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PRODUCT TRAINING
IN
ADOR WELDING LTD MAKES OF
WELDING CONSUMABLES FOR
STEEL PLANT applications
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1- Carbon Steels
2 - Nickel steels;
3 - Nickel-chromium steels;
4 - Molybdenum steels;
5 - Chromium steels;
6 - Chromium-vanadium steels;
7 - Tungsten-chromium steels;
9 - Silicon-manganese steels.
The second digit of the series indicates the concentration of the major element in percentiles (1
equals 1%). The last two digits of the series indicate the carbon concentration to 0.01%.
Example:
SAE 5130 indicates a chromium steel alloy, containing 1% of chromium and 0.30% of carbon.
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Alloy Steel:
To meet the Specific Mechanical or Physical properties ,
one or more alloying elements to be added in to the Steel.
Major Alloying Elements are Cr,Mo,Ni and Si etc.( In the
range of 1% 50%)
If we add Cr- Improve the Hardness and Corrosion
Resistance.
Mo Improve Toughness
Ni Improve Corrosion and Toughness.
Si- Improve Strength and Magnetic Properties
Divided in to Two Groups : i) Low Alloy Steels and high
alloy Steels
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Stainless Steel:
Stain means : Marks,Colours or Rust that cant be removed Easily.
Disadvantage of Mild Steel: If we will exposed in to the Air or
Moisture , Mild Steel get it Rusted and it is not Strong as compared
with Weight.
Stainless steel (Inox Steels)- A steel alloy with Min. 10% Cr. It
does not readily Corrode or rust.
Types of Stainless Steels:
1) Austenitic Stainless Steel
2) Ferritic Stainless Steel
3) Martensitic Stainless Steel
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welding, by dipping a bare iron wire in a thick mixture of carbonates and silicates.
Molten Metal absorbsoxygen and nitrogen, and becomesbrittleor is otherwise
adversely affected.
A slag cover is needed to protect molten or solidifying weld metal from the
atmosphere. This cover can be obtained from the electrode coating.
The coating protects the metal from damage, stabilizes the arc, and improves the
weld.
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Welding process where a coated consumable electrode is used to lay the weld
2)TIG /GTAW (Tungsten Inert Gas/ Gas Tungsten Arc Welding):
Manual Welding (welder has to use two hands to weld)
Inert Gas (Argon,Co2,Helium),It Provides the Protective Shield of Arc and Molten Metal.
Non-consumable tungsten electrode to produce the weld.
TIG welding is the most difficult of the processes, it produces the highest quality weld. TIG
welding is mostly used for critical weld joints
Arc Welding Process, which arc was shielded by Inert Gas (Co2,Ar,He).
Consumable of Filler Wire having the Similar Composition of Parent metal, and it continuously feed from
the Spool to the Arc Zone. The Arc Heats and Melts both the Edges ( Filler Wire and Weld Joint).Fused
Filler Wire material supplied to the surface of the Parent Metal, fills the Weld Spool and Forms the
Joint.
4) SAW (Submerged Arc Welding (SAW) Process:
> Fully Automatic Type ( Both Wire Feeding and Arc Produced are Controlled by M/c)
>SAW Process involves the formation of an arc between a continuously fed electrode and the work piece.
> Function of Flux, which generates a protective gas shield, also be used to add alloying elements, protects
the weld zone.
> A shielding gas is not required.
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1.20 to 2.00
Dia
2.50
2)
2.00 to 5.00
3.15
3)
5.00 to 8.00
4.00
4)
5.00
Gauge vs Size in mm
Gauge
Size (mm)
6.3 x 450
5.00 x 450
4
8
6.3
4.00x x450
450
10
3.15 x 450
12
2.50 x 350
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Size (mm)
Current Ranges
(Amps)
1)
2.50
60-95
2)
3.15
110 to 130
3)
4.00
140 165
4)
5.00
170 to 260
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1) Welding Consumables
i) Welding Electrodes
ii) CWC ( Continuous Welding Consumables)
2) Welding and Cutting Equipment
3) Gas Cutting Products and PPE ( Personal Protective Equipment)
4) CNC Cutting Machine
5) PEB ( Project Engineering Business)
6) Welding Automation ( WAPS)
7) Skill Development
E- Electrode
60 - UTS min .60,000 PSI
Conversion of PSI In to Mpa ) 1 PSI = Mpa x 145.0377
13 - Rutile Coating ( High Titanium Potassium),Position : H,F,OH,V(Up and Down), Current : AC or
DCEP ( DC+)
Rutile Coated Electrode, Deposits smooth.
Radiographic Quality weld metal with smooth spatter.Weld Bead shape is uniform , Smooth and
Slag removal is easy.
Application: Storage Tanks , All Kind of construction works,Automobile Bodies,Ship Building
,Pressure Vessels,Furniture,Sheet Metal Works, Pipes
Suitable for Joining Steels Confirming to ASTM Specification :SA-36/SA-36M(P.O-1),SA-53/SA53M(P.O-1)A,B,C,D Grades of SA-283/SA-283M(P.No.1).
Approvals : LRA,DNV,BV,ABS,IRS,PDO(Petroleum Development Oman),KNPC(Kwait National
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E-6011- Celwel-60S
Medium Coated Electrode,Having High Melting Speed,Suitable for welding in all
position.
It has a deeper penetrating arc and Easily removable Slag.
Application : Pipe lines,Ship Building,Storage Tanks and Pressure Vessels.
E-7010G Celwel-70G
Ideal For Root Pass and Capping.
All Position welding (V-Down)
X-Ray Quality even for Pipe Welding.
E-8010G CELWEL-80G
Welding of High Strength, Large Diameter Pipelines.
For Hot Passes
Meet with API (American Petroleum Institute) Code requirements.
Suitable for welding thin welded X80 Pipes.
Deposit 25/12 SS, Excellent Corrosion and Oxidation resistance in continuous Service
Temperature up to 1100 degree C
Joining of MS to SS, Low alloy Steels to SS.
E-309L-16- Betanox-DL
Extra Low Carbon Electrode Deposits 25/12 SS.
Excellent Corrosion and Oxidation resistance in Continious Service Tempearture up to
1100 degree C
Joining of MS to SS and Low alloy steels to SS.
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E-4043 Albond-5Si :
It has a special coating and High Melting Rate.
To avoid burn through keep short arc length.
If Section thicj]kness will be more than 8mm should be preheated to Min. 200 Degree C
Electrodes dia should be roughly equivalent to Plate thickness.
E-NiCrMo-6 Nickalloy-Mo-6
Welding of High grade welding of High Mo Ni Base alloys as well as Ni-Cr-Mo Steels with
High Mo -Content
Welding of low temperature and cryogenic steels like 9%Ni Steels.
Weld metal is highly resistant to hot cracking, stress corrosion,Thermal Shock.
Highest Quality weld metal.
Welding of 9% Ni steels in Cryogenic applications, Especially LNG Storage Systems.
Welding of Ni Base alloys to Steel
From 21 to 30
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Code
Digit
Max. Test
Temp.
0
2
3
4
5
6
7
8
Z
in (C )
0
(-) 20
(-) 30
(-) 40
(-) 50
(-) 60
(-) 70
NOT SPECIFIED
No Impact
Requirement
Min. Avg.Impact
Value
in (Joules)
27
27
27
27
27
27
27
27
N/A
There is progressively increasing role of welding not only in fabrication Industries but also in Repair
and Maintenance welding also.
Based on the Application we are dividing as below:
1)Mild Steel Electrodes (Rutile Coated)
2) Hydrogen Controlled Electrodes ( Basic Coated ie. Iron Powder)
3) Low Alloy Steel Electrodes
4) Electrodes for High Strength and Low Alloy steels
5) Wear Resistant Electrodes
6) Stainless Steel Electrodes.
7) Cast Iron Electrodes
8) Cutting Electrodes
9) Arc Welding Electrodes for Copper,Bronze,Cast Iron ,Aluminium,and Nickel etc .
These are suitable for all position welding of Structural not subjected to dynamic
loading.
Mechanical Properties UTS 460 TO 550 ,YS 360 TO 480MPa,% of Elongation
min.22 to 30
2) AWS: E-6013 Superbond-S:
Medium Coated Rutile Type,X Ray Quality Electrode.
Good Penetration Properties.
Electrodes Suitable for Critical Structural Joints subject to Dynamic Loading .
Mechanical Properties : UTS 460-550 Mpa ,YS- 370 TO 480MPA, Elongation min 22 to
28% (L=4xd),CVN @ 0 Degree C Min. 50Joules.
Zedalloy-600
Heavy Coated H2 Controlled Basic type Iron Powder Type.
Weld metal Hardness will be 600BHN(58RC) as welded condition.
Non Machinable Type.
H2 controlled basic type coating enables , electrodes to be used for High Carbon and High Sulphur Steels.
Zedalloy-600B
Weld metal having the Hardness of 600BHN as welded condition.
Subject to Friction and Abrasion.
Non-Machinable.
When Hardfacing of Difficult to weld steels particularly austenitic Manganese Steels Buffer layer of Betachrome-ND is
recommended on hard base materials.
Zedalloy-VB
Weld Metal Depsited is alloyed cast iron ,
Weld Metal Hardness 600BHN as welded Condition.Non Machinable Type.
which is extremely hard and Extremely resistant to abrasion and metal to metal wear.
Zedalloy-12Mn:
An electrode deposits work hardable weld metal having typically 12%Mn. Achievable Hardness will be 200BHN which
increase up to 500BHN while exposed to severe impact condition.
When using of this electrode on MS,Low Alloy Steel parts buffer layer of Betachrome-N is recommended.Machinable Type.
Weld metal is Extremly hard and Non Machinable.Ideal for Gauging type abrasion wear.
Zedalloy BELL:
Weld metal Hardness will be 500 to 550BHN
Hard weld Deposit to severe abrasion especialy at elevated
temperature.
Alloying elements Mo and Ni added to the weld deposit.
Weld metal does not crack during the build up operation by this
electrode.
Zedalloy-16
Heavy coated basic type electrode, Weld metal having the
Hardness of about 60RC.Weld metal has excellent resistance to
severe abrasion up to 500 degree C and Moderate Impact.
Deposit 25/12 SS, Excellent Corrosion and Oxidation resistance in continuous Service Temperature up to 1100
degree C
Joining of MS to SS, Low alloy Steels to SS.
E-309L-16- Betanox-DL
Extra Low Carbon Electrode Deposits 25/12 SS.
Excellent Corrosion and Oxidation resistance in Continious Service Tempearture up to 1100 degree C
Joining of MS to SS and Low alloy steels to SS.
E-318-16 Superinox-2A
18/8/3Mo type stabilized with Nb.
Used for Stress Corrosion cracking ,chemical and inter-crystalline Corrosion.
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