CONTACT TIP
CONTACT TIP
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
GAS CUP
INSULATED
GUIDE TUBE
GAS SHIELD
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
FLUX CORE
FLUX CORE
Lesson 8
Hardsurfacing
Electrodes
SELF SHIELDED
GAS SHIELDED
FLUX-CORED ARC WELDING
FIGURE 18
Lesson 9
Estimating &
Comparing Weld
Metal Costs
further protection of the weld metal as it cools. The slag is manually removed with a wire brush
or chipping hammer.
2.5.1
Lesson 10
Reliability of Welding
Filler Metals
Turn
Self Shielded Process - The main advantage of the self shielding method is that
its operation is somewhat simplified because of the absence of external shielding equipment.
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Lesson 1
The Basics of Arc
Welding
LESSON II
Although self shielding electrodes have been developed for welding low alloy and stainless
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steels, they are most widely used on mild steels. The self shielding method generally uses a
Lesson 2
Common Electric
Arc Welding
Processes
long electrical stick-out (distance between the contact tube and the end of the unmelted electrode) commonly from one to four inches. Electrical resistance is increased with the long
extension, preheating the electrode before it is fed into the arc. This enables the electrode to
burn off at a faster rate and increases deposition. The preheating also decreases the heat
Lesson 3
Covered Electrodes
for Welding
Mild Steels
available for melting the base metal, resulting in a more shallow penetration than the gas
Go T
shielded process.
P
2.5.1.1
A major drawback of the self shielded process is the metallurgical quality of the
deposited weld metal. In addition to gaining its shielding ability from gas forming ingredients
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
in the core, the self shielded electrode contains a high level of deoxidizing and denitrifying
Glo
alloys, primarily aluminum, in its core. Although the aluminum performs well in neutralizing the
affects of oxygen and nitrogen in the arc zone, its presence in the weld metal will reduce
ductility and impact strength at low temperatures. For this reason, the self shielding method is
Lesson 5
Welding Filler Metals
for Stainless Steels
The self shielding electrodes are more suitable for welding in drafty locations than
the gas shielded types. Since the molten filler metal is on the outside of the flux, the gases
Turn
formed by the decomposing flux are not totally relied upon to shield the arc from the
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
atmosphere. The deoxidizing and denitrifying elements in the flux further help to neutralize the
affects of nitrogen and oxygen present in the weld zone.
2.5.2
The Gas Shielded Process - A major advantage with the shielded flux cored
electrode is the protective envelope formed by the auxiliary gas shield around the molten
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
puddle. This envelope effectively excludes the natural gases in the atmosphere without the
need for core ingredients such as aluminum. Because of this more thorough shielding, the
weld metallurgy is cleaner which makes this process suitable for welding not only mild steels,
but also low alloy steels in a wide range of strength and impact levels.
Lesson 8
Hardsurfacing
Electrodes
2.5.2.1
The gas shielded method uses a shorter electrical stickout than the self shielded
process. Extensions from 1/2" to 3/4" are common on all diameters, and 3/4" to 1-1/2" on
larger diameters. Higher welding currents are also used with this process, enabling high
deposition rates to be reached. The auxiliary shielding helps to reduce the arc energy into a
Lesson 9
Estimating &
Comparing Weld
Metal Costs
columnar pattern. The combination of high currents and the action of the shielding gas
contributes to the deep penetration inherent with this process. Both spray and globular
transfer are utilized with the gas shielded process.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
2.5.3
Current Density - Flux cored arc welding utilizes the same principles of current
Cu
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density, as explained in section 2.4.1, but there is one significant difference between the flux
Lesson 2
Common Electric
Arc Welding
Processes
cored electrode and the solid electrode. With the flux cored electrode, the granular core
ingredients are poor electrical conductors and therefore, the current is carried primarily
through the outer metal sheathing. When an equal diameter cross section of the two are compared (See Figure
Lesson 3
Covered Electrodes
for Welding
Mild Steels
CURRENT PATH
Go T
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
2.5.3.1
Lesson 5
Welding Filler Metals
for Stainless Steels
1/16" FLUX-CORED
ELECTRODE
solid electrode.
2.5.4
1/16" SOLID
ELECTRODE
FIGURE 19
EQUIPMENT - The equipment used for flux cored arc welding is the same as
shown previously in Section 2.3.2.2, Figure 12, with the exception that the self shielded
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.5.4.1
Flux cored arc welding is done with direct current. All of the gas shielded electrodes
are designed for DCEP operation. The self shielded electrodes are either designed
specifically for DCEN or DCEP.
2.5.5
Power Source - The recommended power source is the direct current constant
voltage type. The constant current type can be used but with less satisfactory results.
2.5.6
Wire Feeder - The function of the wire feeder in FCAW is the same as discussed in
the section on GMAW. Since the flux cored electrode is tubular in construction, precautions
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
must be taken not to flatten the electrode. To facilitate feeding by means other than pressure
alone, specially designed feed rolls with knurled or grooved surfaces are used. Some feeders
use four feed rolls rather than two to minimize unit pressure on the electrode.
2.5.7
The Welding Gun - As compared to GMAW, the main difference in FCAW welding
guns is in those used with the self shielding process. The gun is somewhat more compact due
to the absence of an external gas shielding nozzle. Since the self shielding process normally
requires a longer electrode extension, the self shielding gun may have an insulated guide tube
(Refer back to Figure 18) to give stability to the electrode. Water cooled guns are available for
Lesson 10
Reliability of Welding
Filler Metals
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Lesson 1
The Basics of Arc
Welding
LESSON II
2.5.7.1
Flux cored welding generates fumes, that for environmental reasons, must be
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removed from the welding area. This is usually done with an external exhaust system, but
Lesson 2
Common Electric
Arc Welding
Processes
welding guns with internal fume extractors have been developed. They are heavier than the
regular gun and must be properly maintained so that the extracting mechanism does not
disturb the shielding gas.
2.5.8
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
and 25% CO .
2
A carbon dioxide shield produces deep penetration and the transfer is globular. As
previously discussed, CO will dissociate in the heat of the arc. To counteract this
2
Glo
characteristic, deoxidizing elements are added to the core ingredients of the electrode. The
deoxidizers react to form solid oxide compounds that float to the surface as part of the slag
covering.
2.5.8.2
The addition of Argon to CO will increase the wetting action, produce a smooth arc
2
arc, and reduce spatter. The transfer is spray-like, and the penetration is somewhat less than
with the straight carbon dioxide.
2.5.8.3
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Go T
shielding of the flux cored electrode. The other commonly used gas is a mixture of 75% Argon
2.5.8.1
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
SHIELDING GASES - Carbon dioxide is the most widely used gas for auxiliary
Turn
While some flux cored electrodes are designed to operate well on both the 100%
CO or the 75/25 mixture, others are formulated specifically for the CO shield or the Argon/
2
CO mixture. If the recommended gas is not used with these electrodes, the weld chemistry
2
may be affected. The reason for this is that inert gas, such as Argon, does not react with the
other elements; therefore, allowing them to be transferred across the arc into the weld metal.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
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An electrode designed for CO shielding contains deoxidizing elements, such as silicon and
2
manganese. If a high percentage of Argon is used in the shielding medium, a large portion of
these elements may pass into the weld metal causing the weld metallurgy to be less ductile
than intended.
Lesson 8
Hardsurfacing
Electrodes
2.5.8.3
The opposite happens with electrodes formulated for a 75/25 mixture. These
electrodes are usually designed for high yield and tensile strength. If a high percentage of CO
is used with them, the CO may react with the elements needed to attain these strength levels,
2
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.6
Submerged Arc Welding (SAW) is different from the previously explained arc welding
processes in that the arc is not visible. The arc is submerged beneath loose granular flux. A
Lesson 10
Reliability of Welding
Filler Metals
continuous electrode is fed by automatic drive rolls through an electrode holder where current
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Lesson 1
The Basics of Arc
Welding
LESSON II
is picked up at the contact tube. The electrode moves into the loose flux and the arc is
Cu
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initiated. The flux is deposited from a separate container that moves at the same pace as the
Lesson 2
Common Electric
Arc Welding
Processes
Submerged Arc Flux - The flux helps form the molten puddle, slows the cooling
rate, and acts as a protective shield. The flux, which is in close contact with the arc, is fused
into a slag cover and that which is not fused is collected for reuse. The flux can contain alloying
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
elements that, when molten, will pass into the weld metal affecting the metallurgy. Some fluxes
are specifically prepared for their alloy altering capabilities while others, known as neutral
fluxes, are chosen when a minimal alloy change is desired. Although these latter fluxes are
called "neutral", they still have the ability to slightly alter the weld chemistry.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
FLUX HOPPER
Lesson 5
Welding Filler Metals
for Stainless Steels
ELECTRODE
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
BASE
METAL
MOLTEN PUDDLE
FUSED SLAG COVER
SOLIDIFIED WELD METAL
SUBMERGED ARC WELDING
FIGURE 20
2.6.2
The Welding Gun - Although there are hand-held welding guns for the submerged
arc process, the majority of SAW is done with fully automatic equipment. The basic compo-
Lesson 8
Hardsurfacing
Electrodes
nents include a wire feeder, a power source, a flux delivery system, and in some instances, an
automatic flux recovery system.
2.6.3
Lesson 9
Estimating &
Comparing Weld
Metal Costs
may be a DC rectifier or generator of either the constant current or constant voltage variety.
The power source must be rated for high current output. When current requirements exceed
the value of a single machine, two or more of the same type may be connected in parallel.
2.6.4
Lesson 10
Reliability of Welding
Filler Metals
Equipment - Most submerged arc welding is done with DCEP because it provides
easy arc starting, deep penetration and excellent bead shape. DCEN provides the highest
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Lesson 1
The Basics of Arc
Welding
LESSON II
deposition rates but minimum penetration. Alternating current is often used as a trailing arc in
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tandem arc applications. In this type of application, the leading DCEP arc provides deep
Lesson 2
Common Electric
Arc Welding
Processes
penetration, and the closely trailing AC arc provides high deposition with a minimum of arc
blow.
2.6.5
arc welding. They are usually solid electrodes refined with the appropriate alloys at the steel
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
mill, and then shipped to electrode manufacturers where they are drawn down to a specific
diameter and packaged. There is another type of sub arc electrode known as a composite
electrode, that is fabricated in the same manner as a flux cored electrode. A chief advantage
of this type is that the alloying elements can be added to the core of the electrode more
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
cheaply than a steel mill can produce those same alloys in a solid form. The electrodes for
widely used.
2.6.6
Lesson 5
Welding Filler Metals
for Stainless Steels
Summary - Submerged arc welding has some advantages over other welding
processes. Since the radiance of the arc is blanketed by the loose flux, there is no need for a
protective welding hood (although safety glasses are recommended), there is no spatter and
only a very minimal amount of fumes escape from under the blanket. High welding currents,
quite commonly in the 300 to 1600 ampere range, are used. These high currents, combined
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
applications that require a series of repetitious welds. Some setups allow two or more electrodes to be fed simultaneously into the joint, further increasing the deposition rate and speed.
Although SAW has these advantages, it does have some limitations. The flux must
be deposited and collected for every welding pass. This requires additional equipment and
handling. Also because of the loose flux, the process is limited to the flat and horizontal
positions. The equipment for SAW is commonly quite bulky which limits its mobility, and
although the process works well on thick materials, it usually is not satisfactory for thin gauge
Lesson 8
Hardsurfacing
Electrodes
Turn
with fast travel speeds, make SAW a high deposition process that is especially suitable for
2.6.6.1
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Glo
SAW vary in diameter from 1/16 inch to 1/4 inch with the larger diameters being the most
material. The process requires care in the operation. The amperages commonly used may
cause excessive heat buildup in the base metal, that may result in distortion or brittleness.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
LESSON II
2.7
Cu
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Electroslag Welding (ESW) and Electrogas Welding (EGW) comprise only a minor portion
of all welding done in the country, but they are uniquely adapted to certain applications,
primarily the joining of very thick materials. The joining of a 12 inch material along a 40 foot
line is not an uncommon application for the Electroslag process.
Electroslag Welding (See Figure 21) is technically not an arc welding process,
2.7.1
although it utilizes a current carrying consumable electrode. The only time there is an arc
Go T
between the electrode and the work piece is when current is initially charged through the
electrode. This initial charge heats a layer of loose flux that becomes molten and extinguishes
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
the arc.
Glo
WATER INLET/OUTLET
ELECTRODE
COPPER SHOE
Lesson 5
Welding Filler Metals
for Stainless Steels
GUIDE TUBE
(CONSUMABLE GUIDE METHOD)
BASE METAL
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
MOLTEN FLUX
WELD POOL
SOLIDIFIED METAL
ELECTROSLAG WELDING
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
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FIGURE 21
2.7.2
Flux - The flux used in ESW is high in electrical resistance. As current is applied,
enough heat is generated from this resistance to keep the flux, base metal, and electrode in a
Lesson 8
Hardsurfacing
Electrodes
molten state. This axis of the weld joint is on a vertical plane. The two pieces of metal, usually
of the same thickness, are positioned so that there is an opening between them. One or more
electrodes are fed into the opening through a welding bead that travels vertically as the joint is
filled. To contain the molten puddle, water cooled copper shoes or dams are placed on the
Lesson 9
Estimating &
Comparing Weld
Metal Costs
sides of the vertical cavity. As the weld joint solidifies, the dams move vertically so as to
always remain in contact with the molten puddle.
2.7.3
Process - A variation of ESW is the consumable guide method. The process is the
same with this method except that the guide tube that feeds the electrode to the molten pool is
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
also consumed. The chief advantage with this method is the elimination of the electrode
Cu
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Tab
Con
holder which must move vertically with the weld pool. Also since the guide tube is consumed,
Lesson 2
Common Electric
Arc Welding
Processes
Equipment - The equipment used in ESW is all automatic and of special design.
The power source may use either AC or DC current. The electrode may be either solid or flux
cored, although if the flux cored is used, it must be specially formulated so as not to contain its
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
pects are concerned. The equipment is automatic, the welding head travels vertically, and the
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
molten puddle is retained by shoes on the sides of the joint. The difference is that Electrogas
Welding utilizes an arc and it is externally gas shielded. The power source is also limited to
Glo
DC operation. The electrodes used in EGW can be either solid or flux cored.
Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
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Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
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Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON II
APPENDIX A
Lesson 2
Common Electric
Arc Welding
Processes
Arc Blow
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
- Deviation of the direction of the welding arc caused by magnetic fields in the
Go T
P
Straight
Polarity
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Cu
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Tab
Con
Glo
Reverse
Polarity
Slag
- The brittle mass that forms over the weld bead on welds made with coated
electrodes, flux cored electrodes, submerged arc welding and other slag
producing welding processes. Welds made with the gas metal arc and the
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Manual Arc
Welding
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Semi-Automatic
Welding
- Welding with a coated electrode where the operator's hand controls travel
speed and the rate the electrode is fed into the arc.
- Welding with a continuous solid wire or flux cored electrode where the wire
feed speed, shielding gas flow rate, and voltage are preset on the equipment,
and the operator guides the hand held welding gun along the joint to be
Lesson 8
Hardsurfacing
Electrodes
welded.
Slag
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
Inclusion
Root Pass
- A weld defect where slag is entrapped in the weld metal before it can float to
the surface.
- The initial pass in a multi-pass weld, usually requiring 100% penetration.
Lesson 10
Reliability of Welding
Filler Metals
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Lesson 1
The Basics of Arc
Welding
LESSON II
Gas Ions
- Shielding gas atoms that, in the presence of an electrical current, lose one or
Cu
Ch
Tab
Con
more electrons and therefore, carry a positive electrical charge. The provide
Lesson 2
Common Electric
Arc Welding
Processes
a more electrically conductive path for the arc between the electrode and the
work piece.
High
Frequency
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Inert Gases
- Gases that are chemically inactive. They do not readily combine with other
elements.
Flux
Lesson 5
Welding Filler Metals
for Stainless Steels
- In arc welding, fluxes are formulations that, when subjected to the arc, act as
a cleaning agent by dissolving oxides, releasing trapped gases and slag and
generally cleaning the weld metal by floating the impurities to the surface
where they solidify in the slag covering. The flux also serves to reduce spatter
and contributes to weld bead shape. The flux may be the coating on the
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Density
Slope or Slope
Lesson 8
Hardsurfacing
Electrodes
Control
welding. Slope Control reduces the short circuiting current each time the
electrode touches the weld puddle (See Section 2.5.3).
Inductance
Lesson 9
Estimating &
Comparing Weld
Metal Costs
- A necessary feature in welding power sources used for short circuiting arc
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
Contact Tip
Cu
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Tab
Con
- That part of a gas metal arc welding gun or flux cored arc welding gun that
transfers the welding current to the welding wire immediately before the wire
Lesson 2
Common Electric
Arc Welding
Processes
Spray
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Transfer
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Globular
- Mode of metal transfer across the arc where the molten metal droplets are
smaller than the electrode diameter and are axially directed to the weld puddle.
Go T
Requires high voltage and amperage settings and a shielding gas of at least
80% argon.
Transfer
- Mode of metal transfer across the arc where a molten ball larger than the
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
Pulse
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Transfer
- Mode of metal transfer somewhat between spray and short circuiting. The
Turn
specific power source has built into it two output levels: a steady background
level, and a high output (peak) level. The later permits the transfer of metal
across the arc. This peak output is controllable between high and low values
up to several hundred cycles per second. The result of such a peak output
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Shortcircuiting
Transfer
Lesson 8
Hardsurfacing
Electrodes
Transfer takes place each time the electrode touches or short-circuits to the
weld puddle, extinguishing the arc. The short-circuiting current causes the
electrode to neck down, melt off, and then repeats the cycle.
Trimix or
Lesson 9
Estimating &
Comparing Weld
Metal Costs
- Mode of metal transfer in gas metal arc welding at low voltage and amperage.
Triple Mix
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON II
Electrical
Lesson 2
Common Electric
Arc Welding
Processes
Cu
Ch
Tab
Con
- In any welding process using a solid or flux cored wire, the electrical stick-out
is the distance from the contact tip to the unmelted electrode end. Sometimes
Stick-Out
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Out-of-Position
Weld
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Welds
Glo
Positions
FLAT
HORIZONTAL FILLET
Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
VERTICAL
OVERHEAD
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Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
HORIZONTAL
BUTT
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POSITIONED FILLET
(FLAT)
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
Cu
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Tab
Con
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
BASIC
WELDING FILLER
METAL TECHNOLOGY
A Correspondence Course
LESSON III
COVERED ELECTRODES FOR
WELDING MILD STEELS
An Introduction to Mild Steel
Covered Electrodes
Go T
Glo
Turn
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ESAB
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
Cu
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Tab
Con
TABLE OF CONTENTS
LESSON III
COVERED ELECTRODES FOR WELDING
MILD STEELS
Lesson 2
Common Electric
Arc Welding
Processes
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Section Nr.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Page
3.1
3.2
3.2.1
3.2.2
3.3
3.3.1
3.3.2
3.3.3
3.4
11
3.4.1
12
3.4.2
Electrode Deposition.........................................................................
14
3.5
15
3.6
3.7
Lesson 8
Hardsurfacing
Electrodes
Section Title
15
16
3.7.1
16
3.7.2
17
3.7.3
18
3.7.4
19
3.7.5
20
3.7.6
21
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Glo
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Cu
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Con
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
TABLE OF CONTENTS
LESSON III - Con't
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Section Nr.
Section Title
Page
3.7.7
21
3.7.8
22
3.7.9
23
3.7.10
24
3.7.11
25
3.7.12
26
Appendix A
GLOSSARY OF TERMS...................................................................
27
Glo
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Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
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Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Se
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Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Cu
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LESSON III
3.1
During the 1890's, arc welding was accomplished with bare metal electrodes. The welds produced were
porous and brittle because the molten weld puddle absorbed larg quantities of oxygen and nitrogen
from the atmosphere. Operators noticed that a rusty rod produced a better weld than a shiny clean rod.
Observations also showed than an improved weld could be made by wrapping the rod in newspaper or by
welding adjacent to a pine board placed close to and parallel with the weld being made. In these cases,
some degree of shielding the arc form the atmosphere was being accomplished. These early observations
led to the development of the coated electrode.
Go T
P
3.1.0.1 Around 1920, the A.O. Smith Corporation developed an electrode spirally wrapped with paper,
soaked in sodium silicate, and then baked. This was the first of the cellulosic type electrodes.
It produced an effective gas shield in the area and greatly improved the ductility of the weld metal.
Glo
3.1.0.2 Because of the method used to manufacture these paper covered electrodes, it was difficult
to effectively add other ingredients to the coating. In 1924, the A.O. Smith Corporation began work
on coatings that could be extruded over the core wire. This method allowed the addition of other
flux ingredients to furhter improve or modify the weld metal and by 1927, these electrodes were
being produced commercially.
3.1.0.3 Since 1927, many improvements have been made and many different types of electrodes have
been developed and produced. Through variations in the formulations of the covering and the amount
of covering on the mild steel core wire, many different classifications of electrodes are produced today.
3.2
Turn
Mild steel covered electrodes, also commonly called coated electrodes, consist of only two major elements;
the core wire or rod and the flux covering. The core wire is usually low carbon steel.
It must contain only small amounts of aluminum and copper, and the sulfur and phosphorous levels
must be kept very low since they can cause undesirable brittleness in the weld metal. The raw material
for the core wire is hot-rolled rod (commonly called "hot rod"). It is
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Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
Cu
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Con
LESSON III
received in large coils, cleaned, drawn down to the proper electrode diameter, straightened,
and cut to the proper electrode length.
Lesson 2
Common Electric
Arc Welding
Processes
3.2.0.1
The coating ingredients, from which there are literally hundreds to choose, are
carefully weighed, blended in a dry state, wet mixed, and compacted into a large cylinder that
fits into the extrusion press. The coating is extruded over the cut core wires which are fed
Go T
through the extrusion press at a rapid rate. The coating material is removed from the end of
Lesson 3
Covered Electrodes
for Welding
Mild Steels
the electrode that is clamped into the electrode holder to assure electrical contact, and also
3.2.0.2
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
from the welding end of the electrode to assure easy arc initiation.
The electrodes are then stamped with the type number for easy identification before
entering the ovens, where they go through a controlled bake cycle to insure the proper mois-
Glo
Of the many quality control checks made during the manufacturing process, one of
the most important is the procedure that insures that the coating thickness is uniform. In
Lesson 5
Welding Filler Metals
for Stainless Steels
shielded metal arc welding, the coating crater, or the cup-like formation of the coating, that
extends beyond the melting core wire, performs the function of concentrating and directing the
arc. See Figure 1.
A
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
CONCENTRIC COATING
NON-CONCENTRIC COATING
FIGURE 1
3.2.0.4
Concentration and direction of the arc stream is attained by having a coating crater,
somewhat similar to the nozzle on a water hoze, directing the flow of weld metal. When the
coating is not concentric to the core wire, it can cause the condition shown at B in Figure 1.
The poor arc direction causes inconsistent weld beads, poor shielding, and lack of penetration. The electrode burns off unevenly, leaving a projection on the side where the coating is the
Lesson 10
Reliability of Welding
Filler Metals
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Lesson 1
The Basics of Arc
Welding
LESSON III
3.2.1
Cu
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Con
coatings can be classified physically in a broad manner as liquids and solids. The liquids are
Lesson 2
Common Electric
Arc Welding
Processes
generally sodium silicate or potassium silicate. The solids are powdered or granulated materials that may be found free in nature, and need only concentration and grinding to the proper
particle size. Other solid materials used are produced as a result of chemical reactions, such
as alloys or other complex synthetic compounds.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
3.2.1.1
The particle size of the solid material is an important factor. Particle size may be as
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
fibrous or amorphous (non-crystalline). Crystalline materials such as rutile, quartz and mica
are commonly used. Rutile is the naturally occurring form of the mineral titanium dioxide and
Glo
is widely used in electrode coatings. Fibrous materials such as wood fibers, and non-crystalline materials such as glasses and other organic compounds are also common coating ingredients.
Lesson 5
Welding Filler Metals
for Stainless Steels
3.2.1.3
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
shield the weld metal from the oxygen and nitrogen of the air as it is being transferred across
Turn
the arc, and while it is in the molten state. This shielding is necessary to ensure the weld metal
will be sound, free of gas pockets, and have the right strength and ductility. At the high temperatures of the arc, nitrogen and oxygen combine readily with iron to form iron nitrides and
iron oxides that, if present in the weld metal above certain minimum amounts, will cause brittle-
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
ness and porosity. Nitrogen is the primary concern since it is difficult to control its effect once it
has entered the deposit. Oxygen can be counteracted by the use of suitable deoxidizers. In
order to avoid contamination from the air, the stream of molten metal must be protected or
shielded by gases that exclude the surrounding atmosphere from the arc and the molten weld
metal. This is accomplished by using gas-forming materials in the coating that break down
Lesson 8
Hardsurfacing
Electrodes
Stabilization of the Arc - A stabilized arc is one that starts easily, burns
smoothly even at low amperages, and can be maintained using either a long or a short arc
Lesson 9
Estimating &
Comparing Weld
Metal Costs
length.
c) Alloying Additions to Weld Metal - A variety of elements such as chromium,
nickel, molybdenum, vanadium and copper can be added to the weld metal by including them
in the coating composition. It is often necessary to add alloys to the coating to balance the
Lesson 10
Reliability of Welding
Filler Metals
expected loss of alloys of the core wire during the welding operation, due to volatization and
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Lesson 1
The Basics of Arc
Welding
LESSON III
chemical reaction. Mild steel electrodes require small amounts of carbon, manganese and
Cu
Ch
Tab
Con
silicon in the deposit to give sound welds of the desired strength level. A portion of the carbon
Lesson 2
Common Electric
Arc Welding
Processes
and manganese is derived from the core wire, but it is necessary to supplement it with
ferromanganese and in some cases ferrosilicon additions in the coating.
d) Concentration of the Arc Stream - Concentration or direction of the arc
stream is attained by having a coating crater form at the tip of the electrodes as discussed
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
earlier. Use of the proper binders assures a good hard coating that will maintain a crater and
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
protection against atmospheric contamination, (2) to act as a cleaner and absorb impurities
that are floated off and trapped by the slag, (3) to slow the cooling rate of the molten metal to
allow the escape of gases. The slag also controls the contour, uniformity and general appearance of the weld. This is particularly true in fillet welds.
f)
primarily titanium compounds, in the coating that makes it possible to weld out-of-position ,
vertically, and overhead. Slag characteristics, primarily surface tension and freezing point,
determine to a large degree the ability of an electrode to be used for out-of-position work.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Glo
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Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Ferromanganese is probably the most common ingredient used to attain the correctly balanced formula.
h) Specific Mechanical Properties to the Weld Metal - Specific mechanical
properties can be incorporated into the weld metal by means of the coating. High impact
Lesson 8
Hardsurfacing
Electrodes
values at low temperature, high ductility, and increases in yield and tensile properties can be
attained by alloy additions to the coating.
i)
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Insulation of the Core Wire - The coating acts as an insulator so that the core
wire will not short-circuit when welding in deep grooves or narrow openings; coatings also
serve as a protection to the operator when changing electrodes.
3.2.2
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON III
Cu
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Tab
Con
manganese and others impart specific mechanical properties to the weld metal.
Lesson 2
Common Electric
Arc Welding
Processes
b) Binders - Soluble silicates such as sodium and potassium silicates, are used in
the electrode coating as binders. Functions of binders are to form a plastic mass of coating
material capable of being extruded and baked. The final baked coating should be hard so that
it will maintain a crater and have sufficient strength so that it will not spall, crack or chip. Bind-
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
ers are also used to make coating non-flammable and avoid premature decomposition.
P
c) Gas Formers - Common gas forming materials used are the carbohydrates,
hydrates, and carbonates. Examples would be cellulose (such as wood flock), the carbonates
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
of calcium and magnesium, and chemically combined water as is found in clay and mica.
These materials evolve carbon dioxide (CO ), carbon monoxide (CO), and water vapor (H O)
2
Glo
at the high temperature of the welding arc. Free moisture is another gas-forming ingredient
that is found particularly in cellulosic type electrodes and is a part of the formulation in amounts
of 2%-3%. It has a marked influence on the arc and is a necessary ingredient in the E6010
Lesson 5
Welding Filler Metals
for Stainless Steels
type electrode.
d) Arc Stabilizers - Air is not sufficiently conductive to maintain a stable arc, so it
becomes necessary to add coating ingredients that will provide a conductive path for the flow
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
of current. This is particularly true when welding with alternating current. Stabilizing materials
are titanium compounds, potassium compounds, and calcium compounds.
e) Fluxes and Slag Formers - These ingredients are used primarily to give body
to the slag and impart such properties as slag viscosity, surface tension, and melting point.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Plasticizers - Coatings are often very granular or sandy, and in order to suc-
Lesson 8
Hardsurfacing
Electrodes
used.
3.2.2.1
The chart in Figure 2 shows typical coating constituents and their functions for two
types of mild steel electrodes. Note that the moisture content in the cellulosic E6010 is much
Lesson 9
Estimating &
Comparing Weld
Metal Costs
higher than in the low hydrogen E7018 type. The moisture in the E6010 coating is necessary
to produce the driving arc characteristic and is not harmful when welding the lower strength
steels. Hydrogen can cause problems when welding the higher strength steels and will be
discussed in detail in Lesson IV.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON III
Class
Lesson 2
Common Electric
Arc Welding
Processes
E6010
Composition
Cellulose (C6H10 O5)
35%
Gas Former
40% H2
15%
40% CO + CO2
Deoxidizer - Alloying
20% H2O
Ferromanganese
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
5%
Talc
15%
Slag Former
Sodium Silicate
25%
Go T
5%
Calcium Carbonate
30%
Fluorspar (CaF2)
20%
Ferromanganese
E7018
Shielding
Rutile (TiO2)
Moisture
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Function
Deoxidizer - Alloying
80% CO
Potassium Silicate
15%
20% CO2
Iron Powder
30%
Deposition Stabilizer
Moisture
5%
Cu
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Tab
Con
Glo
0.1%
Lesson 5
Welding Filler Metals
for Stainless Steels
FIGURE 2
3.3
This American Welding Society (AWS) specification has been developed over the years by a
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
ESAB, users from the welding industry, and independent members from colleges, universities
and independent laboratories. This balanced membership is required to prevent prejudice
from entering into the specifications.
3.3.0.1
Individual Mild Steel electrodes are classified by the manufacturer according to the
above specification on the basis of the mechanical properties (also called physical properties)
of the weld metal, the type of covering, the welding position of the electrode, and the type of
current (AC or DC). The classification system is designed to give certain information about
Lesson 8
Hardsurfacing
Electrodes
the electrode and the weld metal produced from it. The significance of the AWS designations
are shown in tabular form in Figure 3.
3.3.0.2
These classifications, with the AWS Specification A5.1-91, are assigned by the
manufacturer of the electrodes according to the results of his own tests. The American Weld-
Lesson 9
Estimating &
Comparing Weld
Metal Costs
The American Society of Mechanical Engineers (ASME) uses the AWS Electrode
Specifications word for word by adding the letters SF before the specification number. Thus,
AWS Specification A5.1-91 becomes ASME Specification SFA5.1. The classification and
Lesson 10
Reliability of Welding
Filler Metals
Turn
filler metals committee, composed of members who represent electrode producers, such as
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Se
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Lesson 1
The Basics of Arc
Welding
LESSON III
MILD STEEL COVERED ELECTRODES
EXAMPLE:
Lesson 2
Common Electric
Arc Welding
Processes
1.
2.
E
(1)
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
EXX10
EXXX1
EXXX2
EXXX3
EXXX4
EXXX5
EXXX6
EXXX8
EXX20
EXX22
EXX24
EXX27
EXX28
EXX48
3.
0
(3)
(4)
Current
DCEP
AC or DCEP
AC or DCEN
AC or DCEN
AC or DCEN
DCEP
AC or DCEP
AC or DCEP
AC or DCEN
AC or DCEN
AC or DCEN
AC or DCEN
AC or DCEP
AC or DCEP
or DCEP
or DCEP
or DCEP
or DCEP
or DCEP
Penetration
Digging
Digging
Medium
Soft
Soft
Medium
Medium
Medium
Medium
Medium
Soft
Medium
Medium
Medium
Deep
Deep
Medium
Light
Light
Medium
Medium
Medium
Medium
Medium
Light
Medium
Medium
Medium
Lesson 5
Welding Filler Metals
for Stainless Steels
Iron Powder
Cellulose - sodium
Cellulose - potassium
Titania - sodium
Titania - potassium
Titania - iron powder
Low hyd. - sodium
Low hyd. - potassium
Low hyd. - iron powder
Iron oxide - sodium
Iron oxide - sodium
Titania - iron powder
Iron oxide- iron powder
Low hyd. - iron powder
Low hyd. - iron powder
0- 10%
0
0-10%
0- 10%
25-40%
0
0
25-40%
0
0
50%
50%
50%
25-40%
Glo
Turn
are as follows:
a)
b)
Classification E7018 and E7027 must have no more than 1.60% Manganese, 0.75% Silicon, 0.30% Nickel, 0.20% Chromium, 0.30% Molybdenum, and 0.08% Vanadium.
Lesson 8
Hardsurfacing
Electrodes
Se
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Se
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specimens in the "as-welded" condition. This means that the weldment or weld metal is not
subjected to any type of heat treatment. Tensile test specimens for all electrode classifications
other than the low hydrogen types (E7015, E7016, E7018, E7028 and E7048) are aged at
200F to 220F for forty-eight (48) hours prior to being subjected to the tensile test. This is not
considered heat treatment. It simply accelerates the diffusion of hydrogen from the weld metal
Lesson 10
Reliability of Welding
Filler Metals
FIGURE 3
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Go T
ELECTRODE CLASSIFICATION
3.3.1
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Classification
Lesson 3
Covered Electrodes
for Welding
Mild Steels
60
(2)
Cu
Ch
Tab
Con
Lesson 1
The Basics of Arc
Welding
LESSON III
3.3.2.1
Classifications E6010, E6011 and E6027 weld metals are required to have more
Cu
Ch
Tab
Con
than 62,000 psi tensile strength, 50,000 psi yield strength, 22% elongation in two inch gauge,
Lesson 2
Common Electric
Arc Welding
Processes
Classification E6020 weld metals are required to have more than 62,000 psi
tensile strength, 50,000 psi yield strength, 22% elongation in two inch gauge, and no Charpy
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
3.3.2.3
Classifications E6012 and E6013 weld metals are required to have more than
67,000 psi tensile strength, 55,000 psi yield strength, 17% elongation in two inch gauge, and
no Charpy V-notch impact requirements.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
3.3.2.4
Classifications E7014 and E7024 weld metals are required to have more than
72,000 psi tensile strength, 60,000 psi yield strength, 17% elongation in two inch gauge, and
no Charpy V-notch impact requirements.
3.3.2.6
Classifications E7015, E7016, E7018, D7027 and E7048 are required to have
more than 72,000 psi tensile strength, 60,000 psi yield strength, 22% elongation in two inch
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
3.3.2.7
Classification E7028 is required to have more than 72,000 psi tensile strength,
60,000 psi yield strength, 22% elongation in two inch gauge, and 20 ft-lb at 0F Charpy V-
3.3.3
Lesson 8
Hardsurfacing
Electrodes
with mineral silicates, deoxidizers, and sodium silicate. The amount of coating
on the electrode is low, about 10-12% by weight. Because the wood pulp
burns away during welding, the slag is minimal and is usually easily removed.
The arc has deep penetration and with proper manipulation of the arc, good
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
notch impacts.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Glo
tensile strength, no requirement for yield strength and no Charpy V-notch requirements.
3.3.2.5
Lesson 5
Welding Filler Metals
for Stainless Steels
Classification E6022 weld metals are required to have more than 67,000 psi
welds can be deposited in all positions. Most of the ships built in the United
States during World War II were welded with this classification of electrode.
Special formulations of this classification are used to weld line pipe joints in
the vertical-down position. Reasonably sound welds can be deposited in open
root butt joints (see Appendix A - Glossary) with this electrode.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
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(Fa
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Se
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Lesson 1
The Basics of Arc
Welding
LESSON III
b)
E6011 electrodes are similar to E6010 except that sufficient potassium com-
Cu
Ch
Tab
Con
pounds have been added to the coating to stabilize the arc stream and allow
Lesson 2
Common Electric
Arc Welding
Processes
E6012 electrodes have several common names. In Europe, they are called
rutile (see Glossary) electrodes. Many welders call them cold rods. The
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
coating contains large percentages of the mineral rutile (titanium dioxide), i.e.,
the titania referred to in the classification. The arc has low penetration, and
with proper manipulation wide gaps can be bridged. Although the specification calls for operation on either AC or DC, the arc is smoother and spatter
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
potassium compounds to stabilize the arc sufficiently for welding with alternating current.
e)
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
E7014 electrodes are related to 6013 electrodes except that iron powder has
Turn
been added and a heavier coating is applied to the core wire. This results in
higher deposition rates with the E7014 electrode than with the E6013.
f)
E7015 electrodes were the first of the low hydrogen electrodes. They were
developed in the 1940's to weld hardenable steels such as armor plate. All of
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
to, the weld bead. Limestone and other ingredients that are low in moisture
are used in the coating, eliminating this hydrogen induced cracking. The
coating is a low hydrogen, sodium type that limits these electrodes to be used
only with direct current, reverse polarity. E7015 electrodes are not generally
Lesson 9
Estimating &
Comparing Weld
Metal Costs
available today having been replaced by the E7016 and E7018 type.
g)
E7016 electrodes are very similar to the E7015 type except that the use of
potassium in the coating allows these electrodes to be used with alternating
current as well as direct current, reverse polarity.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
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Se
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Lesson 1
The Basics of Arc
Welding
LESSON III
h)
E7018 electrodes are the more modern version of the low hydrogen electrode.
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
a smoother arc with less spatter. This modern balance of covering ingredients
results in a great improvement in arc stability, arc direction and ease of handling in all welding positions.
i)
E6020 electrodes have a coating that consists mainly of iron oxide, manga-
Go T
nese compounds and silica. They have a spray-type arc and produce a heavy
slag that provides protection of the molten weld metal. The molten weld metal
E6022 electrodes are for high speed, high current single pass welding of
sheet metal. They are not generally available today.
k)
Glo
E7024 electrodes have a coating similar to the E6012 and E6013 types, but
have a very heavy coating that contains 50% iron powder by weight. Run at
relatively higher currents, the deposition rate is high. Welds are limited to the
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
E6027 electrodes are also a high iron powder type, the coating consisting of
Turn
50% iron powder by weight. Current may be AC or DC, either polarity. The
penetration is medium and the weld beads are slightly concave with good side
wall fusion. As with all high iron powder electrodes, deposition rate is high.
n)
E7028 electrodes are much like the E7018 electrodes except that the coating
is heavier and contains 50% iron powder by weight. Unlike the E7018 electrode, they are suitable for flat and horizontal fillet welding only. Deposition rate
Se
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is very high.
o)
E7048 electrodes are much like the E7018 electrodes except they are designed for exceptionally good vertical-down welding.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON III
3.4
Many factors must be considered when selecting the proper electrode for a given application.
Some items to be considered are:
a) Type of Base Metal - Welding mild steels or low carbon steels (carbon content
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
Ch
Tab
Con
Go T
below 0.30%) with mild steel coated electrodes presents no problems as far as tensile
strength is concerned since the tensile strength of the weld metal usually exceeds the tensile
strength of the base metal. However, chemistry of the base metal is important. Welds made
on free machining steels that have a relatively high sulfur content, will be porous unless welded
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
with a low hydrogen type electrode such as E7018. Sometimes off analysis steels or mild
steels of doubtful analysis are encountered. In this case, one of the low hydrogen types would
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
electrode or a flat and horizontal type electrode should be used. Higher welding currents, and
therefore, higher deposition rates are possible when welding flat or horizontally. Whenever
possible, the work should be positioned both for ease of welding and to attain the highest
welding speed.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2. For lower penetration and higher deposition rate, use DC straight polarity
(Electrode Negative).
3. For freedom of arc blow, use AC.
d) Plate Thickness - When welding sheet metal, low penetration electrodes
Lesson 8
Hardsurfacing
Electrodes
should be chosen. Heavier plate may demand an electrode with deep penetration. Very
heavy plate may require a deep penetrating electrode for the initial or root pass, and a higher
deposition type for succeeding passes.
e) Fit-Up - Some electrodes are more suitable than others for bridging gaps
Lesson 9
Estimating &
Comparing Weld
Metal Costs
between the members to be welded. This is termed "poor fit-up" and some electrode manufacturers produce electrodes that are specially formulated for this purpose.
f)
Welding Costs - The major factors that affect welding costs are labor and
overhead, deposition rate, efficiency of the electrode being used and the cost of the elec-
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
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(Fa
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Se
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Lesson 1
The Basics of Arc
Welding
LESSON III
trodes. The cost of electrical power is also a factor to a lesser degree. By far, the largest
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
g) Welder Appeal- Welder appeal is definitely important, although this factor must
not be allowed to subordinate other more significant criteria.
3.4.1
3.4.1.1
The E6010 and E6011 classification electrodes would most likely be used for
Go T
welding a mild steel joint in the vertical position with an open root. If there are only AC power
sources available, the choice between these two must be the E6011 type. Many times arc
blow is encountered when welding with direct current. The use of E6011 electrodes on alter-
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
The E6012 classification electrodes are largely used today in repair and welding of
less critical structures. Carbon steels with some rust present can be welded with this type of
electrode. It can be used to bridge or weld across wide gaps. The use of this electrode,
Lesson 5
Welding Filler Metals
for Stainless Steels
however, has diminished greatly in the past few years. Before the advent of the low hydrogen
electrodes and other welding processes, the E6012 electrode made up 60% of the total
production of electrodes. Today, it represents about 6% of the total production in the United
Turn
States.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
3.4.1.3
The E6013 classification of covered mild steel electrodes was originally designed
to have low arc penetration and flat smooth weld beads. These features allowed the electrode
to weld sheet metal. Today, many 6013 electrodes are used instead of 6012 electrodes
because of the smoother arc, less spatter and more uniform weld bead surface.
3.4.1.4
The E7014 classification of covered mild steel electrodes, as indicated earlier, have
iron powder added to the coating formulation of the E6013 electrodes. This addition allows
the electrode to be welded at higher currents, resulting in higher deposition rates and deposi-
Lesson 8
Hardsurfacing
Electrodes
tion efficiencies. Applications for the E7014 are similar to those of the E6013 electrodes.
3.4.1.5
The E7016 covered mild steel electrodes are, as indicated earlier, low hydrogen
with a basic slag system. This combination of attributes allows the electrode to be used to
weld some of the higher carbon steels and some low alloy steels. This electrode has dimin-
Lesson 9
Estimating &
Comparing Weld
Metal Costs
ished in usage because of its lower deposition rate and lower deposition efficiency than the
more modern E7018 electrode.
3.4.1.6
The E7018 classification is the low hydrogen iron powder electrode. The appre-
ciable amount of iron powder in the coating and the somewhat heavier amount of coating on
Lesson 10
Reliability of Welding
Filler Metals
the core wire allow the electrodes to be used at higher currents than those used with the
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Lesson 1
The Basics of Arc
Welding
LESSON III
E7016. The smooth arc and easy welding with the E7018 electrode make it a welder's favor-
Cu
Ch
Tab
Con
ite. The relatively high welding currents and the addition of the iron powder melting into the
Lesson 2
Common Electric
Arc Welding
Processes
weld metal result in higher deposition rates and higher deposition efficiencies. The E7018
covered mild steel electrode deposits the highest quality weld metal available from manual arc
welding. The only major disadvantage of the E7018 is the need to be kept dry. Electrodes
that have picked up moisture by exposure to the atmosphere or other sources deposit porous
Lesson 3
Covered Electrodes
for Welding
Mild Steels
weld metal. Also E7018 electrodes cannot be used to weld the root pass in an open butt joint
Go T
without excess porosity. When E7018 electrodes are to be used in butt welds, the root should
be closed by a backing bar, ceramic back-up tape, or consumable insert. If a backing bar is
used, it must be removed after the joint is welded by the gas metal arc or the gas tungsten arc
process and successive passes applied with E7018 for a high quality weld metal deposit.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Glo
3.4.1.7
The E7024 classification of covered mild steel electrodes is the result of heavy
additions of iron powder to the E6012 formulation and large increases in the amount of coating on the core wire. About 50% of the coating is iron powder. Very high deposition rates and
deposition efficiencies result from this combination of more coating and iron powder. The
electrode is limited to welding horizontal fillets and flat positions. The quality of the weld metal
is not as high as that from E7018 electrodes since the ductility of E7024 weld metal is lower.
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
DEPOSITION RATE 5/
32" DIA. COVERED
ELECTRODES
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Se
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150
200
250
WELDING AMPERES
DEPOSITION RATE, 5/32" DIAMETER COVERED ELECTRODES
FIGURE 4
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON III
3.4.2
Cu
Ch
Tab
Con
total cost of depositing weld metal substantially. The deposition rate is the weight of weld
Lesson 2
Common Electric
Arc Welding
Processes
metal deposited in a unit of time. Deposition rate increases as the welding current increases
within the limits of a given electrode. As can be seen in Figure 4, a 5/32" diameter E7024
electrode can deposit weld metal more than twice as fast as a 5/32" diameter E6010 electrode. It is apparent that a substantial saving in labor and overhead can be achieved if one of
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
The deposition efficiency of a given electrode also has an effect on welding costs.
The deposition efficiency is the weight of the weld metal deposited compared to the weight of
the electrode consumed, expressed as a percentage.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Average
Class
Efficiency*
E6010
63.8%
E6011
68.5%
E6012
66.9%
E6013
66.8%
E7014
64.6%
E7016
62.8%
E7018
69.5%
E6020
65.2%
E7024
66.8%
E7027
68.6%
* Includes 2" Stub Loss
Glo
Stub Loss **
Stub
Length
5/32" 6010
% Deposit
% Loss
14" Electrode
2"
63.8%
36.2%
3"
58.5%
41.5%
4"
53.2%
46.8%
5"
47.9%
52.1%
6"
42.6%
57.4%
Turn
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
FIGURE 5
3.4.2.2
Lesson 8
Hardsurfacing
Electrodes
Se
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(Fa
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When welding with coated electrodes, some of the electrode weight is lost as slag,
spatter, fumes, gases, and stubs. If an electrode is 65% efficient, it means that for every 100
pounds of electrodes consumed, 65 pounds of weld metal will be produced. Stub loss, the
part of the electrode that is thrown away, is not considered in the deposition efficiency, since
the stub length will vary with the operator or the application. Figure 5 illustrates how stub loss
Lesson 9
Estimating &
Comparing Weld
Metal Costs
affects efficiency. An 6010 electrode has an actual average efficiency of 71.5% before the
allowance for stub loss. A 2" stub results in the efficiency dropping to 63.8%. If 6" stubs are
thrown away, 100 pounds of electrodes will produce only 42.6 pounds of weld metal. Methods
of calculating total weld costs will be covered in a subsequent lesson.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Doc
(Sl
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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON III
3.5
The type of slag produced from covered electrodes has a definite effect on the quality of the
weld metal. The E6010, 6011, 6012, 6013, 7014, 7024 and other cellulosic and rutile electrodes, produce slags that are predominantly silicon dioxide (sand) and have an acidic behavior. Acid slag systems do no refining of the weld metal. In contrast, the slag from the E7016,
E7018 and other low hydrogen electrodes is made up mostly of lime and fluorspar,two items
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
that are basic in chemical behavior. Basic slags do some refining of the weld metal, resulting
in lower nonmetallic inclusion content.
3.6
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Cu
Ch
Tab
Con
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
structure made of medium or low carbon steel has been welded with mild steel covered electrodes. The welding advantages of this process are several. It is the simplest welding process available. All that is needed is a constant current power source, two electrical leads and
the electrode. It is the most flexible welding process in that it can be used in any position on
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
almost any thickness of carbon steel in any location. The disadvantages are that the covered
mild steel welding has lower deposition rates than other processes, thus making it less efficient. Also, the use of covered mild steel electrodes requires more welder training than the
semi-automatic and automatic welding processes.
Se
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Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Se
Doc
(Sl
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Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON III
3.7
3.7.1
electrode that is especially suited for pipe welding but also functions as an excellent general
purpose 6010 wire. As a pipe welding electrode, it produces the consistent, deep penetration
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
Ch
Tab
Con
Go T
required to maintain a proper keyhole when welding in open root pipe joints. Recommended
for API grades A25, A, B, and X42 grade pipe and for general structural, ship, barge, and
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
27 ft-lbs @ 0F
22 ft-lbs @ -20F
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Carbon
0.12%
Phosphorus
0.009%
Manganese
0.28%
Sulfur
0.017%
Silicon
0.18%
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Electrode
Diameter
SUREWELD 10P*
Amperage
Efficiency, %
Deposition
(Lbs/Hr .)
3/32"
70
100
72.0%
65.0%
1.5
1.7
1/8"
100
130
76.34
68.81
2.12
2.31
5/32"
140
170
73.57
64.14
2.8
2.93
3/16"
160
190
74.9
69.7
3.3
3.52
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Se
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Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON III
3.7.2
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
Ch
Tab
Con
cially suited for welding high strength pipe. It produces the consistent, deep penetration
required to maintain a proper keyhole when vertical-down welding in open root pipe joints. Xray quality welds can be produced using flat, horizontal, overhead, vertical-up, and verticaldown procedures. Recommended for X46, X52, and X56 grade pipe, it may also be used for
Go T
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
29 ft-lbs @ -20F
26 ft-lbs @ -50F
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Carbon
0.10%
Sulfur
0.016%
Manganese
0.31%
Nickel
0.53%
Silicon
0.18%
Molybdenum
0.24%
Phosphorus
0.008%
1/8"
Turn
SUREWELD 710P*
Amperage
70
100
Efficiency, %
72.0%
65.0%
Deposition
(Lbs/Hr .)
1.5
1.7
100
130
76.34
68.81
2.12
2.31
5/32"
140
170
73.57
64.14
2.8
2.93
3/16"
160
190
74.9
69.7
3.3
3.52
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON III
SUREWELD 810P (AWS E8010-P1) - An all-position cellulosic electrode espe-
3.7.3
Cu
Ch
Tab
Con
cially suited for welding high strength pipe. It produces the consistent, deep penetration
Lesson 2
Common Electric
Arc Welding
Processes
required to maintain a proper keyhole when vertical-down welding in open root pipe joints. Xray quality welds can be produced using flat, horizontal, overhead, vertical-up, and verticaldown procedures. Recommended for X60, X65, and X70 grade pipe.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
31 ft-lbs @ -20F
Glo
25 ft-lbs @ -50F
The typical chemical composition of the weld metal is:
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Carbon
0.10%
Sulfur
0.014%
Manganese
0.48%
Nickel
0.98%
Silicon
0.24%
Molybdenum
0.11%
Phosphorus
0.008%
Turn
SUREWELD 810P*
Amperage
70
100
Efficiency, %
72.0%
65.0%
Deposition
(Lbs/Hr .)
1.5
1.7
1/8"
100
130
76.34
68.81
2.12
2.31
5/32"
140
170
73.57
64.14
2.8
2.93
3/16"
160
190
74.9
69.7
3.3
3.52
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON III
3.7.4
Cu
Ch
Tab
Con
that has the arc stabilized to weld with alternating current. It produces an easily controlled
Lesson 2
Common Electric
Arc Welding
Processes
forceful arc with a deep penetration and high quality weld metal that meets specification requirements for soundness. Typical applications include welding of bridges and buildings,
piping, ships, pressure vessels and tanks.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
31 ft-lbs @ -20F
Carbon
0.10%
Phosphorus
0.012%
Manganese
0.36%
Sulfur
0.016%
Silicon
0.15%
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Glo
Turn
SW14*
Electrode
Diameter
Deposition
Amperage
Efficiency, %
(Lbs/Hr.)
1/8"
120
70.7
2.3
5/32"
150
77.0
3.7
3/16"
180
73.4
4.1
7/32"
210
74.2
5.0
1/4"
250
71.9
5.0
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON III
SUREWELD SW612 (AWS E6012) - This is a multiple purpose rutile electrode that
3.7.5
Cu
Ch
Tab
Con
is useful for poor fitup welding. It deposits convex weld beads that have great resistance to
Lesson 2
Common Electric
Arc Welding
Processes
cracking. It withstands the high amperage of production welding without coating breakdown.
The weld deposit has excellent mechanical properties for the classification. The SW612
electrode is used to weld truck bodies, trailers, tanks, farm machinery and auto parts.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
0.05%
Phosphorus
0.008%
Manganese
0.31%
Sulfur
0.016%
Silicon
0.12%
SW612*
Electrode
Diameter
Deposition
Amperage
Efficiency, %
130
81.8
2.9
5/32"
165
78.8
3.2
200
69.0
3.4
220
77.0
4.0
250
74.5
4.2
320
69.8
5.6
3/16"
7/32"
Turn
(Lbs/Hr .)
1/8"
1/4"
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Glo
320
70.0
5.6
360
67.7
6.6
380
66.0
7.1
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON III
SUREWELD SW15 (AWS E6013) - This is a fine high production electrode that
3.7.6
Cu
Ch
Tab
Con
can weld thicknesses from light gauge sheet to heavy plate. High welding currents and travel
Lesson 2
Common Electric
Arc Welding
Processes
speeds can be used without undercut. The slag is self-cleaning. SW15 may be used to weld
metal fixtures, road equipment, farm machinery, building structures, storage tanks, and iron
work.
Typical mechanical properties of the weld metal are:
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
5/32"
3/16"
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Carbon
0.06%
Phosphorus
0.012%
Manganese
0.32%
Sulfur
0.013%
Silicon
0.23%
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Glo
7/32"
1/4"
SW15*
Amperage
Efficiency, %
Deposition
(Lbs/Hr .)
140
75.6
2.60
160
74.1
3.02
180
71.2
3.48
180
73.9
3.20
200
71.1
3.80
220
72.9
4.09
250
71.3
5.30
270
73.0
5.70
290
72.7
6.08
290
75.0
6.20
310
73.5
6.50
330
72.1
7.10
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 9
Estimating &
Comparing Weld
Metal Costs
3.7.7
6013LV (AWS E6013) - The arc characteristics, weld metal properties and in-
tended applications are similar to SW-15 (E6013) electrodes. This electrode is intended for
use on AC power sources where there is less than 50 open circuit volts. These lower open
circuit voltage machines make the arc initiation and restrike difficult with a conventional E6013
Lesson 10
Reliability of Welding
Filler Metals
Turn
Lesson 1
The Basics of Arc
Welding
LESSON III
SUREWELD SW15-IP (AWS E7014) - This electrode has iron powder added to
3.7.8
Cu
Ch
Tab
Con
the coating, permiting use of higher welding currents. The deposition rate is increased by the
Lesson 2
Common Electric
Arc Welding
Processes
use of higher welding currents while the iron powder content of the covering increases the
deposition efficiency. Both of these increases make the welding operation more efficient. The
high currents and high welding speeds can be used without undercut. The slag removal is
easy and complete. Typical applications include construction equipment, metal fixtures, auto-
Lesson 3
Covered Electrodes
for Welding
Mild Steels
0.04%
Phosphorus
0.015%
Manganese
0.31%
Sulfur
0.019%
Silicon
0.14%
Lesson 9
Estimating &
Comparing Weld
Metal Costs
SW15-IP*
Turn
Electrode
Diameter
1/8"
5/32"
3/16"
Lesson 8
Hardsurfacing
Electrodes
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Go T
7/32"
1/4"
Deposition
Amperage
Efficiency, %
(Lbs/Hr .)
120
63.9
2.45
150
61.1
3.10
160
71.9
3.04
200
67.0
3.69
230
70.9
4.50
270
73.2
5.50
290
67.2
5.82
330
70.3
7.12
350
68.7
7.08
400
69.9
8.70
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON III
SUREWELD 70LA-2 (AWS E7016) - This low hydrogen electrode has a special
3.7.9
Cu
Ch
Tab
Con
lime covering that allows the electrode to deposit trouble-free welds on difficult to weld steels,
Lesson 2
Common Electric
Arc Welding
Processes
such as high carbon, low alloy, sulfur bearing free machining, and cold rolled steels. It is usable with high amperages with corresponding high deposition rates making it more economical than conventional electrodes on heavy work. The electrodes must be kept dry, and welding
should be performed using as short an arc as possible.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
0.07%
Manganese
0.09%
Silicon
0.50%
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
70LA-2*
Turn
Electrode
Diameter
5/32"
3/16"
Lesson 8
Hardsurfacing
Electrodes
1/4"
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Deposition
Amperage
Efficiency, %
(Lbs/Hr .)
140
70.5
3.01
160
69.1
3.24
190
66.0
3.61
175
71.0
3.79
200
71.0
4.23
225
70.0
4.40
250
65.8
4.77
250
74.5
5.93
275
74.1
6.42
300
73.2
6.78
350
71.5
7.58
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON III
ATOM ARC 7018 (AWS E7018) - This electrode was the original iron powder low
3.7.10
Cu
Ch
Tab
Con
hydrogen electrode in the United States and continues to be the standard of comparison
Lesson 2
Common Electric
Arc Welding
Processes
against all others. Outstanding economy and mechanical properties are achieved when Atom
Arc 7018 electrodes are used to weld carbon steels, high sulfur steels, enameling steels, and
low alloy high tensile steels in all thicknesses. In addition, Atom Arc 7018 electrodes today are
manufactured with a moisture resistant coating. Preheat levels may be reduced when welding
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
today. It has been especially useful in welding large oil storage tanks, nuclear plant parts, and
in many critical weldments that require the highest possible quality and reliability.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
70 ft-lbs @ -20F
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
The typical chemical composition of Atom Arc 7018 weld metal is:
Carbon
0.045%
Phosphorus
0.015%
Manganese
1.10%
Sulfur
0.014%
Silicon
0.4%
Se
Ch
(Fa
Dow
Electrode
Diameter
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
1/8"
5/32"
Deposition
Amperage
Efficiency, %
(Lbs/Hr .)
120
71.6
2.58
140
70.9
2.74
160
68.1
2.99
140
75.0
3.11
170
73.5
3.78
200
73.0
4.31
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
LESSON III
3/16"
7/32"
1/4"
200
76.4
4.85
250
74.6
5.36
300
70.3
5.61
250
75.0
6.5
300
74.0
7.2
350
73.0
7.4
300
78.0
7.72
350
77.0
8.67
400
74.0
9.04
Cu
Ch
Tab
Con
Go T
Glo
*Note: Efficiencies do not include stub loss
Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
3.7.11
ATOM ARC 7018AC (AWS E7018) - This iron powder low hydrogen electrode was
specifically designed for optimum performance on AC power sources. This electrode features
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
easier arc starting, improved restrike, and smoother metal transfer than a standard E7018
electrode on AC. Typically, this electrode is used as a tacking electrode.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON III
SUREWELD 7024 (AWS E7024) Conforms to 7024-1 - The Sureweld 7024
3.7.12
Cu
Ch
Tab
Con
electrode is approved by the American Bureau of Shipping. It is a high speed electrode using
Lesson 2
Common Electric
Arc Welding
Processes
heavy concentrations of iron powder in the coating. Used with high welding currents, it produces high deposition rates in horizontal fillet and flat welding positions. The electrode has
excellent operator appeal and produces equal leg 45fillets that eliminate overwelding. The
welds have excellent appearance and a self-cleaning slag. The 7024 electrode is ideal for
Lesson 3
Covered Electrodes
for Welding
Mild Steels
making high speed horizontal fillets and lap welds on mild steel and some low alloy steels in
Go T
weldments such as earth moving and construction equipment, truck bodies, ships, barges and
railcars.
Typical mechanical properties of 7024 weld metal are:
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
0.06%
Phosphorus
0.010%
Manganese
0.80%
Sulfur
0.018%
Silicon
0.27%
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Efficiency, %
Deposition
(Lbs/Hr.)
140
69
3.57
66
5.1
180
67
4.48
200
70
5.23
240
67
6.67
250
69
7.34
290
68
9.15
7/32"
320
69
9.43
1/4"
400
70
12.58
Lesson 8
Hardsurfacing
Electrodes
3/16"
Lesson 10
Reliability of Welding
Filler Metals
Amperage
180
5/32"
Lesson 9
Estimating &
Comparing Weld
Metal Costs
7024*
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
LESSON III
APPENDIX A
LESSON III - GLOSSARY OF TERMS
Electrode
Core Wire
Electrode
- The mixture of chemicals, minerals and metallic alloys applied to the core
wire. The coating controls the welding current, the welding position, and
Glo
the welding slag that absorbs impurities from the weld metal. It also helps
shape the weld bead and becomes an insulating blanket over the weld bead.
Mild Steel
Lesson 5
Welding Filler Metals
for Stainless Steels
- An alloy of mostly iron with low content of alloying elements such as carbon
and manganese.
Low Alloy
Steel
Hardenable
Steel
Deposition
- The relationship of the electrode used to the amount of the weld metal de-
Lesson 8
Hardsurfacing
Electrodes
Arc Blow
- Welding with direct current may set up a magnetic field in the steel plate
being welded. This magnetic field causes the arc to flutter and blow, creating
difficulty in controlling the arc.
Cellulose
Turn
Deposition
Rate
Efficiency
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Go T
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
- The steel wire about which the coating is applied. The electrode size is
P
Coating
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Cu
Ch
Tab
Con
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON III
Rutile
Titania
- The synthetic form of titanium dioxide (TiO ). In this text the terms rutile and
Root Pass
- The initial weld bead deposited in a multi-pass weld requiring high weld
integrity.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
Ch
Tab
Con
Go T
Root Opening - The intentional gap between members to be joined to assure 100% penetra-
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Se
Ch
(Fa
Dow
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Se
Doc
(Sl
Dow
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Cu
Ch
Tab
Con
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
BASIC
WELDING FILLER METAL
TECHNOLOGY
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Glo
A Correspondence Course
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Go T
LESSON IV
COVERED ELECTRODES FOR
WELDING LOW ALLOY STEELS
AN INTRODUCTION TO LOW
ALLOY COVERED ELECTRODES
Turn
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
ESAB
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON IV
COVERED ELECTRODES FOR WELDING
LOW ALLOY STEELS
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Cu
Ch
Tab
Con
Section Nr.
Section Title
Page
Go T
P
4.1
4.2
4.2.1
Preheat .............................................................................................
4.3
4.3.1
4.3.2
4.4
4.4.1
4.4.2
4.4.3
Impact Properties..............................................................................
4.5
4.5.1
4.5.2
4.5.3
Equipment.........................................................................................
10
4.6
11
4.6.1
11
4.6.2
11
4.6.3
12
4.6.4
13
4.6.5
13
4.6.6
14
4.6.7
14
4.6.8
15
4.6.9
15
4.6.10
16
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, INC.
Glo
Turn
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Cu
Ch
Tab
Con
TABLE OF CONTENTS
LESSON IV- Con't
Section Nr.
Section Title
Page
4.6.11
16
4.6.12
17
4.6.13
17
4.6.14
17
Appendix A
19
Appendix B
Go T
Glo
20
Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
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Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
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Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON IV
Cu
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Tab
Con
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Low alloy steels, as discussed in Lesson I, are those steels to that have small amounts of
alloying elements added for specific purposes; i.e., to increase strength, toughness, corrosion
and rust resistance, or to alter the response to heat treatment. Nearly every steel manufacturer
makes a family of low alloy steels that are usually sold under trade names such as Maynari R,
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Cor-ten, Man-ten, and many others. Many of the steels are designed to develop their specific
Glo
properties such as high strength or toughness in the hot rolled and controlled cooling condition,
rather than by subsequent heat treatment. Other compositions of low alloy steels are designed
to develop specific properties following heat treatments. Examples of these types are U.S.
Steel T-1, Armco Steel SS-100, Great Lakes Steel NA XTRA 100, all of which are quenched
Lesson 5
Welding Filler Metals
for Stainless Steels
and tempered to reach high strength with good toughness. Covered low alloy welding electrodes are designed, in most cases, to match the properties of the low alloy steels rather than
to match the exact chemical composition of the steel. Exceptions to this are the chromium
molybdenum electrodes that need to contain about the same amounts of the alloy ingredients
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
corresponding increase in weld defects. It was quickly realized that hardenable steels could
not be welded in the same manner and with the same electrodes as were then commonly used
for welding the lower strength mild steels. Through extensive research, it was found that entrapped hydrogen was the culprit in causing weld defects, and the term "hydrogen
Lesson 9
Estimating &
Comparing Weld
Metal Costs
present in the electrode coating, as is common with mild steel electrodes, the chemically
combined hydrogen is dissociated into atomic hydrogen by the heat of the welding arc. The
Lesson 10
Reliability of Welding
Filler Metals
Turn
molten weld metal has the capacity to dissolve the atomic hydrogen. However, as soon as the
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Lesson 1
The Basics of Arc
Welding
LESSON IV
weld metal solidifies, it loses the ability to hold the hydrogen in solution and the hydrogen is
Cu
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Tab
Con
either expelled into the atmosphere or moves throughout the weld zone. Steel and weld metal
Lesson 2
Common Electric
Arc Welding
Processes
are not as solid as they appear to the naked eye, being filled with tiny submicroscopic pores.
The hydrogen atoms are smaller than the crystalline structure of the steel or the weld metal,
and the hydrogen can move about somewhat freely in the steel, just as air can move through a
filter. The hydrogen atoms move out of the weld metal into the heat affected zone. The heat
Lesson 3
Covered Electrodes
for Welding
Mild Steels
affected zone (HAZ) is an area of critical importance in welding, especially in welding high
Go T
strength steels.
P
4.2.0.2
The heat affected zone (See Figure 1) is that area of the weld joint that did not
become molten in the welding process, but underwent a microstructure change as a result of
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Glo
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
the heat affected zone are a natural collecting place for atomic hydrogen. When two hydrogen atoms meet, they immediately unite to
Lesson 8
Hardsurfacing
Electrodes
form molecular hydrogen. The resulting molecules are larger than the crystalline structure of
the metal and can no longer move about freely. As more and more hydrogen atoms come into
the pores, form molecules, and are trapped, tremendous pressure can develop. Mild steel and
lower strength steels are sufficiently plastic to move a little with the hydrogen pressure and not
Lesson 9
Estimating &
Comparing Weld
Metal Costs
cause the steel to crack. Steels that have high hardness and high strength do not have sufficient plasticity to move with the pressure, and if enough hydrogen is present, cracking of the
steel occurs.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON IV
4.2.0.3
This hydrogen caused defect, known as underbead cracking (See Figure 2), begins
Cu
Ch
Tab
Con
in the HAZ making it particularly sinister since the crack is not immediately apparent to the
Lesson 2
Common Electric
Arc Welding
Processes
eye. It occurs after the metal has cooled from about 400F to room temperature, and it is
sometimes referred to as
may occur immediately after
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
it happens.
Preheat - Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
BASE METAL
4.2.1
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
WELD METAL
UNDERBEAD CRACKING
FIGURE 2
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
compounds high in moisture content. In fact, control of the moisture levels in the coating is
critical in the manufacture and use of low hydrogen electrodes.
4.3.0.1
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
entails a high temperature bake cycle. After the coating is extruded onto the core in the same
manner as a mild steel coated electrode, the low hydrogen electrodes are given an initial low
temperature bake (300-400F), and then rebaked in a separate high temperature oven (800900F) for a specified period of time. This procedure practically eliminates all moisture, and
to guard against the reabsorbing of moisture that is naturally present in the atmosphere, the
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON IV
electrodes are immediately packaged in hermetically sealed metal containers following the
Cu
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Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
4.3.1
Storage and Reconditioning - All low hydrogen electrodes will absorb some
moisture from the air after the electrode container is opened. Therefore, those electrodes that
are not intended for use within a given period of time must be stored in a vented oven and
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
Various structural and military codes allow only specified times of exposure. These
may be anywhere from 30 minutes to 8 hours depending on the electrode alloy, the relative
humidity in the work area, and the critical nature of the application. If the low hydrogen elec-
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
trodes are exposed to the atmosphere beyond these time limits, they must be scrapped or
Glo
The recommended storage and rebake temperatures for Atom Arc low hydrogen
Lesson 5
Welding Filler Metals
for Stainless Steels
4.3.2
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
STORAGE
RECONDITIONED
225-300F
1 hr. @700F
have a high level of relative humidity. As the temperature and relative humidity increase, the
chance of absorbing moisture in the low hydrogen coating is greatly increased. To combat this
possibility, major electrode manufacturers have in recent years developed low hydrogen
electrodes with moisture resistant coatings. These coatings low the rate of moisture absorp-
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
tion in electrodes that have been exposed to the air for extended periods, thus adding an extra
degree of reliability to low hydrogen electrodes.
4.3.2.1
resistant coating. The tests were conducted on Atom Arc 7018 electrodes. The method of
Lesson 8
Hardsurfacing
Electrodes
moisture testing chosen by ESAB is that described in Section 25 of the AWS A5.5-96 Specification. This method was chosen because it satisfies the AWS specifications and is sensitive
only to water, making it one of the most accurate and reliable methods of moisture determination currently in use.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
users such as shipbuilders and oil rig fabricators who are situated in areas of the world that
4.3.2.2
The AWS structural code and military specifications allow a maximum of 0.40% and
0.20% moisture content, respectively, for E70XX low hydrogen electrodes. As shown on the
preceding graphs, the Atom Arc 7018 electrode satisfied this low moisture requirement for
exposure times beyond those normally allowed in field use.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON IV
Cu
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Tab
Con
.40
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
0
1
12
24
36 48
96
Moisture at
Zero Hours .09
.40
Glo
.30
Lesson 5
Welding Filler Metals
for Stainless Steels
01
Moisture at
Zero Hours .08
12
24
36 48
96
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
.40
.30
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
0
1
Moisture at
Zero Hours .10
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Se
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.10
12
24
4.4
ELECTRODES A5.5-96
With very few exceptions, low alloy electrodes are made by adding the appropriate alloying
elements to the electrode coating rather than having a core wire that matches the low alloy
steel. Low alloy covered electrodes are classified according to the American Welding Society
filler metal specification A5.5-96. This specification contains the mechanical property require-
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON IV
ments and stress relieved condition, the chemical requirements, and the weld metal sound-
Cu
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Tab
Con
ness requirements. Electrodes are classified under this specification according to the me-
Lesson 2
Common Electric
Arc Welding
Processes
chanical properties and chemical composition of the weld metal, the type of covering, and the
welding position of the electrode. The classification of the electrode is designated by the
manufacturer according to the results of his own tests. The manufacturer, thereby, guarantees
his electrode to meet the requirements of the AWS specification.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
4.4.0.1
The letter-number designations for low alloy electrode classifications mean much
the same as with mild steel electrodes, except that the major alloy composition is indicated by
a letter-number suffix. For example, E7018-A1 indicates an electrode (letter E); with a minimum of 70,000 psi tensile strength (70); is weldable in all positions (1); is iron powder low
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
hydrogen (8); and contains nominally 1/2% molybdenum (A1). The full list of nominal alloy
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
A1
1/2% Molybdenum
B1
B2
B2L
B3
B3L
Turn
B4L
B5
C3
1% Nickel
C1
2% Nickel
C2
3% Nickel
D1
D2
Needs only a minimum of one of the elements listed in the AWS A5.5 Table
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4.4.1
4.4.1.1
Molybdenum - When mild steel weld metal is stress relieved, the yield point is
lowered 3,000 psi or more and the tensile strength is also lowered 3,000 psi or more. When
1/2% of molybdenum is added to the weld, both the yield point and the tensile strength remain
constant from the as-welded to the stress relieved condition. The presence of molybdenum
Lesson 10
Reliability of Welding
Filler Metals
Glo
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Lesson 1
The Basics of Arc
Welding
LESSON IV
4.4.1.2
Chromium - When chromium is added to the weld metal, the corrosion and high
Cu
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Tab
Con
temperature scaling resistance are increased. The combination of chromium and molybde-
Lesson 2
Common Electric
Arc Welding
Processes
num allows the weld metal to retain high strength levels at medium high temperatures.
4.4.1.3
Nickel - Mild steel weld metal usually becomes brittle at temperatures below -20F.
The addition of 1-3% nickel to the weld metal enables the weld metal to remain tough at considerably lower temperatures. The presence of the nickel also makes the weld metal more
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
P
4.4.1.4
the tensile strength and when 1/3% molybdenum is added in combination, the high strength
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
4.4.1.5
It should be noted that the A5.5-96 specification covers not only the low alloy low
hydrogen electrodes, but also low alloy versions of the cellulosic, titania, and iron oxide type
electrodes. A full list of all the electrodes covered by this specification is presented in Table 2.
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
E8018-B2
E9015-B3L
E11018-M
E7011-A1
E8018-B2L
E9016-B3
E12018-M
E7015-A1
E8015-B4L
E9018-B3
E7016-A1
E8016-B5
E9018-B3L
EXX10-G
E7018-A1
E8016-C1
E9015-D1
EXX11-G
E7020-A1
E8018-C1
E9018-D1
EXX13-G
E7027-A1
E8016-C2
E9018-M
EXX15-G
E8018-C2
E8016-C3
E10015-D2
EXX18-G
E8018-B1
E8018-C3
E10016-D2
E7020-G
E9015-B3
E10018-M
E8016-B2
4.4.2
Turn
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EXX16-G
E8016-B1
E8015-B2L
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
E7010-A1
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E10018-D2
Mechanical Properties (AWS A5.5-96) - Since many low alloy steels require
some post-weld heat treatment to relieve the internal stresses generated from the welding
process, physical testing on the weld metal of most low alloy electrodes is required to be
performed after the specimen has been stress-relieved. Only the E8016-C3, E8018-C3,
E9018-M, E11018-M, and E12018-M types are permitted to be tested in the as-welded condi-
Lesson 10
Reliability of Welding
Filler Metals
Lesson 1
The Basics of Arc
Welding
LESSON IV
4.4.3
Lesson 2
Common Electric
Arc Welding
Processes
Cu
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Tab
Con
Impact Properties - Since many low alloy steels are developed for low tempera-
tures service, impact properties of the weld metal designed to join these steels are very important. Except for those types already mentioned, all impact testing is performed on specimens
after they have been stress-relieved. Table 3 lists the minimum charpy v-notch impacts required in the A5.5 specification.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
TABLE 3.
P
AS WELDED
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
MINIMUM REQUIREMENT
E8016-C3
)-------
E8018-C3
20 ft.-lbs. @-40F.
E9018-M
E9015-D1
E10018-M
E9018-D1
E11018-M
)-------
E10015-D2
E12018-M
E10016-D2
E10018-D2
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
20 ft.-lbs. @-75F. --------
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
STRESS-RELIEVED
20 ft.-lbs. @-100F.-------
E8016-C1
E8018-C1
E8016-C2
E8018-C2
4.5
As stated earlier, low alloy electrodes are often selected to match the properties of the steel to
be welded rather than matching the exact chemical composition of the steel. These properties
(i.e., strength, toughness, creep, and corrosion resistance) reflect the type of service for which
Lesson 8
Hardsurfacing
Electrodes
the steel is intended. The letter-number suffix of the electrode classification gives an indication
of that service. Whenever possible, the electrode should be selected on the basis of the
appropriate strength levels and the intended service of the weldment.
4.5.1
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
Service Conditions - The large family of "proprietary" steels that are sold in the as
rolled, controlled, cooled condition have a 50,000 psi minimum yield point and 70,000 psi
minimum tensile strength. Electrodes that deposit low hydrogen weld metal of those strength
levels are used to weld them.
Lesson 10
Reliability of Welding
Filler Metals
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Lesson 1
The Basics of Arc
Welding
LESSON IV
4.5.1.1
Some of the low alloy high strength steels are intended for use at subzero tempera-
Cu
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Tab
Con
tures. Nickel bearing low hydrogen electrodes (C1, C2, C3 types) are available for such low
Lesson 2
Common Electric
Arc Welding
Processes
temperature applications.
4.5.1.2
Chromium molybdenum low alloy steels are used for moderately high temperature
service. Piping, tubing, boilers, etc., that are used extensively in power generating plants, are
Go T
fabricated from these steels. Chrome-moly low hydrogen electrodes (B1, B2, B3, etc.) are
Lesson 3
Covered Electrodes
for Welding
Mild Steels
P
4.5.1.3
Many bridges and outdoor structures are constructed from "weathering" grade
steels. These are low alloy steels that, on exposure to the atmosphere, develop a thin, tightly
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
adhering layer of rust that prevents further rusting and eliminates the need for painting. Low
Glo
alloy electrodes with additions of chromium and copper are available for welding these steels.
4.5.1.4
Quenched and tempered low alloy steels usually develop high strength with good
toughness. These types are used where substantial savings in the weight of the structure is
Lesson 5
Welding Filler Metals
for Stainless Steels
important. Quite often, but not exclusively, these steels are used by the military. One of the
more exotic applications for quenched and tempered low alloy steels is in the fabrication of the
pressure hulls for nuclear submarines. The "M" series of high tensile low hydrogen electrodes
is intended to weld these steels.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
4.5.1.5
Turn
High tensile line pipe for the transmission of oil and gas is being used with greater
frequency today. Low alloy cellulosic electrodes of the 7010 and 8010 variety are used for
field welding.
4.5.2
Joint Design - In fillet welding of high strength quenched and tempered steels, toe
cracking alongside the welds (see Figure 4) is frequently a problem. The toe cracking is
caused by the high strength weld metal having a higher yield point and tensile strength than the
steel.
4.5.2.1
BASE
METAL
CRACK AT TOE
OF WELD
Lesson 9
Estimating &
Comparing Weld
Metal Costs
HEAT AFFECTED
ZONE
WELD METAL
TOE CRACKING
FIGURE 4
Lesson 10
Reliability of Welding
Filler Metals
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Lesson 1
The Basics of Arc
Welding
LESSON IV
With a somewhat lower strength weld metal as the filler, the yield point of the weld metal is
Cu
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Tab
Con
reached during the shrinkage on cooling. The weld metal stretches without overloading in the
Lesson 2
Common Electric
Arc Welding
Processes
4.5.3
Equipment - The electrode selected will operate only on the appropriate power
source. Table 4 lists the type of current for which each class of electrode is designed.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Current
EXX10-X*
DCRP
EXX11-X
AC or DCEP
EXX13-X
AC or DC either polarity
EXX15-X
DCEP
EXX16-X
AC or DCEP
EXX18-X
AC or DCEP
EXX20-X
Glo
EXX27-X
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
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Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
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Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON IV
4.6.1
category and classification, the mechanical properties of the weld metal are sufficient to meet
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
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Tab
Con
Go T
the similar properties of the 50,000 psi yield and 70,000 psi tensile strength steels. Usually,
preheat and interpass temperature control of those steels is not necessary when welding with
Atom Arc 7018, although heavier thicknesses of steel may require some preheat. Common
applications include: welding carbon steels, high sulfur steels, enameling steels, and some
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
68,500
62,000
75,000
72,000
% Elongation (2")
31
% Reduction
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
77
@72F.
125 ft.-lbs.
130 ft.-lbs.
@-20F.
70 ft.-lbs.
75 ft.-lbs.
Mn
Silicon
0.06%
1.10%
0.50%
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Atom Arc 7018 Mo (AWS E7018-A1) - This electrode, which deposits 1/2%
molybdenum weld metal, is useful in welding power piping and pressure vessels of
molybdenum bearing steels designed for use at elevated temperatures. Typical applications
include: welding of low carbon and carbon-moly tubes and piping, forged alloy steel pipe
flanges, fittings and valves for high temperature service, carbon-moly steel boiler and
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
4.6.2
Lesson 8
Hardsurfacing
Electrodes
32
75.5
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Stress-Relieved
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON IV
Typical Mechanical Properties of Weld Metal
As Welded *
Lesson 2
Common Electric
Arc Welding
Processes
73,500
71,000
84,000
81,000
30
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Stress-Relieved*
% Elongation (2")
30
@72F.
95 ft.-lbs.
95 ft.-lbs.
@-10F.
85 ft.-lbs.
85 ft.-lbs.
@-40F.
70 ft.-lbs.
70 ft.-lbs.
Mn
Ni
0.04%
1.06%
2.37%
Glo
Atom Arc 8018N (AWS E8018-C2) - 8018N electrodes with 3% nickel are usually
4.6.3
used to weld 3% nickel steels for low temperature service. It has solved many weld cracking
problems by its weld crack resistance, as well as remaining tough at temperatures as low as -
Turn
low alloy steel forgings and ferritic steel castings for high pressures at low temperatures, high
strength steel castings for structural purposes, carbon steel forgings for railroad use and
concrete reinforcement bars.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
As Welded
83,000
80,500
94,000
90,500
25
% Reduction of Area
Lesson 8
Hardsurfacing
Electrodes
Stress-Relieved
% Elongation (2")
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Go T
100F. Typical applications include: welding of piping for low temperature service, carbon and
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Cu
Ch
Tab
Con
55
@72F.
110 ft.-lbs.
28
74
112 ft.-lbs.
@0F.
91 ft.-lbs.
93 ft.-lbs.
@-40F.
73 ft.-lbs.
63 ft.-lbs.
35 ft-lbs.
30 ft.-lbs.
@-100F.
Mn
Si
Ni
0.5%
0.84%
0.37%
3.30%
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON IV
Atom Arc 8018CM (AWS E8018-B2) - This 1-1/4% chrome, 1/2% moly electrode
4.6.4
Cu
Ch
Tab
Con
deposits weld metal that retains high strength at temperatures up to 600F. The 8018CM
Lesson 2
Common Electric
Arc Welding
Processes
electrodes are used to weld the 1/2% chrome-1/2% moly, 1% chrome-1/2% moly steels, as
well as the 1-1/4% chrome-1/2% moly power piping, boiler tubing, plates and castings. Many
of the fossil fired steam boilers in electric generating plants in the United States have been
welded with this electrode and its relative 9018CM.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
hrs. @1150F.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
82,400
63,800
78,300
23
% Reduction of Area
@30F.
60.7
79.1
64 ft.-lbs.
127 ft-lbs.
Mn
Si
Ni
Mo
0.06%
1.10%
0.40%
1.00%
0.50%
Turn
Atom Arc 8018W (AWS E8018-G) - The balanced alloy combination of chromium,
4.6.5
nickel and copper of this electrode causes the weld metal to "weather" similarly to the
Stress-Relieved
As Welded
Lesson 8
Hardsurfacing
Electrodes
hr. @1025F.
84,600
79,100
94,400
90,100
% Elongation (2")
Lesson 10
Reliability of Welding
Filler Metals
Se
Ch
(Fa
Dow
metal with the weathered steel makes these electrodes the ideal choice when architectural
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Glo
32
weathering grade steels when exposed to the atmosphere. The inform color blend of this weld
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
hrs. @1350F.
100,000
% Elongation (2")
Lesson 5
Welding Filler Metals
for Stainless Steels
Stress-Relieved
27
28
68.8
72.3
63 ft-lbs.
44 ft.-lbs.
% Reduction of Area
Charpy V-Notch Impacts
@-60F.
Mn
Si
Ni
Mo
0.05%
1.11%
0.32%
1.70%
0.28%
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON IV
Atom Arc 9018CM (AWS E9018-B3) - These 2-1/4% chrome - 1% moly electrodes
4.6.6
Cu
Ch
Tab
Con
are used to weld and match the composition of the 2-1/4% chrome - 1% moly steels in
Lesson 2
Common Electric
Arc Welding
Processes
pressure piping and power boilers. The chromium-molybdenum content of the weld metal
helps retain appreciable strength at temperatures up to 800F.
Typical Mechanical Properties of Weld Metal
Stress-Relieved
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
hr. @1275F.
Stress-Relieved
2
hrs. @1350F.
87,000
75,000
102,000
91,000
% Elongation (2")
23
27
% Reduction of Area
67
70
Mn
Si
Ni
Mo
0.05%
0.75%
0.60%
2.20%
1.05%
Glo
Turn
Atom Arc 9018-B3L (AWS E9018-B3L) - The low carbon content of this 2-1/4%
4.6.7
chrome - 1% moly electrode makes the weld metal more crack resistant in heavy sections and
allows lower preheat and interpass temperatures to be used. Typical applications include:
high temperature power piping, boilers, heat-exchanger and condenser tubes, pressure vessel
hrs. @1150F.
Lesson 8
Hardsurfacing
Electrodes
hrs. @1350F.
86,900
69,800
86,400
% Elongation (2")
Stress-Relieved
103,800
21
24
67.6
73
60 ft.-lbs.
79 ft.-lbs.
% Reduction of Area
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Go T
Mn
Si
Ni
Mo
0.02%
0.74%
0.61%
2.47%
1.10%
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON IV
Atom Arc 10018 (AWS E10018-M) - The manganese-nickel-molybdenum
4 .6.8
Cu
Ch
Tab
Con
composition of Atom Arc 10018 is used mostly on thinner sections of quenched and tempered
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
low alloy steels where 100,000 psi tensile strength, along with good ductility and toughness at
temperatures as low as -60F, are required. This product is used primarily for military
applications.
Typical Mechanical Properties of Weld Metal
Stress-Relieved
As Welded
96,000
103,000
104,000
24
24
63.5
67
33 ft.-lbs.
22 ft.-lbs.
% Reduction of Area
Charpy V-Notch Impact @-60F.
1 hr. @1025F.
96,000
% Elongation (2")
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
Mn
Si
Ni
Mo
0.05%
1.58%
0.40%
1.50%
0.30%
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Atom Arc 10018MM (AWS E10018-D2) - This electrode, with its combination of
4 .6.9
manganese and molybdenum, was originally developed during World War II to repair and
fabricate manganese-molybdenum castings and armor plate. It is used to weld similar
composition low alloy steels, as well as heat treatable steels comparable to hardenable steels.
Typical Mechanical Properties of Weld Metal
Stress-Relieved
As Welded
Lesson 8
Hardsurfacing
Electrodes
101,000
91,500
106,000
104,000
% Elongation (2")
22
% Reduction of Area
Charpy V-Notch Impacts
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
2 hrs. @1100F.
26
51
68
@72F.
83 ft.-lbs.
73 ft.-lbs.
@0F.
55 ft.-lbs.
50 ft.-lbs.
@-40F.
38 ft.-lbs.
34 ft.-lbs.
Mn
Si
Mo
0.09%
1.77%
0.68%
0.35%
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON IV
Atom Arc 12018 (AWS E12018-M) - This electrode deposits high strength weld
4 .6.10
Cu
Ch
Tab
Con
metal in both the as welded and stress-relieved conditions, which is required for welding many
Lesson 2
Common Electric
Arc Welding
Processes
of the high strength quenched and tempered steels. It is used to weld steels with 120,000 psi
tensile strength in applications, such as welding carbon and high strength alloy steel forgings
for railroad equipment, high strength steel castings for structural work, and steel castings for
highway bridges.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Stress-Relieved
As Welded
hr. @1025F.
120,000
119,000
132,000
129,000
% Elongation (2")
20
22
% Reduction of Area
56
60
@72F.
52 ft.-lbs.
54 ft.-lbs.
@-60F.
32 ft.-lbs.
31 ft.-lbs.
Mn
Si
Cr
Ni
Mo
0.05%
1.90%
0.25%
0.85%
2.00%
0.50%
4 .6.11
Turn
Atom Arc "T" (AWS E11018-M) - Atom Arc "T" electrodes were developed for
Se
Ch
(Fa
Dow
has since been used to weld all of the quenched and tempered steels, including HY-80, the
steel used for the pressure hulls of nuclear submarines.
Typical Mechanical Properties of Weld Metal
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
Glo
welding U.S. Steels T-1 steel, which is quenched and tempered to high strength and ductility. It
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Stress-Relieved
As Welded
hr. @1025F.
103,000
102,000
115,000
116,000
% Elongation (2")
22
% Reduction of Area
Charpy V-Notch Impacts
@72F.
24
62
63
80 ft.-lbs.
73 ft.-lbs.
@0F.
55 ft.-lbs.
50 ft.-lbs.
@-40F.
48 ft.-lbs.
42 ft.-lbs.
@-60F.
41 ft.-lbs.
26 ft.-lbs.
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON IV
Typical Chemical Composition of Weld Metal
C
Mn
Si
Cr
Ni
Mo
0.06%
1.53%
0.27%
0.31%
1.88%
0.43%
Atom Arc 9018HT (AWS E9018G) - As the HT indicates, this electrode is intended
4.6.12
Lesson 3
Covered Electrodes
for Welding
Mild Steels
molybdenum steel castings and is also useful in the repair and rebuilding of hot forging dies.
P
Typical Mechanical Properties of Weld Metal
Quenched @1700F.
Quenched @1600F.
Tempered @1275F.
Tempered @900F.
78,000
133,000
98,000
180,000
% Elongation (2")
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Go T
for heat treated applications. It deposits weld metal with properties that match chromium-
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
% Reduction of Area
20
12.5
57.5
27
Mn
Si
Cr
Mo
0.14%
0.80%
0.65%
2.30%
1.00%
Turn
Atom Arc 4130 (No AWS Classification) - This composition was developed to
4.6.13
Se
Ch
(Fa
Dow
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Glo
weld heat treatable steels such as SAE4130, providing a weld metal that responds similarly to
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Cu
Ch
Tab
Con
Quenched @1600F.
Tempered @950F.
121,000
152,000
138,000
163,000
% Elongation (2")
18
15
% Reduction of Area
32
36
Mn
Si
Cr
Ni
Mo
0.18%
1.25%
0.40%
2.50%
1.28%
0.20%
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON IV
Atom Arc 4130 LN (No AWS Classification) - This alloy combination has less
4.6.14
Cu
Ch
Tab
Con
than 1% nickel so that it may be used safely to weld oil field equipment that handles "sour"
Lesson 2
Common Electric
Arc Welding
Processes
(high sulfur) crude oil. The weld metal is hardenable by quenching and tempering similar to
SAE4130 steel.
Typical Mechanical Properties of Weld Metal
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Quenched @1600F.
Quenched @1600F.
Tempered @1200F.
Tempered @900F.
109,000
151,500
125,000
167,000
% Elongation (2")
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
% Reduction of Area
21
14
58.6
44.6
Go T
Glo
Mn
Si
Cr
Ni
Mo
0.26%
1.25%
0.47%
0.49%
0.80%
0.16%
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
4.6.15
contained in the Atom Arc product catalog and the Atom Arc handbook for welding low alloy
high tensile steels, published by ESAB.
Se
Ch
(Fa
Dow
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Se
Doc
(Sl
Dow
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON IV
APPENDIX A
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
AMPS
3/32
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
1/8
Lesson 5
Welding Filler Metals
for Stainless Steels
5/32
DEPOSITION EFFICIENCYELECTRODE
RATE lbs/hr
%
DIAMETER
70
1.37
70.50
90
1.65
66.30
110
1.73
64.40
120
2.58
71.60
140
2.74
160
2.99
140
3.11
75.00
170
3.78
200
4.31
3/16
AMPS
DEPOSITION EFFICIENCY
RATE lbs/hr
%
200
4.85
76.40
250
5.36
74.60
300
5.61
70.30
250
6.50
75.00
70.90
300
7.20
74.00
68.10
350
7.40
73.00
300
7.72
78.00
73.50
350
8.67
77.00
73.00
400
9.04
74.00
7/32
1/4
Glo
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
DEPOSITION
2"
3"
4"
5"
LENGTH
EFFICIENCY
STUB
STUB
STUB
STUB
60%
50.0%
45.0%
40.0%
35.0%
65%
54.2%
48.7%
43.3%
37.9%
70%
58.3%
52.5%
46.6%
40.8%
75%
62.5%
56.2%
50.0%
43.7%
80%
66.6%
60.0%
53.3%
46.6%
60%
51.4%
47.1%
42.8%
38.5%
65%
55.7%
51.1%
46.4%
41.8%
70%
60.0%
55.0%
50.0%
45.0%
75%
64.3%
58.9%
53.6%
48.2%
80%
68.5%
62.8%
57.1%
51.4%
60%
53.3%
50.0%
46.6%
43.3%
65%
57.7%
54.2%
50.5%
46.9%
70%
62.2%
58.3%
54.4%
50.5%
75%
66.6%
62.5%
58.3%
54.2%
80%
71.1%
66.6%
62.2%
57.7%
12"
14"
18"
DIAMETER
LENGTH
Inches
mm
Inches
mm
3/32
1/8
5/32
3/16
7/32
1/4
5/16
2.4
3.2
4.0
4.8
5.6
6.4
8.0
12
14
14
14/18
18
18
18
300
350
350
350/450
450
450
450
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON IV
APPENDIX B
LESSON IV - GLOSSARY OF TERMS
Quench
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
Cu
Ch
Tab
Con
Temper
Go T
following the quenching of steel. This usually lowers the hardness and
Glo
temperature and time is 1150F. for 1 hr. per inch of thickness. This
reheating removes most of the residual stresses put in the weldment by the
heating and cooling during welding.
Transformation
Temperature
Heat Affected
Zone
The area of the base metal that did not become molten in the welding
Turn
induced into that area. If the HAZ in hardenable steels is cooled rapidly, the
area becomes excessively brittle.
Underbead
Cracking
A weld defect that starts in the heat affected zone and is caused by
referred to as cold cracking, since it occurs after the weld metal has cooled.
Low Hydrogen
Electrodes
Stick electrodes that have coating ingredients that are very low in
Steel
layer of rust. This initial layer prevents further rusting and thus, the need to
Low alloy steel that is specially formulated to form a thin tightly adhering
paint the steel is eliminated. The main alloys in this steel are copper and
chromium.
Toe
Cracking
occurs when the weld metal does not stretch with the base metal because
A weld defect that occurs at the toe of the weld metal. The cracking
the yield and tensile strength of the weld metal is greater than the steel.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Cu
Ch
Tab
Con
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
BASIC
WELDING FILLER METAL
TECHNOLOGY
Go T
Glo
A Correspondence Course
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
LESSON V
WELDING FILLER METALS
FOR STAINLESS STEELS
Se
Ch
(Fa
Dow
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Turn
Se
Doc
(Sl
Dow
ESAB
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON V
TABLE OF CONTENTS
LESSON V
WELDING FILLER METALS
FOR STAINLESS STEELS
Lesson 2
Common Electric
Arc Welding
Processes
Section Nr.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Section Title
Page
5.1
5.2
5.3
5.4
5.4.1
5.4.2
5.5
5.6
10
5.7
10
5.8
11
5.9
12
5.10
12
5.11
13
5.12
16
5.12.1
16
5.12.2
17
5.12.3
17
5.12.4
17
5.13
18
5.13.1
18
5.13.2
18
5.13.3
18
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Cu
Ch
Tab
Con
Go T
Glo
Turn
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
LESSON V
TABLE OF CONTENTS
LESSON V - Con't.
Section Nr.
Lesson 10
Reliability of Welding
Filler Metals
Page
5.13.4
5.13.5
19
5.13.6
19
5.13.7
19
5.13.8
19
5.13.9
19
5.13.10
20
5.13.11
20
5.13.12
20
5.13.13
20
5.13.14
21
5.13.15
21
5.14
21
5.15
19
5.15.2
22
5.15.3
22
5.15.4
22
5.15.5
23
5.15.6
23
5.15.7
23
5.15.8
23
Glo
Turn
5.16
Go T
22
22
5.15.1
5.17
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Section Title
Cu
Ch
Tab
Con
23
24
5.17.1
Core-Bright 307.................................................................................
24
5.17.2
24
5.17.3
24
5.17.4
25
5.17.5
25
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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON V
TABLE OF CONTENTS
LESSON V - Con't.
Section Nr.
Section Title
Cu
Ch
Tab
Con
Page
5.17.6
Core-Bright 347.................................................................................
25
Lesson 3
Covered Electrodes
for Welding
Mild Steels
5.18
25
5.19
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
5.20
Go T
Lesson 5
Welding Filler Metals
for Stainless Steels
P
26
Glo
26
5.20.1
26
5.20.2
27
5.20.3
27
5.20.4
27
5.20.5
28
5.20.6
Shield-Bright 347...............................................................................
28
5.21
ARCALOY NICKEL ALLOY COVERED WELDING ELECTRODES FEATURES AND DATA ....................................................................
29
5.21.1
29
5.21.2
29
5.21.3
30
5.21.4
31
5.22
32
5.22.1
Nickel-Arc 55 .....................................................................................
32
5.22.2
Nickel-Arc 550...................................................................................
33
5.22.3
Nickel-Arc 99 .....................................................................................
33
5.22.4
Nicore 55 ..........................................................................................
33
5.22.5
34
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
35
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON V
Cu
Ch
Tab
Con
STAINLESS STEELS
5.1
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Stainless steel, introduced commercially during the early 1930's, presented industry with a new
"wonder metal" with its shiny surface and ability to resist rust and corrosion. This new steel
alloy also presented welding problems that had not been previously encountered. It took many
years of research and experimentation to develop successful welding filler metals and welding
procedures for this "rustless iron" as it was then called.
Glo
5.1.0.1
Most of us think of stainless as an attractive metal used for trim on our stoves and
automobiles, or as bright, easy-to-clean cooking utensils and cutlery. Besides being used for
its corrosion resisting properties, however, stainless steel is used for low temperature applica-
Lesson 5
Welding Filler Metals
for Stainless Steels
tions, and for applications where its resistance to scaling at high temperatures is important.
5.1.0.2
Stainless steel is basically an alloy of iron and chromium. As the amount of chro-
mium added to a steel alloy is increased, the corrosion resistance increases until the amount
of chromium reaches 11% to 12%, at which point it is considered a stainless steel. The graph
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
in Figure 1 shows how the amount of chromium affects the rate of corrosion in a semi-rural,
outdoor air environment. Corrosion rate will vary with the corrosive media to which the stainless steel is exposed and with the type of stainless employed.
.001
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MILD STEEL
.0008
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.0006
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
.0004
STAINLESS STEEL
.0002
10
12
14
PERCENT CHROMIUM
CORROSION RATE VERSUS PERCENT CHROMIUM
OUTDOOR ATMOSPHERE, SEMI-RURAL ENVIRONMENT
FIGURE 1
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON V
5.1.0.3
The mechanism by which chromium imparts corrosion resistance to steel has been
Cu
Ch
Tab
Con
well established. Essentially, the chromium combines with oxygen of the atmosphere to form a
Lesson 2
Common Electric
Arc Welding
Processes
stable non-metallic oxide film on the surface of the steel. This film protects the steel by acting
as a protective coating. As the chromium content of the steel increases, the tenacity, impermeability and strength of this film increases, imparting greater and greater corrosion resistance. This film is too thin to be seen. What we do see is the shiny, unoxidized steel just below
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
this film.
5.1.0.4
In Lesson I we learned that the application of heat to metals can change the micro-
structure and thereby, the properties of that metal. The fabricator of ordinary carbon steel
understands that successful welds depend upon how that material behaves under the heat of
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
the arc. With that information as a guide, welds can be produced that satisfy the mechanical
vation of corrosion resistance and heat resistance must also be considered.
5.1.0.5
Lesson 5
Welding Filler Metals
for Stainless Steels
Glo
requirements of the welded joint. With stainless steel, however, other aspects such as preser-
Stainless steel may be welded by most of the common arc welding processes.
Shielded metal-arc welding with coated electrodes is still probably the most widely used
process. Other commonly used processes are flux cored arc welding, gas metal-arc welding,
gas tungsten-arc welding and submerged arc welding as discussed in Lesson II.
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
5.1.0.6
The cost of stainless steel is approximately six times that of mild steel. For this
reason, it is important that the proper electrodes or filler metals are selected and the proper
welding procedures are followed to minimize rework or scrap losses due to faulty welds. An
understanding of the peculiarities of the four types of stainless steel, and how they compare to
mild or carbon steels, will help to avoid costly mistakes.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
5.1.0.7
There are four primary grades of stainless steel: austenitic, martensitic, ferritic, and
duplex. The names are metallurgical terms derived from the crystal structure of the steel at
room temperature and will be covered in more detail later in this lesson. Figure 2 shows the
basic differences and the composition of the four types.
Lesson 8
Hardsurfacing
Electrodes
TYPE
AUSTENITIC
MARTENSITIC
FERRITIC
DUPLEX
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Lesson 9
Estimating &
Comparing Weld
Metal Costs
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16
11
11
18
30%
18%
30%
28%
NICKEL
8 - 40%
0 - 5%
0 - 4%
4 - 8%
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON V
5.1.0.8
That group of stainless steels that contain both chromium and nickel (austenitic
Cu
Ch
Tab
Con
grade) is more readily and satisfactorily welded than those that contain less than 5% nickel
Lesson 2
Common Electric
Arc Welding
Processes
(martensitic and ferritic grades). Weld joints produced in austenitic stainless steels are strong,
ductile and tough in their as-welded condition. They do not normally require preheat or post
weld heat treatment. On the other hand, the martensitic and ferritic stainless steels are characterized by hardness or brittleness after welding, and preheat and post-heating is necessary to
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
martensitic and ferritic steels are commonly called the "straight chrome" types.
Glo
The behavior of stainless steel in the heat of the arc differs from that of mild steel. Figure 3
Lesson 5
Welding Filler Metals
for Stainless Steels
shows that the rate of expansion of the chromium-nickel types is about 50% greater than that
of carbon steel. This means that distortion from warping must be compensated for to a
greater extent.
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
CARBON
STEEL
CHROMIUMNICKEL
TYPES
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
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STRAIGHT
CHROMIUM
TYPES
.020
Lesson 8
Hardsurfacing
Electrodes
.040
.060
.080
.100
INCHES EXPANSION PER FOOT
1000F TEMPERATURE RISE
.120
RATE OF EXPANSION
FIGURE 3
Lesson 9
Estimating &
Comparing Weld
Metal Costs
5.2.0.1
When welding an austenitic stainless steel to a carbon steel, the different rates of
expansion can cause cracking due to internal stresses unless the proper electrode and welding procedure is used. The expansion of the straight chromium types is about the same as or
slightly less than that of carbon steels.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON V
5.2.0.2
The melting temperature of all stainless steels are lower than that of carbon steel as
Cu
Ch
Tab
Con
shown in Figure 5, and both chrome-nickel and straight chrome types are much more fluid in
Lesson 2
Common Electric
Arc Welding
Processes
the melted state. Therefore, less heat (welding current) is required to weld stainless steels
compared to carbon steels.
CARBON
Go T
STEEL
Lesson 3
Covered Electrodes
for Welding
Mild Steels
CHROMIUM-
NICKEL
TYPES
STRAIGHT
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
CHROMIUM
TYPES
2000
2250
2500
2750
3000
DEGREES FAHRENHEIT
MELTING TEMPERATURES
Lesson 5
Welding Filler Metals
for Stainless Steels
FIGURE 4
5.2.0.3
The electrical resistance of both the chrome-nickel and the straight chrome types is
considerably higher than that of the plain carbon steels as shown in Figure 5. This higher
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
resistance creates more resistance heating in the stainless steel electrode and in the base
plate. Lower welding current or amperage is required to avoid overheating the electrode. The
CARBON
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
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STEEL
CHROMIUMNICKEL
TYPES
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STRAIGHT
Lesson 8
Hardsurfacing
Electrodes
CHROMIUM
TYPES
MICROHMS/SQ
CM/CM AT 20 C.
10
20
30
40
50
60
70
80
ELECTRICAL RESISTANCE
Lesson 9
Estimating &
Comparing Weld
Metal Costs
FIGURE 5
electrical resistance of the chrome-nickel alloys is about six times that of carbon steel and may
be substantially higher if the stainless is cold-worked. The straight chrome types have electri-
Lesson 10
Reliability of Welding
Filler Metals
cal resistances varying from three to six times that of carbon steel.
Lesson 1
The Basics of Arc
Welding
LESSON V
5.2.0.4
The chrome-nickel stainless alloys conduct heat only 40% to 50% as fast as carbon
Cu
Ch
Tab
Con
steel and in the straight chrome types, heat conductivity is 50% to 65% that of carbon steel as
Lesson 2
Common Electric
Arc Welding
Processes
shown in Figure 6. This means that the heat remains in the vicinity of the arc for a longer
period of time instead of being dispersed throughout the weldment rapidly, as it does when
welding materials of high thermal conductivity. This is another reason that lower amperages
are required to weld these steels.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
P
CARBON
STEEL
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
CHROMIUMNICKEL
TYPES
STRAIGHT
CHROMIUM
Lesson 5
Welding Filler Metals
for Stainless Steels
TYPES
AT 20 - 100 C
CAL/SEC/SQ CM
.020
.040
.060
.080
.100
.120
Turn
THERMAL CONDUCTIVITY
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
FIGURE 6
Lesson 8
Hardsurfacing
Electrodes
structure ferrite. The high temperature structure, austenite, is non-magnetic, plastic and has
lower strength and greater ductility than the room temperature form of ferrite.
5.3.0.1
Lesson 9
Estimating &
Comparing Weld
Metal Costs
When more than 17% chromium and 7% nickel are added to the steel, the high
temperature crystalline structure of the steel austenite, is stabilized so that it persists at all
temperatures from the very lowest to almost melting. This alloy combination is the basis for the
austenitic category of stainless steels . Many alloy additions are made to that base as modifications for different service requirements.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON V
5.3.0.2
When certain alloy steels are cooled rapidly from above the transformation tempera-
Cu
Ch
Tab
Con
ture, a very hard brittle phase occurs. This phase is called martensite. Steels that contain 5-
Lesson 2
Common Electric
Arc Welding
Processes
15% chromium have this special characteristic. Unless special care is used in welding such
steels, they become crack sensitive. These are the martensitic stainless steel alloys.
5.3.0.3
When more than 16% chromium is added to the steel, the room temperature crystal-
line structure, ferrite, is stabilized and the steel remains in the ferritic condition at all tempera-
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
tures. Hence the name, ferritic stainless steel is applied to this alloy base.
are shown in Figure 7. About 80% of the stainless steel welded is of the austenitic type.
AISI No.
301
302
304
309
310
316
317
347
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Chromium % Nickel %
17
18
19
23
25
17
19
18
7
9
10
13
20
12
13
11
Molybdenum % Columbium %
Turn
2.5
3.5
1
5.4.1
Carbide Precipitation - Many of the austenitic stainless steels are subject to the
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Carbide precipitation has no other effect on the steel, however, other than loss of
corrosion resistance in the heat affected zone. During welding, the heat-affected zones along
the sides of the weld in austenitic stainless steel are exposed to the temperatures that cause
Lesson 10
Reliability of Welding
Filler Metals
Glo
can Iron & Steel Institute (AISI). Nominal compositions of some of the more important types
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Go T
carbide precipitation.
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Lesson 1
The Basics of Arc
Welding
LESSON V
HEAT
AFFECTED
ZONES
INSIDE OF
TANK
Lesson 2
Common Electric
Arc Welding
Processes
WELD
METAL
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
INTERGRANULAR CORROSION
FIGURE 8
5.4.1.2
Cu
Ch
Tab
Con
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
a. Carbide precipitation is a function of the carbon content. Keeping the carbon content
as low as possible in the steel (0.04% maximum) and welding it with low carbon electrodes is one solution.
Lesson 5
Welding Filler Metals
for Stainless Steels
b. If the carbon of the steel and weld metal are tied up by an element that has a stronger
affinity for carbon than does chromium, carbide precipitation cannot occur. Columbium
and titanium are alloys that have a stronger affinity for carbon. Steels with columbium or
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
c. Another method, although not as practical, is to heat the finished weldment to at least
1850F allowing all of the precipitated carbides to go back into solution. The weldment
is then rapidly cooled and quenched so that it passes through the critical temperature
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
(1200F) very quickly, allowing little or no carbides to reform. However, stainless steel
weldments heated to such high temperatures would be subject to warping, sagging and
other loss of dimension as well as being covered with heavy scale.
5.4.2
Lesson 8
Hardsurfacing
Electrodes
Ferrite in Austenitic Stainless Steel - Stainless weld metal that is fully austenitic is
non-magnetic and has a relatively large grain structure. This results in the weld being cracksensitive. By controlling the balance of the alloying elements in the electrode, small amounts of
another phase, ferrite, can be introduced in the weld metal. The ferrite phase causes the
austenitic grains to be much finer and the weld becomes more crack-resistant.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
5.4.2.1
Certain alloying elements used in stainless steels and weld metals behave as
austenite stabilizers and others as ferrite stabilizers. Among the austenite stabilizers are
nickel, carbon, manganese and nitrogen. The ferrite stabilizers are chromium, silicon, molybdenum and columbium. It is the balance between the two types of alloying elements that
Lesson 10
Reliability of Welding
Filler Metals
Turn
titanium, and covered electrodes with columbium present, are made for this purpose.
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Lesson 1
The Basics of Arc
Welding
LESSON V
5.4.2.2
The amount of ferrite in austenitic stainless steel weld metal may be measured by
Cu
Ch
Tab
Con
magnetic devices because the ferrite is magnetic. A small amount of ferrite in austenitic
Lesson 2
Common Electric
Arc Welding
Processes
stainless weld metal is good, because it prevents weld cracking. If the weldment is to be in
very low temperature service, however, large amounts of ferrite should be avoided because
ferrite is not tough at low temperatures. Also, if the weldment is to be used in high temperature
(higher than 1000F) service, the ferrite should be maintained at low levels because the ferrite
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
Glo
between the austenite and ferrite forming elements in iron. When the chemical composition of
the weld metal is known, the Schaeffler or WRC-1992 diagrams can be used. See Figures 9
and 10.
Lesson 5
Welding Filler Metals
for Stainless Steels
5.5.0.1
The purpose of these diagrams is to calculate the nickel and chromium equivalent of
the weld metal in question and plot the point on the appropriate diagram. The nickel equivalent is the sum of the nickel content and all other austenite formers, multiplied by coefficients
representing their austenite forming effect as compared to that of nickel. The chromium
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
equivalent is calculated in the same manner. In both diagrams, the nickel equivalent is the
vertical axis, and the chromium equivalent is the horizontal axis. The WRC-1992 diagram has
an advantage since it also takes the nitrogen content into consideration. Nitrogen is a powerful austenite forming element. If the nitrogen content is not known, we assume 0.06% for
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
GTAW and SMAW electrodes and, 0.08% for GMAW and FCAW filler metals.
5.5.0.2
When chemical composition is not available, two common instruments can also be
used to determine ferrite content. Since ferrite at room temperature is magnetic and austenite
is not, a relationship between magnetic response and ferrite content can be established. The
Lesson 8
Hardsurfacing
Electrodes
more magnetic response to the instrument, the more ferrite present in the metal. The two
commercially available instruments that use this principal to measure ferrite content are the
Magne gage and the Severn gage. The Magne gage is a laboratory instrument, while the
Severn gage is a pocket-size instrument designed for on-site readings.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
5.5.0.3
In the past, ferrite was expressed as a volume percent of the metal. However,
Lesson 10
Reliability of Welding
Filler Metals
(WRC), the American Welding Society (AWS), and other agencies. Ferrite numbers (FN) are
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Lesson 1
The Basics of Arc
Welding
LESSON V
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
SHAEFFLER CONSTITUTION DIAGRAM FOR STAINLESS STEEL WELD METAL
FIGURE 9
Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
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Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
WRC-1992 DIAGRAM FOR STAINLESS STEEL WELD DATA
Lesson 8
Hardsurfacing
Electrodes
FIGURE 10
the same as the volume percent numbers in the range of 0-7%. At higher contents, FN values
Lesson 9
Estimating &
Comparing Weld
Metal Costs
become increasingly higher than the previous percent ferrite values. The DeLong diagram
shows this comparison.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON V
Go T
on the particular electrode in question. However, some users of stainless steel require the
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
Ch
Tab
Con
ferrite content be above or below the normal ranges as found in typical chemical analyses. An
example of this is the SMAW 316 electrode. Normally, a 316 stick electrode has a FN in the 02 range, but a specially formulated 316 stick electrode could have a minimum of 5 FN, if
needed. Since these electrodes require special chemical formulations, they must be ordered
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
Steel Institute. They are magnetic and contain from 11.5% to 18% chromium. As previously
noted, they get the name martensite because of the crystalline structure of the steel at room
temperature. With a lower alloy content than the austenitic steels, they are lower in cost than
Turn
the austenitic types. They have adequate corrosion resistance in many environments because
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
they form the characteristic chromium oxide surface film. They also have a high hardenability
characteristic.
5.7.0.1
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Other chromium bearing heat resistant steels that have only 4% to 10% chromium
(not a true stainless steel by the 11.5% minimum chrome requirement) have similar
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hardenability characteristics. These steels are designated by the 500 series numbers according to the American Iron and Steel Institute and from a welding standpoint, may be considered
in the same grouping as the martensitic stainless steels. Nominal compositions of these types
are shown in Figure 11.
Lesson 8
Hardsurfacing
Electrodes
5.7.0.2
Lesson 9
Estimating &
Comparing Weld
Metal Costs
AISI No.
403
410
501
502
Carbon
Chromium
%*
0.15
0.15
0.10 min
0.10
%*
11.5 - 13
11.5 - 13.5
4-6
4-6
Molybdenum
%*
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0.40 - 0.65
0.40 - 0.65
Lesson 10
Reliability of Welding
Filler Metals
heating the steel, since preheating lowers the thermal difference between the weld area and
Lesson 1
The Basics of Arc
Welding
LESSON V
the base metal. This allows the weld area to cool more slowly and as a result, the steel in the
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
5.7.0.3
The preheating temperature used is in the range of 350F to 500F and should be
maintained during the entire welding operation. Upon completion of welding, the weldment
should be cooled slowly, preferably furnace cooled, allowing gradual temperature change.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
5.7.0.4
since they harden intensely, even on relatively slow cooling from high temperatures. The weld
deposit and the steel that surrounds the weld deposit is hard and brittle. Heat treatment of the
weldment is necessary to improve these physical properties.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
5.7.0.5
Glo
a higher alloy austenitic stainless steel electrode (such as 309) that deposits tough, ductile
weld metal without cracking. This solution would depend on the required properties of the
weldment and is not recommended in all cases. Martensitic stainless steels make up about
Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Ferritic stainless steels are straight chrome alloys in the AISI 400 series. They are magnetic
and have varying ranges of chromium content as shown in Figure 12.
5.8.0.1
All ferritic stainless steels have the room temperature crystal structure of ferrite
stabilized to all temperatures. The higher chromium content provides good resistance to high
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Other %*
405
0.08
11.5 - 14.5
430
0.12
16.0 - 18.0
--
446
0.20
23.0 - 27.0
Nitrogen
0.25
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Se
Ch
(Fa
Dow
temperature scaling. For this reason, the ferritic stainless steels are used to make heat treat-
Aluminum
0.10 - 0.30
Se
Doc
(Sl
Dow
FIGURE 12
short as possible, these steels should be mildly preheated to about 300F, welded with small
diameter electrodes and with the lowest possible welding current, thereby limiting the heat
input. About 5% of the stainless steels welded are of the ferritic category.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON V
Cu
Ch
Tab
Con
Duplex means "two". Duplex stainless steels consist of the two "building stones" (microstructure phases) ferrite and austenite and are often termed ferritic-austenitic stainless steels.
Typically, duplex stainless steels have a microstructure consisting of approximately 50% ferrite
and 50% austenite.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
5.9.0.1
to stress corrosion cracking, the austenite provides good toughness, and the two phases in
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
In simple terms, the ferrite could be said to give high strength and some resistance
The most important alloying elements of duplex stainless steels are Cr, Ni, Mo and
N. These elements largely govern the properties of the steels. Some grades also contain
Glo
on the market. At present, the 22% chromium (Cr), 5% nickel (Ni), 3% molybdenum (Mo),
Lesson 5
Welding Filler Metals
for Stainless Steels
0.15% nitrogen (N) grade (commonly called 2205) is the most common type of duplex stainless steel and is used in a wide range of applications. Higher alloyed duplex steels, the socalled super duplex stainless steels, have also been introduced into the market. The 25%
chromium (Cr), 7% nickel (Ni), 4% molybdenum (Mo), 0.25% nitrogen (N) grade (commonly
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
called 2507) is one example of a modern high alloy super duplex stainless steel. These steels
are designed for use in demanding applications where even greater corrosion resistance or
higher strength is required.
Lesson 8
Hardsurfacing
Electrodes
every type of stainless steel, however, because some electrodes produce satisfactory welds
even though the chemical analysis of the steel may be slightly different.
5.10.0.1
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
Type 308 stainless steel electrodes may be used for welding AISI 201 and 202 that
have a lower nickel content and a high manganese content. Type 308 electrodes may also be
used to weld types 301, 302, 304, 305 and of course, 308 itself. Even though their chromiumnickel contents vary slightly, all of these steel types may be considered as one family of alloys.
The chart in Figure 13 shows the proper Arcaloy electrode to be used for the various types of
AISI steels.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Cu
Ch
Tab
Con
LESSON V
Carbon
Manganese
Silicon
Chromium
Other
Elements
Nickel
Weld with
Arcaloy Type
Go T
Austenitic
201
202
301
302
302B
303
303Se
304
304L
305
308
309
309S
310
310S
314
316
316L
317
321
347
348
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.08
0.03
0.12
0.08
0.2
0.08
0.25
0.08
0.25
0.08
0.03
0.08
0.08
0.08
0.08
5.5/7.5
7.5/10.0
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
1.00
1.00
1.00
1.00
2.00/3.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.50
1.50
1.50/3.00
1.00
1.00
1.00
1.00
1.00
1.00
16.00/18.00
17.00/19.00
16.00/18.00
17.00/19.00
17.00/19.00
17.00/19.00
17.00/19.00
18.00/20.00
18.00/20.00
17.00/19.00
19.00/21.00
22.00/24.00
22.00/24.00
24.00/26.00
24.00/26.00
23.00/26.00
16.00/18.00
16.00/18.00
18.00/20.00
17.00/19.00
17.00/19.00
17.00/19.00
3.50/5.50
3.50/5.50
6.00/8.00
8.00/10.00
8.00/10.00
8.00/10.00
8.00/10.00
8.00/12.00
8.00/12.00
10.00/13.00
10.00/12.00
12.00/15.00
12.00/15.00
19.00/22.00
19.00/22.00
19.00/22.00
10.00/14.00
10.00/14.00
11.00/15.00
9.00/12.00
9.00/13.00
9.00/13.00
N 0.25 Max.
N 0.25 Max.
------S 0.15 Min.***
Se 0.15 Min.
------------------Mo 2.00/3.00
Mo 2.00/3.00
Mo 3.00/4.00
Ti 5 x C Min.
Cb + Ta 10 x C Min.
Cb + Ta 10 x C Min.
Ta 0.10 Max.
Cb + Ta 8 x C min.
1.00% Max.
308/308 ELC
308/308 ELC
308/308 ELC
308/308 ELC
308/308 ELC
312
312
308/308 ELC
308 ELC
308/308 ELC
308/308 ELC
309
309
310
310
310/312
316/316 ELC
316 ELC
317/317 ELC
308 ELC/347
308 ELC/347
308 ELC/347
20Cb-3
0.06
2.00
1.00
19.00/21.00
32.50/35.00
1.00
1.00
1.00
1.25
1.25
1.00
1.00
1.00
0.50
1.00
1.00
1.00
1.00
1.00
1.00
1.00
11.50/13.00
11.50/13.50
11.50/13.50
12.00/14.00
12.00/14.00
12.00/14.00
15.00/17.00
11.50/14.00
----1.25/2.50
------1.25/2.50
3.5/4.5
309
309
309/410
312/410
312/410
309/410
309/430
410NiMo
1.00
1.00
1.25
1.25
1.00
1.50
1.00
1.00
1.00
1.00
1.00
1.00
11.50/14.50
14.00/18.00
14.00/18.00
14.00/18.00
18.00/23.00
23.00/27.00
---
Al 0.10/0.30
--S 0.15 Min.***
Se 0.15 Min.
--N 0.25 Max.
309/410
309/430
312/430
312/430
309/310
309/310
320LR
Glo
Turn
320LR
Martensitic
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
403
410
414
416
416Se
420
431
CA6NM
0.15
0.15
0.15
0.15
0.15
Over 0.15
0.2
0.06
Ferritic
405
430
430F
430Se
442
446
0.08
0.12
0.12
0.12
0.2
0.2
-----------
If service allows
Not regarded as weldable
FIGURE 13
/410 Se
/410Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON V
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
type of steel to another (called a transition weld) is made, care must be given to the selection
There are two general conditions and rules for electrode selection to weld dissimilar
Glo
steels.
When the steels are similar metallurgically but dissimilar chemically, match the
electrode to the lower chemical composition or less expensive steel. For example, type 310
steel (25% chromium, 20% nickel) is sometimes welded to type 304 steel (19% chromium,
10% nickel). Both types are austenitic. Type 304 steel, which is welded with 308 electrodes,
is less expensive, so that weld would be made with type 308 electrodes rather than type 310
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Go T
a steel of the same type. Simply match the electrode to the steels. When a change from one
a.
Lesson 5
Welding Filler Metals
for Stainless Steels
Cu
Ch
Tab
Con
Turn
electrodes.
b.
When the steels to be jointed are different metallurgically and chemically, the
electrode is selected to provide a tough, crack resistant weld between the two steels. For
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
example, 304 stainless steel is frequently welded to mild structural steel. Corrosion resistance
cannot be part of the problem because mild steel is on one side of the joint with practically no
corrosion resistance compared to the stainless steel. If this weld is made with mild steel
electrodes to match the mild steel side of joint, the weld metal would be enriched by the wash-
Lesson 8
Hardsurfacing
Electrodes
in of chromium and nickel from the stainless side. This intermediate chrome-nickel is usually
hard and crack sensitive. If the weld is made with type 308 electrodes to match the stainless
steel side of the joint, the chromium and nickel contents of the weldment are diluted by the mild
steel side of the joint to an intermediate level that would again probably be hard and crack
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
sensitive. When welding mild steel to stainless steel, a proportion of 18% chromium and 8%
nickel is desirable in the weld deposit to produce sound welds, with 17% chromium and 7%
nickel being the minimum allowable amounts.
5.11.0.2
The following examples in Figure 14 show the results of making a transition weld of
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON V
ELECTRODE
60%
Lesson 2
Common Electric
Arc Welding
Processes
Cu
Ch
Tab
Con
20%
20%
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
304
MILD
STEEL
308 ELECTRODE
ELECTRODE X 60%
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
CHROMIUM
NICKEL
19.5
9.5
11.7
5.7
304 X 20%
18.0
8.0
3.6
1.6
MILD
STEEL X 20%
0
0
0
0
WELD
METAL
15.3
7.3
The composition of 15.3% chromium and 7.3% nickel does not meet the minimum 17-7%
proportion. The weld metal will be mostly martensitic with a very small amount of ferrite.
This structure is quite brittle.
310 ELECTRODE
Lesson 5
Welding Filler Metals
for Stainless Steels
ELECTRODE X 60%
CHROMIUM
NICKEL
26.0
21.0
15.6
12.6
304 X 20%
18.0
8.0
3.6
1.6
MILD
STEEL X 20%
0
0
0
0
WELD
METAL
19.2
14.2
Turn
The composition of 19.2% chromium and 14.2% nickel is not near the 18/8 proportion.
The weld metal would be fully austenitic and crack sensitive.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
309 ELECTRODE
ELECTRODE X 60%
CHROMIUM
NICKEL
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
23.0
13.0
13.8
7.8
304 X 20%
18.0
8.0
3.6
1.6
MILD
STEEL X 20%
0
0
0
0
WELD
METAL
17.4
9.4
The composition of 17.4% chromium and 9.4% nickel is close to the 18/8 proportion. The
weld metal will be austenitic with some ferrite and a small amount of martensite to keep
the weld metal from being tough and crack resistant. 309 is the best choice.
ELECTRODE SELECTION - 304 STAINLESS TO MILD STEEL
Lesson 8
Hardsurfacing
Electrodes
Glo
FIGURE 14
5.11.0.3
Normally the most severe dilution of the weld metal by the base metal is 40%. Thus,
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
the weld metal in the joint is comprised of 60% from the electrode and 40% from the base
Lesson 9
Estimating &
Comparing Weld
Metal Costs
metal as shown in Figure 14. In the case of butt joints between dissimilar steels, half of the
dilution comes from each side of the joint, or 20% from each base metal.
5.11.0.4
Many times, type 310 and 312 electrodes are used erroneously for welding stain-
less to mild or low alloy steel. In many cases, not only can more dependable welds be made
with 309 electrodes, but appreciable savings can be achieved because of their lower cost.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON V
5.11.0.5
Another common use of stainless steel filler metals is the overlaying or cladding of
Cu
Ch
Tab
Con
less expensive steels with a layer of stainless. Mild steel tanks designed to hold corrosive
Lesson 2
Common Electric
Arc Welding
Processes
liquids may be lined with stainless steel in this manner. Usually, continuous bare or flux cored
electrodes are used with an automated welding setup. Current and penetration must be
controlled closely to limit dilution with the base metal. Sometimes it is necessary to deposit
more than one layer to assure the correct analysis of the deposit.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
5.11.0.6
The welding of stainless clad plate (produced by some steel mills) should also be
mentioned. Thicker sections may be welded with both mild steel and stainless electrodes, and
thinner sections may be welded only with stainless electrodes. Joint preparation, welding
procedure and electrode selection will vary with the thickness and type of clad plate being
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
welded. Welding of clad plate is a specialized area of dissimilar metal welding and beyond
Glo
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
5.12.1
classified according to the American Welding Society Filler Metal Specification A-5.4-92. As
defined by that specification, the electrodes are classified by weld metal composition and type
of welding current. For example, the AWS designation E308-15 means electrode (E), AISI
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
type 308 steel (20% chrome, 10% nickel) and direct current electrode positive (-15). If the
classification reference were E308-16, it would indicate an electrode (E), AISI type 308 steel
(308) and AC-DC electrode positive operation (-16 & -17). Arcaloy lime coated electrodes
have the DC suffix -15, Arcaloy AC-DC electrodes have the suffix -16, and Arcaloy Plus electrodes use the -17 suffix.
Lesson 8
Hardsurfacing
Electrodes
5.12.1.1
Arcaloy high alloy stainless steel covered electrodes are produced by extruding
carefully formulated and mixed coating material on a stainless steel core wire, thus ensuring
constant weld metal properties and composition.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
5.12.1.2
Arcaloy stainless steel electrodes have been among the leaders in the stainless
electrode industry for many years. The strict purchase specifications for the core wire and the
covering materials, and the rigid quality control under which the Arcaloy electrodes are manufactured, have resulted in this position of leadership.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON V
5.12.2
Arcaloy lime coated electrodes were among the earliest stainless steel elec-
Cu
Ch
Tab
Con
trodes developed in the United States. Designed for welding with direct current, reverse
Lesson 2
Common Electric
Arc Welding
Processes
polarity only, the coating contains considerable amounts of limestone and fluorspar producing
a fast freezing slag that facilitates welding in the vertical and overhead positions. The weld
bead is slightly convex and moderately rippled. (See Figure 15).
5.12.2.1
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
removal that is somewhat difficult, the lime type is not the most popular with the welding operators. However, it is the easiest to use stainless electrode for out-of-position welding. Also, the
convex bead can provide the necessary margin of safety in highly stressed joints in many
cases.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
5.12.3
Arcaloy AC-DC Titania coated electrodes were the first such electrodes to
Glo
receive wide acceptance in this country. Designed to operate on alternating current as well as
direct current, the coating contains dominant amounts of rutile (titania), medium amounts of
limestone, and limited amounts of fluorspar. By far, the AC/DC type is the most popular of the
Lesson 5
Welding Filler Metals
for Stainless Steels
coated stainless electrodes. Welders like to use it because of the smoother arc action, low
amount of fine spatter and easy slag removal. Also, the bead is relatively flat, finely rippled and
has good side-wall fusion (See Figure 15). Although used in all positions, vertical and overhead welding requires slightly more operator skill than with the lime types because the slag
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
5.12.4
lime and AC-DC Titania coatings. Designed to operate on DCEP or AC, this coating is
specially formulated to operate on a broad range of current settings, and most significantly,
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
these electrodes perform their best at high heat inputs where conventional AC-DC electrodes
tend to break down.
5.12.4.1
When operating at high currents, Arcaloy Plus electrodes deposit weld metal at
exceptional speeds with a smooth spray transfer. The bead profile is finely rippled, concave,
Lesson 8
Hardsurfacing
Electrodes
and evenly feathered (See Figure 15). Spatter is minimal. The molten slag does not edge
into the weld puddle, thereby assuring easy visibility of the arc transfer.
5.12.4.2
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
Arcaloy Plus electrodes were developed for applications on dairy and food pro-
cessing equipment and chemical containers, to name a few, where the weld radius must be
smooth and concave to prevent particle entrapment. When welding in the flat and horizontal
fillet positions, the concave deposit and absence of surface irregularities make it ideal for
applications where cosmetic appearance, speed, and final finishing are factors.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON V
Lesson 2
Common Electric
Arc Welding
Processes
(-15)
LIME
CONVEX
MODERATE RIPPLE
Lesson 3
Covered Electrodes
for Welding
Mild Steels
(-16)
AC-DC
FLAT
LOW RIPPLE
(-17)
PLUS
CONCAVE
MININUM RIPPLE
P
FIGURE 15
5.12.4.3
Lesson 5
Welding Filler Metals
for Stainless Steels
The weld metal properties are similar for each of the three coating types: lime, AC-
Arcaloy 308L (AWS E308/308L-15 & -16), Arcaloy 308L Plus (AWS E308/308L-
Turn
17) - This extra low carbon composition is intended to weld Type 304L steels to prevent carbide participation. It can also be used to weld Types 321 and 347 steels. Typical chemical
composition of weld metal is:
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
5.13.2
Carbon
0.03%
Chromium
Nickel
9.7%
Manganese
19.1%
1.6%
Silicon
0.4%
Ferrite No.
Arcaloy 309L (AWS E309L-15 & -16), Arcaloy 309L Plus (AWS E309/309L-17)
- The low carbon content of Arcaloy 309 L weld metal makes it useful to weld low carbon
overlay on carbon or low alloy steel to control carbide precipitation in the overlay. The chemical composition of the weld metal is the same as that of Arcaloy 309 except that the carbon
content is 0.04% and the typical ferrite no. is 8.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Glo
5.13.1
Lesson 8
Hardsurfacing
Electrodes
Go T
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Cu
Ch
Tab
Con
5.13.3
Arcaloy 309 Cb (AWS 309Cb-15 & -16) - The addition of columbium to Type 309
weld metal improves its high temperature performance. It is also useful in welding Types 321
and 347 clad steels. The weld metal composition is the same as Type 309, except that 0.80%
columbium is added and the ferrite no. is 8.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON V
5.13.4
Cu
Ch
Tab
Con
denum to Type 309 weld metal makes the electrode useful for welding Type 316 clad steel. The
Lesson 2
Common Electric
Arc Welding
Processes
weld metal composition is the same as Type 309 except for the addition of 2.2% molybdenum
and the ferrite no. is 8.
5.13.5
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Arcaloy 310 (AWS 310-15 & -16) - The 25% chromium and 20% nickel content of
Arcaloy 310 has made it widely used for welding difficult-to-weld steels, especially where
preheat cannot be used. Type 310 steel is used for high temperature applications and Arcaloy
310 electrodes have similar properties for that service. Typical chemical composition of the
Carbon
5.13.6
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
0.15%
Nickel
21.0%
Silicon
0.4%
Chromium
26.0%
Manganese
1.8%
Ferrite No.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
310 makes the electrode suitable for welding types 321 and 347 clad steels. The chemical
composition of the weld metal is similar to Arcaloy 310 weld metal except that 0.8% columbium is added. The ferrite number remains 0.
5.13.7
Arcaloy 310Mo (AWS E310Mo-15 & -16) - The molybdenum addition to type 310
Turn
makes Arcaloy 310Mo suitable for welding type 316 clad steels. It has also been used for
welding liners in pulp digesters in the paper industry. The weld metal composition is the same
as Arcaloy 310 except that 2.5% molybdenum is added. The ferrite number remains 0.
5.13.8
Arcaloy 312 (AWS E312-15 & -16) - The extreme crack resistance of the 29%
chromium, 9% nickel electrode has made it widely used for welding very difficult-to-weld
steels, such as spring steel and abrasion resisting steel. It has the highest tensile strength of
makes it unsuitable for service at high and low temperatures. Typical weld metal composition
is:
5.13.9
Carbon
0.12%
Chromium
Nickel
9.5%
Manganese
Silicon
0.5%
Ferrite No.
29.0%
1.7%
30
Arcaloy 316L (AWS E316L-15 & -16), Arcaloy 316L Plus (AWS E316/316L-17) -
The extra low carbon content allows the weld metal to have minimum carbide precipitation. It
is widely used in the welding of chemical equipment. The weld metal composition is the same
Lesson 10
Reliability of Welding
Filler Metals
Glo
Arcaloy 310 Cb (AWS E310Cb-15 & -16) - The addition of columbium to Arcaloy
all the chromium-nickel stainless steel weld metals. The very high ferrite content, however,
Lesson 8
Hardsurfacing
Electrodes
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Go T
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Lesson 1
The Basics of Arc
Welding
LESSON V
5.13.10
Arcaloy 316LF5 (AWS E316/316L-15 & -16) - is similar to Arcaloy 316 L, except
Cu
Ch
Tab
Con
that the weld metal composition is balanced to give a ferrite number of at least 5 to control
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
weld cracking.
Carbon
0.35%
Nickel
5.13.11
12.5%
Silicon
0.45%
Ferrite No.
5 minimum
Chromium
19.0%
Manganese
1.6%
Molybdenum
2.25%
Arcaloy 317L (AWS E317/317L-15 & -16), Arcaloy 317L Plus (AWS E317/317L-17)
Go T
- This weld metal with higher molybdenum content than Arcaloy 316 has greater resistance
to pitting corrosion. The molybdenum content also greatly improves weld metal crack resistance allowing it to be used to weld hardenable steels. Typical chemical composition of the
Glo
0.06%
Nickel
Lesson 5
Welding Filler Metals
for Stainless Steels
12.7%
Silicon
0.45%
Ferrite No.
Chromium
19.0%
Manganese
1.6%
Molybdenum
3.25%
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
5.13.12
Arcaloy 318 (AWS E318-15 & -16) - This electrode might also be called 316Cb
because it has about 0.8% columbium added to the weld metal of type 316 composition. It is
used to weld 316L and 318 steels where carbide precipitation and the resultant intergranular
corrosion would be a problem.
Carbon
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
5.13.13
Lesson 10
Reliability of Welding
Filler Metals
0.06%
Nickel
12.5%
Silicon
Columbium
Chromium
18.5%
Manganese
1.6%
0.6%
Molybdenum
2.25%
0.8%
Ferrite No.
Arcaloy 320 (AWS E320-15), Arcaloy 320LR (AWS E320LR-16) - The complex
composition of this electrode is designed especially for welding similar steels Carpenter
Stainless #20 CB-3 (Wrought) and Durimet 20 (Cast). These steels are intended to resist
corrosion by sulfuric acid.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Carbon
Nickel
32.5%
Silicon
Chromium
20.0%
Manganese
0.6%
0.4%
Molybdenum
2.0%
Columbium
0.5%
Copper
3.0%
Ferrite No.
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Lesson 1
The Basics of Arc
Welding
LESSON V
5.13.14
Lesson 2
Common Electric
Arc Welding
Processes
Cu
Ch
Tab
Con
Arcaloy 347 (AWS E347-15 & -16), Arcaloy 347 Plus (AWS E347-17) - This
columbium bearing electrode is used to weld types 321 and 347 steels to prevent carbide
precipitation and the resultant intergranular corrosion. Arcaloy 347 electrodes are also used to
impact high strength to the weld metal at elevated temperatures.
Go T
Carbon
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
5.13.15
0.06%
Chromium
19.5%
Nickel
9.5%
Manganese
1.8%
Silicon
0.6%
Columbium
0.8%
Ferrite No.
Arcaloy 410 (AWS E410-16) - This straight chromium electrode deposits a marten-
Glo
sitic weld metal that is used extensively for corrosion and oxidation resistance at temperatures
up to 1200F. When welding type 410 steel with Arcaloy 410 electrodes, preheat must be
used to prevent excess hardening of the heat affected zone and consequent cracking. Typical
Lesson 5
Welding Filler Metals
for Stainless Steels
0.06%
Chromium
Manganese
0.4%
Silicon
12.0%
0.6%
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
tions and receiving instructions, as well as in-process inspection and analyses, insure the final
product to be of the highest possible quality. Modern equipment in a modern plant assures
that every form of electrode has the characteristics needed for each applicable welding process. Temper, cast, helix, and surface finish are closely controlled. The uniformity of these
properties is essential to the maximum efficiency of the Gas Metal Arc Welding (GMAW), Gas
Lesson 8
Hardsurfacing
Electrodes
Tungsten Arc Welding (GTAW), and Submerged Arc Welding (SAW) processes.
5.14.0.1
Arcaloy bare stainless electrodes and welding rods meet the requirements of AWS
Filler Metals Specification A5.9-93. That specification classifies the electrodes on the basis of
Lesson 9
Estimating &
Comparing Weld
Metal Costs
composition, such as ERXXX where ER represents electrode or rod, and XXX represents the
AISI three-digit number of the composition, such as 308, 410, or 502. The chemical composition requirements are based on the electrode rather than the weld metal.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON V
5.14.0.2
Arcaloy bare continuous solid stainless electrodes for gas metal arc or automated
Cu
Ch
Tab
Con
gas tungsten arc welding are smooth drawn to a bright finish. They are chemically cleaned,
Lesson 2
Common Electric
Arc Welding
Processes
layer-wound on plastic spools, sealed in plastic bags, and packed in individual boxes.
5.14.0.3
Arcaloy bare solid stainless steel continuous electrodes for Submerged Arc Weld-
ing are furnished in the fully annealed (soft) condition for smoother, easier feeding. The elec-
Go T
trodes are random wound on fiber rims into coils, packaged in plastic bags, and boxed.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
5.14.0.4
Arcaloy bare solid stainless welding rods are furnished in 36" (914 mm) cut lengths
for manual gas tungsten arc and oxyacetylene welding. Cut length rods are available with
either flags or ink printed identification.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
5.15.1
Arcaloy ER308L (AWS ER308/308L) - is used for welding types 304L, 308L, 321,
and 347 steels. The extra low carbon content prevents carbide precipitation in the weld metal.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
The chemical composition of the electrode is the same as that of ER 308, except that the
carbon content is 0.02%.
5.15.2
the wetting action of the weld metal, resulting in smooth uniform welds of good appearance.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
The chemical composition is the same as ER 308 L, except that the silicon content is 0.75%.
5.15.3
Arcaloy ER309L (AWS ER309/309L) - The extra low carbon content provides
freedom from carbide precipitation. The electrode is used for low carbon overlay work. The
chemical composition of the electrode is the same as ER 309, except that the carbon content
Lesson 8
Hardsurfacing
Electrodes
is 0.03%.
5.15.4
Arcaloy ER310 (AWS ER310) - Used for welding type 310 stainless steel.
It is
also used for welding stainless steel to mild steel, for welding 304 clad steels and for stainless
steel overlay welding on carbon steel. Typical chemical composition of the electrode is:
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Carbon
0.12%
Nickel
21.5%
Silicon
0.4%
Chromium
Manganese
26.5%
1.75%
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON V
5.15.5
Arcaloy ER312 (AWS ER312) - is used for welding difficult-to-weld steels and for
Cu
Ch
Tab
Con
welding stainless steel to mild steel. Typical chemical composition of the electrode is:
Lesson 2
Common Electric
Arc Welding
Processes
Carbon
0.11%
Chromium
Nickel
8.75%
Manganese
Silicon
0.4%
30.0%
1.75%
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
5.15.6
Arcaloy ER316L (ER316/316L) - used for welding types 316L and 318 steels to
avoid carbide precipitation. Chemical composition of the electrode is the same as the ER
316, except that the carbon content is 0.02%.
5.15.7
the wetting characteristics of the weld metal producing a smoother, better looking weld.
tent is 0.75%.
5.15.8
Arcaloy ER347 (AWS ER347) - is used to weld types 321 and 347 steel in appli-
cations that require good resistance to corrosion. It is also used to weld type 347 steel for
high strength at elevated temperatures. Typical chemical composition of the electrode is:
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
0.06%
Chromium
20.0%
Nickel
9.75%
Manganese
1.75%
Silicon
0.4%
Columbium
0.80%
CORED ELECTRODES
ate without an external shielding gas. The carefully formulated mixture of alloys and shielding
agents in the electrode core produces weld deposits of excellent appearance, mechanical
properties, and radiographic quality. The electrode has low weld penetration that is ideal for
overlay and buildup applications. Self shielding, high deposition rates, and reduced cleaning
Lesson 9
Estimating &
Comparing Weld
Metal Costs
time are all built into Core-Bright electrodes, resulting in maximum economy and optimum
efficiency in the welding operation.
5.16.0.1
A5.22-95 for flux cored corrosion resisting chromium and chromium nickel steel electrodes.
Lesson 10
Reliability of Welding
Filler Metals
Turn
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Core-Bright electrodes are flux cored, self-shielding, continuous electrodes designed to oper-
Lesson 8
Hardsurfacing
Electrodes
Glo
Chemical composition of the electrode is the same as ER 316 L, except that the silicon con-
Carbon
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
The specification classifies electrodes on the basis of composition, type of electrode, and type
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Lesson 1
The Basics of Arc
Welding
LESSON V
of gas shield, if any, such as EXXXTX-X. The E indicates that it is a current carrying elec-
Cu
Ch
Tab
Con
trode, and the XXX represents the AISI number of the composition, such as 308L, 3092, or
Lesson 2
Common Electric
Arc Welding
Processes
316L (the L signifying a low carbon type). The "T" indicates tubular or flux cored construction.
The number following this "T" indicates positional characteristics; "1" equals All Position, "0"
equals flat and horizontal only. The last digit indicates the intended shielding gas. The number
"1" equares to carbon dioxide (CO ) as a shielding gas, a number "3" indicates that no exter2
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
nal shielding gas is necessary, a number "4" is 75 - 80% Argon (Ar) and balance carbon
dioxide, and a number "5" indicates 100% Argon.
Carbon
0.10%
Chromium
Nickel
9.8%
Manganese
19.5%
3.8%
Silicon
0.6%
Molybdenum
1.0%
Turn
5.17.2
armor plate, has excellent toughness and crack resistance, and has been used to weld type
316 steel where carbide precipitation is not a problem. Chemical composition of the weld
metal is:
Lesson 8
Hardsurfacing
Electrodes
Carbon
0.11%
Chromium
Nickel
9.9%
Manganese
19.9%
1.54%
Silicon
0.6%
Molybdenum
2.1%
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Glo
armor plate. The weld metal has excellent toughness and crack resistance. Typical chemical
composition of the weld metal is:
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Go T
5.17.3
Core-Bright 308LTo (AWS E308LTo-3) - Welds AISI Steel types 301, 302, 304,
304L, 308, 321, and 347. It is used for welding chemical plant equipment. The typical chemical composition of the weld metal is:
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON V
Carbon
Nickel
Lesson 2
Common Electric
Arc Welding
Processes
Silicon
5.17.4
0.025%
10.1%
Chromium
Manganese
21.0%
Cu
Ch
Tab
Con
1.6%
0.75%
Core-Bright 309L (AWS E309LTo-3) - This was designed primarily for depositing
stainless steel overlay on carbon steel. Can also be used for welding dissimilar steels. Typi-
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
5.17.5
0.023%
Nickel
12.8%
Silicon
0.6%
Chromium
Manganese
24.0%
1.6%
Core-Bright 316L (AWS E316LTo-3) - is used to weld steel types 316, 316L and
Glo
318. The 2% molybdenum increases the resistance to pitting corrosion from sulfur and
chloride acids. Used in the rayon, dye and paper industries. Typical chemical composition of
the weld metal is:
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Carbon
5.17.6
0.025%
Nickel
12.5%
Silicon
0.6%
Chromium
19.7%
Manganese
1.3%
Molybdenum
2.2%
Core-Bright 347 (AWS E347LTo-3) - This electrode is used to weld types 347,
304L, and 321 stainless steels where the maximum corrosion resistance is required. It is also
used for high temperature high strength welds. The typical chemical composition of the weld
metal is:
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
Carbon
0.028%
Nickel
10.1%
Silicon
0.7%
Chromium
20.2%
Manganese
1.5%
Molybdenum
0.57%
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON V
longer arc length, caused by higher arc voltage, allows more nitrogen from the atmosphere to
Cu
Ch
Tab
Con
enter into the weld metal and the ferrite content decreases. Lower arc voltage produces a
Lesson 2
Common Electric
Arc Welding
Processes
shorter arc length, allowing less nitrogen to pass into the weld metal, resulting in an increase of
ferrite.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Shield-Bright & Shield-Bright X-tra, like the Core-Bright flux cored stainless wires, are continu-
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
ous feed electrodes. Their smooth, spray-like metal transfer make them ideally suited for a
Glo
variety of welding positions. The uniquely designed chemical permits the use of either 100%
CO or Argon-CO shielding. The deposited weld metal and superior mechanical properties
2
make them suitable for replacing manual covered electrodes. The economics in both deposi-
Lesson 5
Welding Filler Metals
for Stainless Steels
meet the requirements of AWS Filler Metal Specification A5.22-80 for flux cored corrosion
resisting chromium and chromium nickel steel electrodes. The specific classification for this
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
series of electrodes is EXXXT-1. The ending digit 1 indicates the preference to CO or Argon2
CO shielding gas.
2
5.19.0.2
including .035", .045", and 1/16". They are packaged in an assortment of standard packages, such as 10, 33, and 50 lb spools and coils.
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Shield-Bright 308L (AWS (E308LT1-1/T1-4) - For welding types 301, 302, 304(L),
308(L) grades of stainless. May also be used to weld types 321 and 347 if service temperatures do not exceed 500F (260C). Low carbon content minimizes carbide precipitation.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON V
Lesson 2
Common Electric
Arc Welding
Processes
75/25
CO
Carbon
0.032
0.034
Manganese
1.20
1.17
Chromium
19.50
19.20
Nickel
9.98
9.85
Ferrite No.
Cu
Ch
Tab
Con
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
5.20.2
wrought or cast forms, but used extensively for welding type 304 to mild or carbon steel. Also
used for welding 304 clad sheets and for applying stainless steel linings to carbon steel.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
75/25
CO
Carbon
0.034
0.034
Manganese
1.32
1.25
Chromium
22.63
22.39
Nickel
12.60
12.52
15
15
Ferrite No.
5.20.3
Glo
316 clad steels on the first pass in cladding steels or for welding dissimilar metals, such as
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
plants.
75/25
CO
Carbon
0.038
0.039
Manganese
1.14
.94
Chromium
23.10
22.84
Nickel
12.80
13.26
Molybdenum
2.65
2.58
17
17
Ferrite No.
5.20.4
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Contains molybdenum which increases creep resistance at high temperatures and resists
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
molybdenum-containing austenitic steels to carbon steels used in paper mills and in power
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
pitting corrosion induced by sulfuric and sulfurous acids, chlorides, and cellulose solutions.
Used widely in the rayon, dye, and paper-making industries.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON V
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
75/25
CO
Carbon
0.038
0.032
Manganese
1.32
1.25
Chromium
18.52
18.28
Nickel
12.29
12.30
Molybdenum
2.47
2.47
Ferrite No.
5.20.5
Cu
Ch
Tab
Con
Go T
stainless with a maximum of 0.04% carbon in the weld deposit. The higher molybdenum
content, as compared to type 316L, further reduces susceptibility to pitting corrosion. Used in
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
the pulp and paper industry and in other severe corrosion applications involving sulfuric and
sulfurous acids and their salts.
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Glo
75/25
CO
Carbon
0.035
0.032
Manganese
1.31
1.20
Chromium
18.70
18.40
Nickel
12.60
12.50
Molybdenum
3.40
3.40
Ferrite No.
5.20.6
Turn
304L and 321 stainless where service temperatures are below 600F. The addition of colum-
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Carbon
Manganese
Lesson 8
Hardsurfacing
Electrodes
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Chromium
75/25
CO
0.032
0.027
1.2
1.0
19.6
18.5
Nickel
9.6
9.7
Columbium
0.5
0.4
Ferrite No.
8.5
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Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON V
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
5.21.1
ENi-Cu-7) - Arcaloy 9N10 electrodes deposit a high nickel-copper alloy known by the tradename "Monel". The usability and arc stability on DC reverse polarity are excellent in all weld-
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Arcaloy 9N10 electrodes are used for the welding of Monel (Nickel 70 - Copper 30) to itself
and Monel to other alloys. The quality of the weld deposit makes the electrode ideal for Monel
Glo
As Welded
Lesson 5
Welding Filler Metals
for Stainless Steels
51,000
79,500
% Elongation (2")
33
Carbon
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Nickel
0.04%
65.0%
Silicon
Copper
5.21.2
0.7%
Titanium
0.7%
Manganese
3.3%
Aluminum
0.25%
Turn
Remainder
Lesson 8
Hardsurfacing
Electrodes
overlay applications.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Go T
ing positions. There is no spatter and the complete slag cover is easily removed.
electrodes are primarily intended for welding structures subjected to very low temperature.
The electrodes are also used for welding Inconel alloys to themselves and to many dissimilar
alloys. It is useful for welding cryogenic structures because of the toughness of the weld metal
at very low temperatures (-320F).
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON V
Cu
Ch
Tab
Con
As Welded
Lesson 2
Common Electric
Arc Welding
Processes
62,000
96,600
% Elongation (2")
44
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
5.21.3
Carbon
0.03%
Chromium
14.0%
Titanium
0.60%
Manganese
6.10%
Silicon
0.75%
Iron
7.0%
Columbium
1.40%
Nickel - Remainder
Glo
molybdenum alloy designed for welding 5% and 9% nickel steels for low temperature service.
Lesson 5
Welding Filler Metals
for Stainless Steels
The lime type covering on the 3/32", 1/8", and 5/32" sizes has excellent all-position welding
characteristics on direct current reverse polarity. The weld metal has good crack resistance.
The titania covering on the 3/16" size for AC/DC welding is outstanding in the horizontal and
flat welding positions. The heavy covering, containing many of the alloying elements, further
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
5.21.3.1
320F with the thermal coefficient of expansion and tensile strength comparable to the cryogenic alloys usually welded with it. Arcaloy Ni-9 deposits good radiographic quality welds.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
The good wetting action, smooth metal transfer, and low spatter level are all features of this
electrode.
5.21.3.2
Arcaloy Ni-9 electrodes are primarily used to weld the 5% and 9% nickel steels in
structures intended for cryogenic service, such as storage vessels and tanks for Liquified
Lesson 8
Hardsurfacing
Electrodes
Natural Gas (LNG) and Liquid Oxygen (LOX). They can also be used for welding Inconel and
Inconel cladding to mild steel.
A. Typical Mechanical Properties of the Weld Metal
Lesson 9
Estimating &
Comparing Weld
Metal Costs
As Welded
Yield Point, psi
60,000
96,500
% Elongation (2")
Lesson 10
Reliability of Welding
Filler Metals
Turn
38
50 ft-lbs
Se
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(Fa
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Se
Doc
(Sl
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Lesson 1
The Basics of Arc
Welding
LESSON V
Lesson 2
Common Electric
Arc Welding
Processes
Nickel
5.21.4
Chromium
Manganese
14.9%
2.8%
Silicon
0.5%
Iron
6.1%
Columbium
1.40%
Tungsten
1.4%
Chromium
Lesson 3
Covered Electrodes
for Welding
Mild Steels
0.04%
65.0%
Cu
Ch
Tab
Con
14.90%
Go T
Arcaloy Ni-12 is a nickel-chromium-iron alloy with a high conductivity nickel core wire that
permits the use of higher welding currents for increased deposition rates and superior fusion.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
The lime type covering on the 3/32", 1/8", and the 5/32" sizes gives improved crack resistance and excellent welding in all positions on DC reverse polarity. The titania type covering
Glo
on the 3/16" size is designed for horizontal and flat position welding with AC/DC. The heavy
covering, containing many of the alloying elements, further improves the arc direction and adds
to the deposition rate.
Lesson 5
Welding Filler Metals
for Stainless Steels
5.21.4.1
The weld metal of this cryogenic composition has excellent notch toughness @ -
320F. It also has thermal expansion and tensile strength comparable to the alloy metals
usually used in this service. The weld metal is water clear by X-ray.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
5.21.4.2
Turn
Arcaloy Ni-12 is used for joining the nickel-chromium-iron alloys and metal combina-
tions where thermal shock is a problem. Typical applications include coke ovens and nuclear
parts.
A. Typical Mechanical Properties of the Weld Metal
Se
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(Fa
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As Welded
Yield Point, psi
53,500
90,000
% Elongation (2")
41
% Reduction of Area
55
63 ft-lbs
Se
Doc
(Sl
Dow
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Carbon
Nickel
0.04%
70.35%
Silicon
0.4%
Columbium
1.77%
Chromium
15.2%
Manganese
6.1%
Iron
7.67%
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON V
Cu
Ch
Tab
Con
Cast iron is a high carbon alloy of iron, usually containing 3.5% carbon or more. There are
several categories of cast iron. The most common is called gray iron because much of the
carbon has separated from the iron and is scattered through the material in the form of small
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
flakes of free graphite. This graphite causes a broken surface to appear gray.
5.22.0.1
If gray iron is cooled rapidly from the molten condition, the carbon remains tied up
with the iron as a very hard iron carbide called cementite. The presence of the cementite
makes the iron mass very hard and brittle. A broken surface appears white; hence, the name
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
When the white iron is reheated to a high temperature, the iron carbide is taken in
solution. If the heated iron is cooled very slowly, the carbon stays in solution in the iron and the
result is "malleable iron".
Lesson 5
Welding Filler Metals
for Stainless Steels
5.22.0.3
When small amounts of certain elements, such as magnesium, are added to the
molten iron, the magnesium acts as nuclei for the carbon to form small spheres or nodules on
cooling. This is called "nodular iron".
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
5.22.0.4
Turn
Gray iron is not ductile; white iron is very hard and brittle; malleable iron is reason-
wire of 55% nickel and 45% iron. This combination has been developed especially to deposit
crack free welds in cast iron. The electrodes have good usability on both alternating current
and direct current. The high nickel weld metal has the ability to absorb the carbon that is
washed in from the cast iron and still remain tough and ductile. The weld metal is easily machined.
Lesson 8
Hardsurfacing
Electrodes
5.22.1.1
Sound, crack free repair and joining welds can be made in gray, malleable and
nodular iron with Nickel-Arc 55 electrodes. If the part to be welded is a used casting, the oil
and grease should be burned out before welding in order to avoid porosity.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
Color Match
90-100 Rb
Excellent
Good
Se
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(Fa
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Se
Doc
(Sl
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Lesson 1
The Basics of Arc
Welding
LESSON V
5.22.2
Cu
Ch
Tab
Con
made with 55% nickel and 45% iron core wire. The coating is specially designed to give
Lesson 2
Common Electric
Arc Welding
Processes
smooth, stable arcs on both direct and alternating current. Nickel-Arc 550 is also designed to
provide superior resistance to overheating, allowing maximum deposition efficiency during the
welding operation.
A. Typical Properties of Nickel-Arc Weld Metal:
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
5.22.3
58,500
90-100 Rb
Machinability
Excellent
Color Match
Good
Go T
Glo
with pure nickel core wire. The high nickel content of the deposited weld metal absorbs the
carbon from the cast iron and remains tough and ductile. The electrode has good welding
characteristics with smooth stable arc on both direct current and alternating current.
Lesson 5
Welding Filler Metals
for Stainless Steels
Nickel-Arc 90 produces sound crack-free welds in gray, malleable and nodular iron. It is
particularly valuable for welding or overlay of cast iron when high nickel deposits are required
or when ease of machining the weld area is important. Preheat, interpass temperature, and
cooling rate after welding depends on the type and design of the object to be welded. When
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
welding cavities in cast iron, wide weaving and heavy weld beads should be used. Welding
10-20uphill helps deposit thicker weld beads that better resist cracking.
A. Typical Properties of Nickel-Arc Weld Metal:
Tensile Strength (psi)69,900
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Se
Ch
(Fa
Dow
90-100 Rb
Excellent
Good
"wire within a wire" flux cored electrode with approximately 50.5% iron and 48% nickel, providing an excellent match for the coefficient of expansion exhibited by cast irons. The wire produces a light slag that is easily removed enhancing visual weld inspection.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
5.22.4.1
Because of the continuous nature of this wire, operating factor, arc time, and depo-
sition efficiency are all improved over the conventional manual stick electrodes. This electrode
is ideally suited for the repair and joining of various types of cast irons. The machinability
characteristics are similar to that of the 55-grade covered electrodes. DC (electrode positive)
is the recommended current.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON V
5.22.4.2
The shielding gas should be 98% argon-2% oxygen. Welding heavier sections or
Cu
Ch
Tab
Con
the application of cast iron to carbon steel requires the use of 400-600F preheat.
Lesson 2
Common Electric
Arc Welding
Processes
5.22.4.3
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Nicore 55 is available in a variety of sizes from .035" - 3/32" diameters and many
Cupro Nickel Electrodes (AWS A5.6, Class ECuNi) - This 70% copper, 30%
nickel electrode is designed to provide outstanding weld metal in welding 70-30 and 90-10
copper-nickel alloys with direct current reverse polarity. The electrode can be used in all
welding positions. Slag removal is easy and complete from the smooth weld beads. Weld
Go T
deposits are sound by X-ray and have excellent strength and ductility.
5.22.5.1
The primary uses for copper-nickel alloys are in the fabrication of ship condensers,
Glo
distiller tubes, heat exchangers, and other items exposed to sea water corrosion.
A. Typical Mechanical Properties of Weld Metal:
As Welded
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
35,500
Turn
40
0.3%
Manganese
1.3%
Silicon
0.7%
Iron
0.55%
Copper
68.0%
Nickel
30.0%
Se
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(Fa
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Se
Doc
(Sl
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Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON V
APPENDIX A
Lesson 2
Common Electric
Arc Welding
Processes
Cu
Ch
Tab
Con
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Austenite
Martensite
The hard phase that develops on rapid cooling of carbon and low
alloy steels.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
Ferrite
Transition Temperature
Lesson 5
Welding Filler Metals
for Stainless Steels
Carbide Precipitation
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Ferrite in Austenitic
Stainless Steel
Turn
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Ferrite Number
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Metallurgically
Similar Steels
Preheat
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
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Lesson 1
The Basics of Arc
Welding
LESSON V
Interpass Temperature
Cu
Ch
Tab
Con
during welding .
Lesson 2
Common Electric
Arc Welding
Processes
Temper of continuous
welding electrodes
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cast of continuous
Helix of continuous
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
welding electrodes
welding electrodes
Cryogenic Temperatures
Glo
Lesson 5
Welding Filler Metals
for Stainless Steels
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Se
Ch
(Fa
Dow
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Se
Doc
(Sl
Dow
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Cu
Ch
Tab
Con
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
BASIC
WELDING FILLER METAL
TECHNOLOGY
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Glo
A Correspondence Course
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Go T
LESSON IX
ESTIMATING
AND COMPARING
WELD METAL COSTS
Turn
Se
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(Fa
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Se
Doc
(Sl
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ESAB
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
Cu
Ch
Tab
Con
TABLE OF CONTENTS
LESSON IX
ESTIMATING AND COMPARING WELD
METAL COSTS
Lesson 2
Common Electric
Arc Welding
Processes
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Section Nr.
Section Title
Page
9.1
Introduction ..................................................................................................
9.2
9.2.1
9.2.2
9.2.3
9.2.4
9.2.5
9.2.6
9.2.7
9.2.8
9.2.9
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
9.2.10
9.3
9.4
12
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
9.4.1
12
9.4.2
14
9.5
15
9.6
17
9.6.1
Example 3 .......................................................................................................
19
9.7
20
9.8
21
22
26
27
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
Glo
Turn
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
LESSON IX
Cu
Ch
Tab
Con
9.1 INTRODUCTION
Estimating the costs of depositing weld metal can be a difficult task because of the many
Go T
variables involved. Design engineers must specify the type and size of weld joint to withstand
the loads that the weldment must bear. The welding engineer must select the welding process,
and type of filler metal that will provide the required welds at the least possible cost. With
wages and the cost of operations rising, selection of the process that deposits weld metal
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
most expediently must be carefully considered. Labor and overhead account for approxi-
Glo
Welding costs may be divided into two categories; the fixed costs involved regard-
less of the filler metal or welding process selected, and those related to a specific welding
Lesson 5
Welding Filler Metals
for Stainless Steels
process. Fixed costs entail material handling, joint preparation, fixturing, tacking, preheating,
weld clean-up and inspection. Although some of these items will be affected by the process
and filler metal chosen, they are a necessary part of practically all welding operations. Calculating these costs is best left to the manufacturer since they will depend upon his capabilities
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
and equipment. The cost of actually depositing the weld metal however, will vary considerably
with the filler metal and welding process selected. This cost element is influenced by the
users labor and overhead rates, deposition rate and efficiency of the filler metal, operating
factor, and cost of materials and power.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
9.1.0.2
This lesson will cover cost estimating for steel weldments produced by the four most
common arc welding processes in use today: shielded metal-arc welding, gas metal-arc
welding, flux cored arc welding and submerged arc welding. Gas tungsten arc welding will not
be considered here because the variables, such as deposition rate and efficiency, are depen-
Lesson 8
Hardsurfacing
Electrodes
dent on operator technique, stub use, etc. The GTAW process is a relatively costly method of
depositing weld metal, and is usually chosen for weld quality or material thickness and composition limitations, rather than economy.
9.1.0.3
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Large firms will frequently conduct their own deposition tests and time studies to
determine welding costs, but many smaller shops do not know the actual cost of depositing
weld metal.
9.1.0.4
In estimating welding costs, all attempts should be made to work with accurate data,
which in some cases is difficult to secure. For this reason, this lesson contains charts, graphs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
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(Fa
Dow
Se
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Lesson 1
The Basics of Arc
Welding
LESSON IX
and tables that provide average values that you may use. Electrode manufacturers will usually
Cu
Ch
Tab
Con
supply the deposition data you need through their Technical Services Department, if it is not
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
Labor and Overhead - Labor and overhead may be considered jointly in your
calculations. Labor is the welders hourly rate of pay including wages and benefits. Overhead
includes allocated portions of plant operating and maintenance costs. Weld shops in manu-
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
facturing plants normally have established labor and overhead rates for each department.
shows how labor and overhead may vary and suggests an average value to use in your calculations when the actual value is unknown.
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
$10.00 to $25.00/hr.
$25.00 to $50.00/hr
$30.00/hr.
Turn
9.2.2
Deposition Rate - The deposition rate is the rate that weld metal can be deposited
by a given electrode or welding wire, expressed in pounds per hour. It is based on continuous
operation, not allowing time for stops and starts caused by inserting a new electrode, cleaning
slag, termination of the weld or other reasons. The deposition rate will increase as the welding
current is increased.
Lesson 8
Hardsurfacing
Electrodes
9.2.2.1
When using solid or flux cored wires, deposition rate will increase as the electrical
stick-out is increased, and the same amperage is maintained. True deposition rates for each
welding filler metal, whether it is a coated electrode or a solid or flux cored wire, can only be
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Glo
Labor and overhead rates can vary greatly from plant to plant, and also with location. Figure 1
established by an actual test in which the weldment is weighed before welding and then again
after welding, at the end of a measured period of time. The tables in Figures 8-11 contain
average values for the deposition rate of various types of welding filler metals. These are
based on welding laboratory tests and published data.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
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(Fa
Dow
Se
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(Sl
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Lesson 1
The Basics of Arc
Welding
LESSON IX
9.2.3
Cu
Ch
Tab
Con
that is actually spent welding. It is the arc time in hours divided by the total hours worked. A
Lesson 2
Common Electric
Arc Welding
Processes
45% (.45) operating factor means that only 45% of the welders day is actually spent welding.
The balance of time is spent installing a new electrode or wire, cleaning slag, positioning the
weldment, cleaning spatter from the welding gun, etc.
9.2.3.1
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
operating factor is not known, an average of 30% may be used for cost estimates when weld-
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
9.2.3.2
When welding with solid wires (GMAW) or metal cored welding (MCAW) using the
semi-automatic method, operating factors ranging from 45%-55% are easily attainable. Use
Glo
operating factor usually lies between 40%-50%. For cost estimating purposes, use a 45%
operating factor. The estimated operating factor for FCAW is about 5% lower than that of
GMAW to allow for slag removal time.
In semi-automatic submerged arc welding, slag removal and loose flux handling
Turn
Automatic welding using the GMAW, FCAW, and SAW processes, requires that
each application be studied individually. Operating factors ranging from 50% to values approaching 100% may be obtained depending on the degree of automation.
9.2.3.6
The chart in Figure 2 shows average operating factor values for the various welding
processes that may be used for cost estimating when the actual operating factor is not known.
Se
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Doc
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Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
9.2.3.4
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Go T
15%-40% depending upon material handling, fixturing and operator dexterity. If the actual
9.2.3.3
Lesson 5
Welding Filler Metals
for Stainless Steels
When using coated electrodes, (SMAW) the operating factor can range from
WELDING PROCESS
SMAW
+ * GMAW
30%
50%
*FCAW
45%
*SAW
40%
*Semi-Automatic Only
+ Metal Cored Wires are Included
APPROXIMATE OPERATING FACTOR
FIGURE 2
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON IX
9.2.4
Cu
Ch
Tab
Con
the weld metal deposited to the weight of the electrode (or wire) consumed in making a weld.
Lesson 2
Common Electric
Arc Welding
Processes
It can be accurately determined only by making a timed test weld, and carefully weighing the
weldment and the electrode or wire, before and after welding. The efficiency can then be
calculated by the formula:
Deposition efficiency
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Go T
(or)
Deposition Rate (lbs/hr)
9.2.4.1
The deposition efficiency tells us how many pounds of weld metal can be expected
from a given weight of the electrode or welding wire purchased. As an example, 100 pounds
Glo
of a flux cored electrode with an efficiency of 85%, will produce approximately 85 pounds of
weld metal, while 100 pounds of coated electrode with an efficiency of 65%, will produce
approximately 65 pounds of weld metal, less the weight of the stubs discarded, as described
Lesson 5
Welding Filler Metals
for Stainless Steels
below.
9.2.5
definition, and in published data, does not consider the loss of the unused electrode stub that
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
application. Long continuous welds are usually conducive to short stubs while on short intermittent welds, stub length tends to be longer. Figure 3 illustrates how the stub loss influences
the electrode efficiency when using coated electrodes.
9.2.5.1
sidered. It is 75% efficient, and a two inch stub loss is assumed. The 75% efficiency applies
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2"
STUB
LENGTH
LOST TO
SLAG,SPATTER
& FUMES
9"
14"
Lesson 10
Reliability of Welding
Filler Metals
Turn
is discarded. This is understandable since the stub length can vary with the operator and the
FIGURE 3
COPYRIGHT 2000 THE ESAB GROUP, INC.
-4-
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Lesson 1
The Basics of Arc
Welding
LESSON IX
only to the 12 of the electrode consumed in making the weld, and not to the two inch stub.
Cu
Ch
Tab
Con
When the two inch stub loss and the 25% that is lost to slag, spatter and fumes are consid-
Lesson 2
Common Electric
Arc Welding
Processes
ered, the efficiency minus stub loss is lowered to 64.3%. This means that for each 100 pounds
of electrodes purchased, you can expect an actual deposit of approximately 64.3 pounds of
weld metal if all electrodes are used to a two inch stub length.
9.2.5.2
Lesson 3
Covered Electrodes
for Welding
Mild Steels
The formula for the efficiency including stub loss is important, and must always be
Go T
used when estimating the cost of depositing weld metal by the SMAW method. Figure 4
shows the formula used to establish the efficiency of coated electrodes including stub loss. It
is based on the electrode length, and is slightly inaccurate, i.e. it does not take into consideration that the electrode weight is not evenly distributed, due to the flux being removed from the
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
electrode holder end. (Indicated by the dotted lines in Figure 3.) Use of the formula will result
Glo
in a 1.5-2.3% error that will vary with electrode size, coating thickness and stub length. The
formula however, is acceptable for estimating purposes.
9.2.5.3
Lesson 5
Welding Filler Metals
for Stainless Steels
EFFICIENCY
=
MINUS STUB LOSS
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
FIGURE 4
(14-2) x .75
14
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Se
Ch
(Fa
Dow
12 x .75
14
9
14
Lesson 8
Hardsurfacing
Electrodes
.6429 or 64.3%
In the above example, the electrode length is known, the stub loss must be estimated, and the
efficiency taken from the tables in Figures 8 and 9. Use an average stub loss of three inches
for coated electrodes if the actual shop practices concerning stub loss are not known.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
9.2.5.4
The following stub loss correction table will assist in your determination of coated
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON IX
Lesson 2
Common Electric
Arc Welding
Processes
ELEC.
DEPOSITION
2"
3"
4"
5"
LENGTH
EFFICIENCY
STUB
STUB
STUB
STUB
60%
50.0%
45.0%
40.0%
35.0%
65%
54.2%
48.7%
43.3%
37.9%
70%
58.3%
52.5%
46.6%
40.8%
75%
62.5%
56.2%
50.0%
43.7%
80%
66.6%
60.0%
53.3%
46.6%
60%
51.4%
47.1%
42.8%
38.5%
65%
55.7%
51.1%
46.4%
41.8%
12"
Lesson 3
Covered Electrodes
for Welding
Mild Steels
14"
EFFICIENCY INCLUDING
STUB LOSS
FIGURE 5
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
18"
9.2.6
Lesson 5
Welding Filler Metals
for Stainless Steels
70%
60.0%
55.0%
50.0%
45.0%
75%
64.3%
58.9%
53.6%
48.2%
80%
68.5%
62.8%
57.1%
51.4%
60%
53.3%
50.0%
46.6%
43.3%
65%
57.7%
54.2%
50.5%
46.9%
70%
62.2%
58.3%
54.4%
50.5%
75%
66.6%
62.5%
58.3%
54.2%
80%
71.1%
66.6%
62.2%
57.7%
Cu
Ch
Tab
Con
Go T
Glo
Efficiency of Flux Cored Wires - Flux cored wires have a lower flux-to-metal ratio
than coated electrodes, and thereby, a higher deposition efficiency. Stub loss need not be
considered since the wire is continuous. The gas shielded wires of the E70T-1 and E70T-2
types have efficiencies of 83%-88%. The gas shielded basic slag type (E70T-5) is 85%-90%
efficient with CO2 as the shielding gas, and the efficiency can reach 92% when a 75% argon,
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
25% CO2 gas mixture is used. Use the efficiency figures in Figure 9 for your calculations if the
actual values are not known.
9.2.6.1
The efficiency of the self-shielded types of flux cored wires has more variation
because of the large variety of available types that have been designed for specific applications. The high deposition general purpose type, such as E70T-4, is 81%-86%, depending on
wire size and electrical stick-out. The chart in Figure 9 shows the optimum conditions for each
wire size and may be used in your calculations.
9.2.7
Lesson 8
Hardsurfacing
Electrodes
Efficiency of Solid Wires for GMAW - The efficiency of solid wires in GMAW is
very high and will vary with the shielding gas or gas mixture used. Using CO2 will produce the
most spatter and the average efficiency will be about 93%. Using a 75% argon-25% CO2 gas
mixture will result in somewhat less spatter, and an efficiency of approximately 96% can be
expected. A 98% argon-2% oxygen mixture will produce even less spatter, and the average
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Turn
efficiency will be about 98%. Stub loss need not be considered since the wire is continuous.
Figure 6 shows the average efficiencies you may use in your calculations if the actual efficiency is not known.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
.045" - 1/16"
Lesson 1
GMAW
The Basics of Arc
Welding
LESSON IX
9.2.8
Efficiency of Solid Wires for SAW - In submerged arc welding there is no spatter
Cu
Ch
Tab
Con
loss and an efficiency of 99% may be assumed. The only loss during welding is the short
Lesson 2
Common Electric
Arc Welding
Processes
piece the operator must clip off the end of the wire to remove the fused flux that forms at the
termination of each weld. This is done to assure a good start on the succeeding weld.
Go T
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Shielding
Gas
Efficiency
Range
Average
Efficiency
Pure CO2
88 - 95%
93%
94 - 98%
96%
97 - 98.5%
98%
98% Ar - 2% O2
Glo
9.2.9
Cost of Electrodes, Wires, Gases and Flux - You must secure the current cost
per pound of the electrode or welding wire, plus the cost of the shielding gas or flux if applicable, from the supplier. The shielding gas flow rate varies slightly with the type of gas used.
The flow rates in Figure 7 are average values whether the shielding gas is an argon mixture or
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Turn
pure CO2. Use these in your calculations if the actual flow rate is not available.
In the submerged arc process (SAW) the ratio of flux to wire consumed in the weld is approximately 1 to 1 by weight. When the losses due to flux handling and flux recovery systems are
considered, the average ratio of flux to wire is approximately 1.4 pounds of flux for each pound
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
of wire consumed. If the actual flux-to-wire ratio is unknown, use the 1.4 for cost estimating.
FCAW/MCAW
Wire Diameter
Lesson 8
Hardsurfacing
Electrodes
CFH
.035"
30
35
.045"
1/16"
5/64" - 1/8"
35
40
45
Lesson 9
Estimating &
Comparing Weld
Metal Costs
9.2.10
Cost of Power - Cost of electrical power is a very small part of the cost of deposit-
ing weld metal and in most cases is less than 1% of the total. It will be necessary for you to
know the power cost expressed in dollars per kilowatt- hour ($/kWh) if required for a total cost
estimate.
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
LESSON IX
9.3
9.3.1
E6010
DEPOSITION
EFFICIENCY
ELECTRODE
AMPS
RATE lbs/hr
DIAMETER
AMPS
RATE lbs/hr
3/32
1/8
75
100
130
140
170
160
190
190
230
1.5
2.1
2.3
2.8
2.9
3.3
3.5
4.5
5.1
72.0%
76.3%
68.8%
73.6%
64.1%
74.9%
69.7%
76.9%
73.1%
3/32
1/8
5/32
85
125
140
160
180
180
200
220
250
270
290
1.6
2.1
2.6
3
3.5
3.2
3.8
4.1
5.3
5.7
6.1
73.0%
73.0%
75.6%
74.1%
71.2%
73.9%
71.1%
72.9%
71.3%
73.0%
72.7%
5/32
3/16
7/32
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
DEPOSITION
7/32
EFFICIENCY
Glo
EFFICIENCY
DIAMETER
AMPS
RATE lbs/hr
3/32
1/8
5/32
3/16
7/32
1/4
75
120
150
180
210
250
1.3
2.3
3.7
4.1
5
5.6
61.0%
70.7%
77.0%
73.4%
74.2%
71.9%
ELECTRODE
RATE lbs/hr
1/8
120
150
160
200
230
270
290
330
350
400
2.4
3.1
3
3.7
4.5
5.5
5.8
7.1
7.1
8.7
63.9%
61.1%
71.9%
67.0%
70.9%
73.2%
67.2%
70.3%
68.7%
69.9%
EFFICIENCY
DIAMETER
AMPS
RATE lbs/hr
1/8
5/32
130
165
200
220
250
320
2.9
3.2
3.4
4
4.2
5.6
81.8%
78.8%
69.0%
77.0%
74.5%
69.8%
3/16
EFFICIENCY
AMPS
7/32
DEPOSITION
DEPOSITION
DIAMETER
5/32
E6012
ELECTRODE
Turn
E7014
3/16
7/32
Lesson 9
Estimating &
Comparing Weld
Metal Costs
3/16
DEPOSITION
E6011
ELECTRODE
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Go T
6013
DIAMETER
ELECTRODE
Cu
Ch
Tab
Con
1/4
FIGURE 8
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON IX
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
Go T
E7016
Lesson 3
Covered Electrodes
for Welding
Mild Steels
ELECTRODE
DIAMETER
AMPS
1/8
100
130
140
160
190
175
200
225
250
250
275
300
350
5/32
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
DEPOSITION EFFICIENCY
3/16
1/4
RATE lbs/hr
1.7
2.3
3.0
3.2
3.6
3.8
4.2
4.4
4.8
5.9
6.4
6.8
7.6
63.9%
65.8%
70.5%
69.1%
66.0%
71.0%
71.0%
70.0%
65.8%
74.5%
74.1%
73.2%
71.5%
3/32
1/8
5/32
3/16
E7024
ELECTRODE
DEPOSITION EFFICIENCY
DIAMETER
AMPS
1/8
140
180
180
210
240
245
270
290
320
360
400
5/32
3/16
7/32
1/4
RATE lbs/hr
4.2
5.1
5.3
6.3
7.2
7.5
8.3
9.1
9.4
11.6
12.6
7/32
71.8%
70.7%
71.3%
72.5%
69.4%
69.2%
70.5%
68.0%
72.4%
69.1%
71.7%
1/4
DEPOSITION EFFICIENCY
AMPS
70
90
110
120
140
160
140
170
200
200
250
300
250
300
350
300
350
400
RATE lbs/hr
1.37
1.65
1.73
2.58
2.74
2.99
3.11
3.78
4.31
4.85
5.36
5.61
6.50
7.20
7.40
7.72
8.67
9.04
Glo
70.5%
66.3%
64.4%
71.6%
70.9%
68.1%
75.0%
73.5%
73.0%
76.4%
74.6%
70.3%
75.0%
74.0%
73.0%
78.0%
77.0%
74.0%
Turn
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
0.045
Lesson 1
The Basics of Arc
Welding
LESSON IX
9.3.2
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
data for gas shielded FCAW on all low alloy wire types and MCAW on all alloy types.
.035
.045
Lesson 5
Welding Filler Metals
for Stainless Steels
.052
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 8
Hardsurfacing
Electrodes
1/16
5/64
3/32
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Go T
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Cu
Ch
Tab
Con
AMPS
130
140
160
180
200
220
160
180
200
220
240
280
170
190
210
240
270
300
180
200
220
250
275
300
350
250
350
450
400
450
500
DEPOSITION EFFICIENCY
RATE lbs/hr
%
3.2
3.6
4.2
5.6
6.5
7.5
4.0
4.9
6.5
6.8
7.3
10.5
3.9
5.3
5.5
6.7
8.1
10.3
4.2
4.7
5.6
7.7
8.5
9.3
11.7
6.4
10.5
14.8
12.7
15.0
18.5
82%
82%
83%
83%
84%
85%
83%
87%
90%
84%
84%
89%
84%
87%
86%
85%
85%
87%
87%
85%
87%
86%
86%
86%
86%
85%
85%
85%
85%
86%
86%
DEPOSITION
EFFICIENCY
DIAMETER
AMPS
RATE lbs/hr
0.035
150
200
250
250
275
300
275
300
325
300
350
400
450
350
400
450
500
400
450
500
550
4.4
6.5
9.4
8
11.4
11.6
8
9.6
10.1
8.6
11.9
14.6
16.2
11.6
13.2
15.8
20.4
11.5
14.5
16.5
21
93%
92%
92%
91%
93%
95%
90%
93%
93%
89%
94%
93%
96%
94%
95%
97%
97%
95%
97%
97%
98%
0.052
1/16
5/64
3/32
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Glo
Turn
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON IX
9.3.3
Lesson 2
Common Electric
Arc Welding
Processes
GAS METAL ARC WELDING, AND SUBMERGED ARC WELDING - Deposition data
for self-shielded FCAW, and solid wires using
GMAW and SubArc.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
FLUX CORED ARC WELDING (FCAW)
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
SELF-SHIELDED
ELECTRODE
DIAMETER
E70T-3 3/32
E70T-4 3/32
Lesson 5
Welding Filler Metals
for Stainless Steels
0.12
E70T-6 5/64
3/32
E70T-6 3/32
7/64
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
E71T-7 .068
5/64
E71T-8 5/64
3/32
E61T8-K6 5/64
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
E70T-10 .045
1/16
5/64
E71T-11 .045
1/16
5/64
3/32
E70T4-K2 3/32
E71T-GS .030
.035
.045
Lesson 9
Estimating &
Comparing Weld
Metal Costs
1/16
5/64
AMPS
450
400
450
350
480
325
450
200
300
220
300
235
150
220
250
150
200
240
250
300
100
120
150
200
250
DEPOSITION EFFICIENCY
RATE lbs/hr
%
14
15
20
11.9
14.7
11.4
18
4.2
8
4.4
6.7
4.3
2.6
3.3
4
2.4
3.6
4.5
5
14
1.6
2.1
2.4
3.6
3.9
DEPOSITION DATA
Lesson 10
Reliability of Welding
Filler Metals
FIGURE 11
88%
85%
81%
86%
81%
80%
86%
76%
84%
77%
77%
76%
88%
78%
94%
82%
83%
87%
91%
83%
75%
84%
82%
83%
81%
Cu
Ch
Tab
Con
98%A/2%O2
75%A/25%CO2
Straight CO2
*98%
*96%
*93%
2.0
1.9
1.8
2.6
2.6
2.5
4.1
4.0
3.9
6.8
6.7
6.5
2.2
2.1
2.0
2.7
2.7
2.6
4.2
4.1
4.0
6.2
6.0
5.9
9.0
8.8
8.6
2.1
2.0
1.9
2.8
2.8
2.7
3.6
3.5
3.4
5.6
5.5
5.3
7.8
7.6
7.4
10.2
10.0
9.7
13.2
12.9
12.5
6.5
6.4
6.2
7.7
7.6
7.3
9.0
8.8
8.5
11.3
11.0
10.7
14.0
13.7
13.3
17.4
17.1
16.5
Go T
Glo
Turn
ELECTRODE
MELT-OFF
EFFICIENCY
RATE lbs/hr
DIAMETER
AMPS
5/64
300
7.0
3/32
400
500
400
10.2
15.0
9.4
500
600
400
500
13.0
17.2
8.5
11.5
600
700
500
15.0
19.0
11.3
600
700
14.6
18.4
800
22.0
900
600
26.1
13.9
700
800
900
1000
17.5
21.0
25.0
29.2
1100
34.0
1/8
5/32
3/16
Assume
99%
Efficiency
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON IX
9.4.1.1
Example 1 - Calculate the cost of welding 1,280 ft. of a single bevel butt joint as
Cu
Ch
Tab
Con
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Go T
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
9.4.1.2
The formulas for the calculations are shown on the Weld Metal Cost Worksheet in
Figure 12. The following explains each step in the calculations.
Line 1- Labor and Overhead - $30.00/hr (given)
Lesson 5
Welding Filler Metals
for Stainless Steels
Deposition Rate - From shielded metal arc welding deposition data chart in
Figure 9 = 5.36 lbs/hr.
Operating Factor - Since it is not stated above, use an average value of 30% (.30)
Turn
shown in Figure 2.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
The cost of labor and overhead per pound of deposited weld metal can now be
calculated as $18.66/lb.
Line 2 - Electrode Cost Per Pound - $.57 (given)
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Deposition Efficiency - From the shielded metal arc welding deposition table in
Figure 9 = 74.6%. Since this is a coated electrode, the efficiency must be adjusted
for stub loss by the formula following Figure 3. We know that the electrode length is
14" and the stub loss is 2" (given). The formula becomes:
Efficiency - Stub Loss = (14-2) x .746
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Se
Ch
(Fa
Dow
14 = .639 or 63.9%
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
LESSON IX
EXAMPLE 1
WELD METAL COST WORKSHEET
COST PER POUND OF DEPOSITED WELD METAL
Lesson 2
Common Electric
Arc Welding
Processes
1.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
LABOR &
OVERHEAD
2.
ELECTRODE
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
ELECTRODE COST/LB
DEPOSITION EFFICIENCY
30.00
30.00
5.36 x .30
= 18.66
Go T
1.608
P
.57
.89
.639
Glo
3.
GAS
N A
Lesson 5
Welding Filler Metals
for Stainless Steels
Cu
Ch
Tab
Con
5.
FLUX
FLUX COST/LB x
1.4
DEPOSITION EFFICIENCY
POWER
COST/kWh x
VOLTS x
AMPS
1000 x DEPOSITION RATE
1.4
.045 x 25 x 250
1000 x 5.36
281.25
5,360
N A
.052
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
6.
$ 19.60
POUNDS PER
FOOT OF
WELD JOINT
19.60x .814
= $15.95
8.
COST PER
FOOT
1,280x
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
TOTAL FEET X
OF WELD
Lesson 9
Estimating &
Comparing Weld
Metal Costs
15.95
= $20,422
FIGURE 12
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON IX
Line 5 - Cost of Power - $ .045/kWh (given).
Cu
Ch
Tab
Con
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Line 6 - Total Lines 1, 2, and 5 to find the total cost of depositing one pound weld
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
9.4.2
Glo
Calculating the weight of weld metal requires that we consider the following items.
9.4.2.1
a.
b.
c.
d.
Turn
In the fillet weld show in Figure 13, we know that the area of the cross-section (the
triangle) is equal to one-half the base times the height, the volume of the weld is equal to the
area times the length, and the weight of the weld then, is the volume times the weight of the
material (steel) per cubic inch.
9.4.2.2
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Weights may vary depending on the density of the particular material you are at-
tempting to calculate. The chart in Figure 14 will eliminate the need for these calculations for
Lesson 9
Estimating &
Comparing Weld
Metal Costs
steel fillet and butt joints, since it lists the weight per foot directly.
9.4.2.4
Estimating the weight per foot of a weld using the chart, requires that you make a
drawing of the weld joint to exact scale, and dimension the leg lengths, root gap, thickness,
angles and other pertinent measurements as shown in Figure 15. Divide the cross-section of
Lesson 10
Reliability of Welding
Filler Metals
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Go T
calculated as $.052.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
the weld into right triangles and rectangles as shown. Sketch in the reinforcement, i.e., the
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Lesson 1
The Basics of Arc
Welding
LESSON IX
Lesson 2
Common Electric
Arc Welding
Processes
(A)
HEIGHT
1/2"
Volume of Weld = 1/2 B x A x 12
Weight of Steel = .283 lb per cu. in.
Weight of Weld = 1/2 (1/2) x 1/2 x 12 x .283
= .424 lbs.
1/2"
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cu
Ch
Tab
Con
(B) BASE
Go T
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Glo
domed portion above or below the surface of the plate, where required. The reinforcement
Lesson 5
Welding Filler Metals
for Stainless Steels
should extend slightly beyond the edges of the joint. Measure the length and height of the
reinforcement and note them on your drawing. The reinforcement is only an approximation
because the contour cannot be exactly controlled in welding. Refer to the weight tables in
Figure 14 for the weights per foot of each of the component parts of the weld, as sketched.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
The sum of the weights of all the components is the total weight of the weld, per foot as shown
in Figure 15A.
Line 7 - The total cost per pound as determined in Line 6 is entered, and multiplied by the weight per foot as determined in Figure 14.
9.4.3
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
welding process in the double V-groove joint shown in Figure 14 using the following data.
1.
2.
3.
4.
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Se
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Lesson 8
Hardsurfacing
Electrodes
Turn
V-GROOVE
Lesson 1
The Basics of Arc
Welding
LESSON IX
WEIGHT PER FOOT OF WELD METAL FOR FILLET WELDS AND
ELEMENTS OF COMMON BUTT JOINTS (lbs/ft)
STEEL
Lesson 2
Common Electric
Arc Welding
Processes
S
G
C
Lesson 3
Covered Electrodes
for Welding
Mild Steels
S
B
P
C
SINGLE
V-GROOVE
C
DOUBLE
BEVEL
SINGLE V
NO GAP
1/4"
3/8"
1/8
3/16
1/4
.027
.040
.053
.053
.080
.106
.080
.119
.159
.106
.159
.212
.159
.239
.318
5/16
3/8
7/16
9/16
5/8
11/16
3/4
.066
.080
.091
.106
.119
.133
.146
.159
.133
.159
.186
.212
.239
.265
.292
.318
.199
.239
.279
.318
.358
.398
.438
.478
.265
.318
.371
.425
.478
.531
.584
.637
13/16
7/8
15/16
1
.172
.186
.199
.212
.345
.371
.398
.425
.517
.557
.597
.637
1 1/4
1 3/8
1 1/2
.239
.265
.292
.318
.478
.531
.584
.637
.345
.371
.390
.425
.478
.530
.584
.636
1/2"
10
15
.212
.318
.425
.002
.005
.009
.005
.011
.019
.007
.016
.028
.390
.478
.557
.637
.716
.796
.876
.995
.531
.637
.743
.849
.955
1.061
1.167
1.274
.015
.021
.028
.037
.047
.058
.070
.084
.029
.042
.057
.075
.095
.117
.142
.169
.690
.743
.796
.849
1.035
1.114
1.194
1.274
1.380
1.486
1.592
1.698
.098
.114
.131
.149
.716
.796
.876
.955
.955
1.061
1.167
1.274
1.433
1.592
1.751
1.910
1.910
2.123
2.335
2.547
.690
.743
.796
.649
1.035
1.114
1.194
1.274
1.380
1.486
1.592
1.698
2.069
2.229
2.388
2.547
.955
1.061
1.167
1.274
1.433
1.592
1.751
1.910
1.910
2.123
2.335
2.547
2.865
3.184
3.502
3.821
Turn
lbs./ft. Reinforcement C
1/16"
2 3/4
3
3/16"
REINFORCEMENT
lbs./ft. of Triangle B
Inches
2 1/4
T
T
lbs./ft. of Rectangle A
1 5/8
1 3/4
C
A
1/8"
C
B
DOUBLE
Lesson 10
Reliability of Welding
Filler Metals
Go T
B
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 9
Estimating &
Comparing Weld
Metal Costs
SINGLE
BEVEL
Lesson 8
Hardsurfacing
Electrodes
Glo
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
EQUAL LEG
FILLETS
(USE 45COLUMN)
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Cu
Ch
Tab
Con
H
22 1/2
30
45
1/16"
1/8"
3/16"
1/4"
.011
.025
.044
.015
.035
.061
.027
.060
.106
.027
.035
.044
.064
.087
.114
.144
.178
.215
.256
.069
.099
.129
.176
.223
.275
.332
.396
.096
.138
.188
.245
.311
.383
.464
.552
.166
.239
.325
.425
.451
.664
.804
.956
.044
.053
.062
.071
.080
.088
.097
.106
.884
.106
.124
.141
.159
.177
.195
.212
.212
.239
.265
.292
.318
.354
.389
.424
.198
.230
.263
.300
.301
.349
.400
.456
.464
.538
.618
.703
.648
.751
.863
.981
1.121
1.300
1.493
1.698
.115
.124
.133
.141
.230
.248
.266
.283
.345
.371
.398
.424
.460
.495
.530
.566
.188
.232
.281
.334
.379
.468
.567
.674
.577
.712
.861
1.023
.890
1.099
1.330
1.582
1.241
1.532
1.853
2.206
2.149
2.653
3.210
3.821
.159
.177
.195
.212
.318
.354
.389
.424
.477
.531
.584
.637
.637
.707
.777
.849
2.759
2.972
3.184
3.396
.393
.455
.523
.594
.792
.918
1.053
1.197
1.201
1.393
1.599
1.820
1.857
2.154
2.473
2.813
2.589
3.002
3.447
3.921
4.484
5.200
5.970
6.792
.230
.248
.266
.283
.460
.495
.531
.566
.690
.743
.796
.849
.920
.990
1.061
1.132
3.821
4.245
4.669
5.094
.752
.928
1.123
1.337
1.516
1.871
2.264
2.695
2.303
2.844
3.441
4.095
3.561
4.396
5.319
6.330
4.963
6.127
7.414
8.823
8.596 .318
10.613 .354
12.841 .389
15.282 .424
.637
.707
.778
.849
.955
1.061
1.167
1.273
1.273
1.415
1.556
1.698
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FIGURE 14
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Lesson 1
The Basics of Arc
Welding
LESSON IX
22.5
22.5
Cu
Ch
Tab
Con
45
1/
16"
Lesson 2
Common Electric
Arc Welding
Processes
B
5/8"
1/2"
1/2"
1"
1/8"
Go T
1/16"
lbs./ft.
A=
B=
C=
TOTAL WEIGHT/FT.
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
1/2"
.265
.425
.124
.814 lbs
lbs./ft.
B = .176 x 4 =
C = .071 x 2 =
TOTAL WEIGHT/FT.
.704
.142
.846 lbs
5.
6.
7.
8.
9.
10.
Turn
These values are shown inserted into the formulas on the Weld Metal Cost Worksheet in
Figure 16.
Example 1 as shown below. This is because the flux cored process has a higher deposition
rate, efficiency and operating factor and also allows a tighter joint due to the deep penetrating
characteristics of the process.
Example 1 - 1,280 ft x .814 lbs/ft = 1,041.9 lbs at $13,939
Lesson 9
Estimating &
Comparing Weld
Metal Costs
When comparing welding processes, all efforts should be made to assure that you
use the proper welding current for the electrode or wire in the position in which the weld must
Lesson 10
Reliability of Welding
Filler Metals
Glo
FIGURE 15
almost the same, while the total cost of depositing the weld metal is three times higher in
Lesson 8
Hardsurfacing
Electrodes
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
7/8"
C
be made. As an example, consider depositing a given size fillet weld in the vertical-up posi-
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Se
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Lesson 1
The Basics of Arc
Welding
LESSON IX
EXAMPLE 2
WELD METAL COST WORKSHEET
COST PER POUND OF DEPOSITED WELD METAL
Lesson 2
Common Electric
Arc Welding
Processes
1.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
LABOR &
OVERHEAD
2.
ELECTRODE
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
30.00
ELECTRODE COST/LB
DEPOSITION EFFICIENCY
GAS
30.00
4.44
Go T
6.75
15 x .45
P
.80
.93
.86
45 x .03
1.35
1 5
5.
Glo
3.
4.
Lesson 5
Welding Filler Metals
for Stainless Steels
Cu
Ch
Tab
Con
FLUX
FLUX COST/LB x
1.4
DEPOSITION EFFICIENCY
POWER
COST/kWh x
VOLTS x
AMPS
1000
x
DEPOSITION RATE
x 1.4
.045 x 31 x 450
.09
1 5
NA
1000 x 15
627.75
.042
15,000
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
6.
POUNDS PER
FOOT OF
WELD JOINT
5.51
x .846
$4.66
8.
X
COST PER
FOOT
1,280x 4.66
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TOTAL FEET
OF WELD
Lesson 9
Estimating &
Comparing Weld
Metal Costs
$ 5.51
= $5,965
FIGURE 16
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Lesson 1
The Basics of Arc
Welding
LESSON IX
tion by the GMAW process and FCAW process semi-automatically. In both processes the
Cu
Ch
Tab
Con
welding current and voltage must be lowered to weld out-of-position, and in GMAW, the short
Lesson 2
Common Electric
Arc Welding
Processes
circuiting arc transfer must be used. Example 3 compares the weld metal cost per pound
deposited by these processes, using the proper current and voltage for depositing a fillet
weld on plate, vertically up.
Note: The cost of electrical power is comparable in all processes and therefore, can be eliminated as a factor.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
9.6.1
Example 3
P
FCAW
GMAW
Electrode Type -
$30.00/hr
$30.00/hr
Welding Current -
180 amperes
125 amperes
Deposition Rate -
Operating Factor -
45% (Fig. 2)
50% (Fig. 2)
Electrode Cost -
$1.44/lb
$.66/lb
Deposition Efficiency -
85% (Fig. 9)
96% (Fig. 6)
35 cfh (Fig. 7)
35 cfh (Fig. 7)
$.03 CO
Glo
Turn
2
As you can see, the cost of depositing the weld metal is about 33% less using the
Flux Cored Arc Welding process. Since there is no slag to help hold the vertical weld puddle
in the GMAW process, the welding current with solid wire must be lowered considerably. This,
of course, lowers the deposition rate, and since labor and overhead is the largest factor involved, it substantially raises deposition costs. In the flat or horizontal position, where the
Lesson 8
Hardsurfacing
Electrodes
Go T
welding current on the solid wire would be much higher, the cost difference would be considerably less pronounced.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
LESSON IX
The following information/variables must be determined prior to completing calculations:
(1) Proposed Method Cost Calculation
(2) Present Method Cost Calculation
Flux Cored Arc Welding
Gas Metal Arc Welding
E71T-1 .045 Dia. at 180 Amps
(3)
(4)
ER70S-3 .045 Dia. at 125 Amps
Actual Labor & O/H Rate for your Customer
$ 30.00
$ 30.00
Actual Labor & O/H Rate for your Customer
Deposition Rate in Pounds per Hour
4.9
2.8
Deposition Rate in Pounds per Hour
Operating Factor
45%
50%
Operating Factor
Electrode Cost per Pound
$ 1.44
$ 0.66
Electrode Cost per Pound
Deposition Efficiency
85%
96%
Deposition Efficiency
Gas Type
CO2
75% Ar/25% CO2
Gas Type
Gas Flow Rate
35
30
Gas Flow Rate
Gas Cost per Cubic Foot
$ 0.03
$ 0.11
Gas Cost per Cubic Foot
Equipment Cost
$
Prepared For:
NAME INFO
Customer Name:
NAME INFO
Date:
Result
(1) Proposed Method Cost Calculation
(2) Present Method Cost Calculation (Cost
Reduction )
Formulas for Calculating
Flux Cored Arc Welding
Gas Metal Arc Welding
Cost
Cost per Pound Deposited Weld Metal
E71T-1 .045 Dia. at 180 Amps
ER70S-3 .045 Dia. at 125 Amps
Increase
Labor&
Overhead
Electrode
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Cu
Ch
Tab
Con
$30.00
4.9
$30.00 = $13.605
2.205
1.44
Deposition Efficiency
Gas
0.45
$30.00
2.8
1.694
Lesson 9
Estimating &
Comparing Weld
Metal Costs
($7.823 )
0.688
$1.007
1.179
($0.964 )
1.05
0.214 3 0
X 0.11 =
3.3 =
4.9
Total Variable Cost/lb
Deposited Weld Metal
2.8
Turn
( $7.781)
T otal
Total Pounds =
.814 x 1,280
= 1,631 lbs
.630
Glo
1.4
0.96
0.03
= $30.00 = $21.429
0.5 =
0.66
0.85
35
Go T
Welding Time =
.814 x 1,280
5.36 x .30
1,042
= 648 Hrs.
1.608
COPYRIGHT 2000 THE ESAB GROUP, INC.
Se
Ch
(Fa
Dow
Se
Doc
(Sl
Dow
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
LESSON IX
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
Go T
P
Equipment Cost
$ Savings/Lb
Lesson 4
Covered Electrodes
for Welding Low Alloy
Steels
Cu
Ch
Tab
Con
Glo
Substituting the values in the formula:
2,800
7.00
400
If we divide 108 into eight hour days (108 8 = 13.5) the deposited weld metal savings of one
man working an eight hour day for 13-1/2 days will pay for the cost of the equipment.
Turn
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
Se
Ch
(Fa
Dow
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Se
Doc
(Sl
Dow
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROUP, INC.