INDEX 1 3 223 211 1Detail in Contents 2 Electrodes Powder and Iron Mild Steel 3 Electrodes Controlled Hydrogen 4 Steel and Special Electrodes Stainless 5 Consumables Hardfacing Cobalarc 6 Gas Welding Metal Arc (MIG) Wires7 27 Flux Wires Welding Arc (FCAW) Cored 8 Wires Arc Submerged and Fluxes9 39 55 ConsumablesWelding TIG Gas and 71 103 127 171 179 10 and Fluxes Solders 11 Miscellaneous Products 12 InformationTrade and Technical 227 INDEX Notice about CIGWELD’s Welding Consumables Pocket Guide (manual). Consumables Pocket Welding Notice about CIGWELD’s Guide has been prepared as a reference only for use exclusively with the information in this Pocket The products identified in it. user should properly assess the information in the specific context of the Each intended application. this manual there are specific safety warnings. Throughout Disobeying or failing to can result,heed these warnings in some circumstances, emission of poisonous gases, in the unchecked or burns from explosion or electric shock. in compiling this information,Although care has been taken direct, CIGWELD will not be liable for any indirect, (including damage resulting from its negligence), special or consequential damage arising out of, or connected with the use of, or reliance on, this information except for liability imposed by legislation Act), Practices Trade (including the that cannot be excluded. or representations except for those that or give any express or implied warranties CIGWELD does not make Act), Practices Trade are implied by legislation (including the that cannot be excluded. Where the preceding paragraphs cannot legally operate, and to the extent permitted by law, CIGWELD’s implied by law is limited to and completely discharged at liability for breach of any term or warranty option,CIGWELD’s by either: a) replacement of the manual in hard copy form; one. b) payment of the cost of replacing the manual or acquiring an equivalent All rights reserved. © 2008 CIGWELD A.B.N. 56 007 226 815 www.cigweld.com.au 2 QUALITY ASSURANCE AND QUALITY CONTROL www.cigweld.com.au to ensureaconsistentproductthatmeetsthecustomer’s specifiedrequirements. allaspectsofproductionandtestingtofinaldespatch- through purchaseofrawmaterials, The qualitysystemappliesahighlevelofdocumentationandvigorouscontrolfromreceiptorder, and aprogramofcontinuousimprovement. This thirdpartyapproval (certification)representsCIGWELD’s commitmenttoquality and servicing’. installation standard AS/NZS ISO9001 ‘quality systems-modelforqualityassuranceinproduction, has beenapprovedbyLloyd’s RegisterQuality Assurance Limited(LRQA)tothequality management The Weldinggoods andservicesofthehighestquality. ConsumablesQualityManagementSystem CIGWELD’s statedqualitypolicyistocontinuouslysatisfyourcustomer’s expectationsbysupplying QUALITY ASSURANCE AND QUALITY CONTROL QUALITY QUALITY ASSURANCEAND covered bythe Accreditation CertificateNumber001. FORM L019A(8/90) The useofthe Accreditation Markindicates Accreditation inrespectofthose activities CONTENTS IN DETAIL 3 8 11 399 229 227 243 254 286 233 286 249 276 370 392 237 12.9.2 of Stainless Steel... Welding 12.9.3Aluminium... of Welding 12.9.4 of Cast Iron... Welding 12.9.5Alloys... of Copper & Copper Welding 12.9.6 of Dissimilar Metals... Welding 310 357 320 348 368 12.9.1 of Steel... Welding CONTENTS IN DETAIL IN CONTENTS Packaging Information... Packaging Product Index by AS/NZS & AWS/ASME-SFA & AS/NZS Index by Product Classifications... Order... Alphabetical Index by Product 4 Comparable Consumables by Welding Process...Welding by Comparable Consumables from CIGWELD...Available Product Certification Storage,Recommended Consumables... & Conditioning of CIGWELD Care Symbols, Position Welding this guide... used throughout for CIGWELD ConsumablesApprovals Shipping Society 16 Information... Trade and Technical 12.3 13 12.4 & Symbols... Positions Welding 15 22 Defects in welding... 24 12.112.2 & Definitions... Terms Basic types of welded joints... 12.512.6 Distortion, & control... causes 12.7Welding... Safety in 12.8Tables... Consumables Classification 12.9 Shielding Gas Information... Guide... Welding 258 12.10 Hardfacing Information... 12.11 Deposition Data... 12.12 Figures... & Facts Technical www.cigweld.com.au 4 PRODUCT INDEX BY AS/NZS AND AWS/ASME-SFA STANDARDS www.cigweld.com.au edl 533 321 54 321 64 E312-17 A5.4: 63 62 59 61 60 58 E312-16 Page No: A5.4: 56 E316L-16 A5.4: AWS/ASME-SFA 57 E309L-16 E318-17 Classification A5.4: A5.4: E308L-16 E312-17 --- A5.4: 1553.3: E316L-17 --- A5.4: E308L-17 E309Mo-17 A5.4: A5.4: E312-16 1553.3: E316L-16 1553.3: E309L-16 E318-17 1553.3: 44 1553.3: Classification E308L-16 Castcraft 100 1553.3: E316L-17 1553.3: Castcraft 55 52 AS/NZS 51 43 Weldall E309Mo-17 E308L-17 1553.3: 1553.3: Murex Speedex312-16 Page No: 42 50 Murex Speedex316L-16 E11018MH4R A5.5: 49 E9018MH4R Murex Speedex309L-16 E7018 AWS/ASME-SFA A5.5: A5.1: Classification 35 48 Murex Speedex308L-16 E7016H8 47 34 A5.1: Satincrome 318-17 E9018-B3H4R 33 A5.5: E7016H8 32 Satincrome 316L-17 45 A5.1: E8018-C1H4R 46 A5.5: Satincrome 309Mo-17 E8018-B2H4R A5.5: 31 Satincrome 308L-17 E7018-A1H4R 30 A5.5: Name 41 28 E7024 E7018-GH4R E7018-1H4R Product A5.1: A5.5: A5.1: E7618-M H5R 1553.2: E7014 29 E6218-MH5R A5.1: E4818-3H10 E6013 1553.2: 1553.1: A5.1: E6013 36 A5.1: E4816-2H10 E6218-B3H5R Alloycraft 110-HermeticallySealed 1553.1: 1553.2: 37 Classification E6013 E5518-C1H5R E7016H8 E4816-5H10 A5.1: Alloycraft 90-HermeticallySealed E6013 1553.2: A5.1: 1553.1: A5.1: E5518-B2H5R Alloycraft 90-B3-HermeticallySealed Page No: AS/NZS 1553.2: E6013 A5.1: E4818 A1H5R Alloycraft 80-C1-HermeticallySealed 1553.2: E6013 A5.1: Alloycraft 80-B2-HermeticallySealed AWS/ASME-SFA E6011 Classification E4818-GH5R E4818-5H5R Alloycraft 70-A1-HermeticallySealed A5.1: 1553.2: 1553.1: Ferrocraft 61NiH4-HermeticallySealed E6010 E4824-2 A5.1: 1553.1: Ferrocraft 61H4-HermeticallySealed E4814-2 1553.1: E4113-0 Ferrocraft 61 1553.1: E4113-2 1553.1: Ferrocraft 55U E4816-2H10 1553.1: Ferrocraft 7016 E4113-0 1553.1: E4112-0 Ferrocraft 16TXP-HermeticallySealed 1553.1: E4112-0 Name 1553.1: Product E4112-0 1553.1: E4111-2 1553.1: Classification E4110-2 Ferrocraft 22 1553.1: AS/NZS Ferrocraft 21 Speedex 13 Weldcraft Satincraft 13 Speedex 12 Ferrocraft 12XP GP 6012 Ferrocraft 11 PipeArc 6010P Name Product rnerf CD 57 60-2A.:CS- 67 CuSn-C A5.6: --- E6200-A2 2567: Arcair DCCarbons Bronzecraft AC-DC PRODUCT INDEX BY AS/NZSANDAWS/ASME-SFASTANDARDSINDEX PRODUCT Stainless SteelandSpecialElectrodes Hydrogen Controlled Electrodes Mild SteelandIron Powder Electrodes - 68 --- 51:EiC 66 65 ENi-CI A5.15: ENiFe-CI A5.15: PRODUCT INDEX BY AS/NZS AND AWS/ASME-SFA STANDARDS 5 A5.7: ERCuSi-A 124 A5.7: ERCu 123 AS/NZS AWS/ASME-SFA No: Page 2576: 1315-A4 --- 72 2576: 2355-A42576: 2360-A42576: 2460-A4 ------78 82 81 2576: --- 100 2576: 1215-A42576: 1560-A4 ------73 77 2576: 1865-B7 --- 88 2576: 3460-A1 --- 82 2576: 1845-B7 --- 99 Classification2576: 1435-A4 Classification 2576: 1855-A42576: 1860-A4 ------74 75 76 PRODUCT PRODUCT INDEX STANDARDS AWS/ASME-SFA AND AS/NZS BY Gas Welding Metal Arc (MIG) Wires Hardfacing Electrodes & Wires & Electrodes Hardfacing Autocraft 309LSiAutocraft 316LSiAutocraft Deoxidised Copper --- 2717.3: ES309LSi 2717.3: ES316LSi A5.9: ER309LSi A5.9: ER316LSi 115 116 Autocraft Mn-MoAutocraft NiCrMoAutocraft CrMo1Autocraft AL1100 (Pure)AL4043 (5% Sil)Autocraft AL5356 (5% Mag)Autocraft Autocraft AL5183Autocraft 2209Autocraft 307Si 2717.1:Autocraft 308LSi ESD2-GM-W559AH 2717.2: 2717.1: 2717.2: E1100 ESMG-GM-W769AH 2717.2: E4043 E5356 2717.1: ESB2-GM-W559AHAutocraft Silicon Bronze 2717.2: E5183 A5.28: ER80S-D2 A5.28: ER110S-G 2717.3: ES2209 ES307Si 2717.3 A5.28: 2717.3: ER80S-B2 ES308LSi --- 110 A5.10: 111 A5.10: ER1100 A5.10: ER4043 ER5356 112 A5.10: 118 ER5183 119 120 A5.9: A5.9: ER2209 ER307Si A5.9: ER308LSi 122 117 113 114 Stoody 145 Open Arc WireStoody RA45-0 Stoody ‘S’ Flux ProductNameAutocraft LW1Autocraft Super SteelAutocraft LW1-6 2576: 2560-87 2717.1: ES2-GC/M-W503AH 2717.1: AS/NZS --- ES4-GC/M-W503AH 2717.1: Classification ES6-GC/M-W503AH A5.18: ER70S-2 A5.18: ER70S-4 A5.18: ER70S-6 98 106 105 Classification 107 AWS/ASME-SFA No: Page Stoody 105 (Cobalarc 105-SA)Stoody 110 MC (Cobalarc Crome Mang-O)Stoody 965-O (Cobalarc 650-G/O)Cobalarc 850-O Stoody 600 (Cobalarc Impactaclad-O) (1.2,Stoody 101 HC-G/O (Cobalarc Coarseclad-G/O 1.6)) (2.4 & 2.8))Stoody 100 HC-O (Cobalarc Coarseclad-O Abrasoclad-O)Stoody 143-O (Cobalarc 2576: (Cobalarc Fineclad-O)Stoody Fineclad-O 2360-B5/B7 2576: 1715-B7 2576: 2360-B7 --- 2576: 1445-B1 2576: --- 1855-B5/B7 2576: 1955-B7 ------2576: --- 2460-B7 2576: 2565-B7 ------89 92 90 87 94 96 97 91 Cobalarc CR70 Cobalarc 1e Cobalarc 9e Cobalarc Borochrome Borium Stoody Tube Stoody 104 (Cobalarc 104-SA)Stoody Buildup-O (Cobalarc 250-O)Stoody Dynamang-O (Cobalarc Mang Nickel-O)Stoody Super Buildup-O (Cobalarc 350-G/O)Stoody 107 (Cobalarc 107-SA) 2576: 1215-B7 2576: 1435-B5/B7 2576: 1125-B7 2576: 1125-B1 --- 2576: 2560-A4 ------2576: --- 1440-B1 ------84 86 85 93 79 95 Product Name Cobalarc Mangcraft Cobalarc Austex Cobalarc 350 Cobalarc Toolcraft Cobalarc 650 Cobalarc 750 www.cigweld.com.au 6 PRODUCT INDEX BY AS/NZS AND AWS/ASME-SFA STANDARDS www.cigweld.com.au uorf A 881 L2A.7 L2173 174 Page No: 175 AWS/ASME-SFA 175 Classification EM12K A5.17: EL12 A5.17: 176 176 F6A2-EL12 F7A4-EM12K A5.17: A5.17: F7A2-EM12K A5.17: F6A2-EL 12 A5.17: EM12K-FMM-W503A 1851.1: EL12-FMM-W403A 1851.1: Classification EM12K 1858.1: EM12K-FGH-W403A 1858.1: EL12 1858.1: AS/NZS EL12-FGH-W403A 1858.1: 160 158 157 156 Satinarc 4withSA2 Satinarc 4withSA1 --- Satinarc 15withSA2 E71T-GS --- A5.20: 155 E71T-11 Satinarc 15withSA1 A5.20: E71T-Ni1 Autocraft SA2 A5.29: Autocraft SA1 E71T-8 A5.20: Name Product CM2 ETPS-GNn-W500A. --- 151 2203.1: E70T-4 CM2 A5.20: ETP-GNn-W500A. 2203.1: 149 ETD-GNn-W504ANi1 152 2203.1: Stoody 309LT-O ETD-GNn-W503ACM1 E70C-6MH4 2203.1: Stoody 308LT-O A5.18: equivalent electrodeclassification 146 ETD-GNp-W500ACM2H15 2203.1: E70C-6MH4 E110T5K4H4 A5.18: A5.29: ETD-GMn/p-W505ACM1H5 2203.1: 145 E71T-5 H4 A5.20: ETD-GMn/p-W503ACM1H5 144 2203.1: Verti-Cor K4H5 308LT ETD-GCn/p-W769A. 2203.1: Shield-Cor 15 E111T1-K3MH4 142 A529: E91T-1 K2MH4 Shield-Cor 11 A5.29: 138 CM1H5 E81T1-1Ni2MH8 140 ETP-GCn/p-W505A. PageShield-Cor 8Ni No: A5.29: 2203.1: 139 Shield-Cor 8XP 134 Shield-Cor 4XP 136 E81T-1 Ni1H4 AWS/ASME-SFA E81T1-1Ni1H8 E81T-1A1 H4 A5.29: Classification 132 A5.29: Nicore 55 A5.29: ETP-GMp-W768AK3H5 2203.1: Ni2H10 ETP-GMp-W629AK2H5 130 ETP-GMp-W559A. 2203.1: 2203.1: E71T1-12M H4 Tensi-Cor 110TXPH4 A5.20: Metal-Cor 5 E71T-1 H8 A5.20: 129 Ni1H10 Metal-Cor XP ETP-GMp-W554A. E71T-1 H8 ETP-GMp-W554ANi1H5 2203.1: A5.20: 2203.1: E71T-1 H8 A5.20: ETP-GMp-553 A1 H5 CM1H5 ETP-GMp-W503A. 2203.1: 2203.1: CM1H10 ETP-GCp-W503A. E70T-1 H8 2203.1: Supre-Cor 5 A5.20: CM1H10 ETP-GCp-W502A. Verti-Cor 111K3H4 2203.1: CM1H10 ETP-GCp-W503A. Verti-Cor 91K2H4 2203.1: Verti-Cor 81Ni2 Classification CM1H10 ETD-GCp-W502A. 2203.1: AS/NZS Verti-Cor 81Ni1H4 Verti-Cor 81Ni1 Verti-Cor 81 A1 H4 Verti-Cor 3XPH4 Verti-Cor 3XP Verti-Cor Ultra Verti-Cor XP Satin-Cor XP Name Product et-o 1L ------148 Verti-Cor 316LT E70T-5 H4 A5.20: Verti-Cor 309LT CM1H5 ETP-GCn-W503A. 2203.1: Supre-Cor XPH4 Submerged Arc Wires and Fluxes and Submerged Arc Wires Cored(FCAW) Arc Welding WiresFlux BY AS/NZSANDAWS/ASME-SFASTANDARDSINDEX PRODUCT 1.6mm only 231 T-CM-52.C1H0A5.20: CM1H10 ETD-GC/Mp-W502A. 2203.1: --- 152 E110T5K4MH4 148 A5.29: 146 E70T-5M H4 A5.20: ETD-GMn/p-W769AK4H5 2203.1: E71T-5M H4 A5.20: 140 CM1H5 ETP-GMn-W503A. 2203.1: CM1H5 E81T-1 Ni1MH4 ETP-GMn/p-W505A. A5.29: 2203.1: 134 ETP-GCp-W554ANi1H5 130 2203.1: E71T-12M H8 A5.20: E71T-1M H8 A5.20: CM1H10 ETP-GMp-W503A. 2203.1: CM1H10 ETP-GMp-W503A. 2203.1: ------→ 52:E0L11162 E308LT1-1 A5.22: 52:E1L11166 164 E316LT1-1 A5.22: E309LT1-1 A5.22: 51:EieC 154 ENiFe-CI A5.15: 51:FP-M2 175 F6P4-EM12K A5.17: 52:E0L14162 E308LT1-4 A5.22: 52:E1L14166 164 E316LT1-4 A5.22: E309LT1-4 A5.22: 52:E0L03169 168 E309LT0-3 A5.22: E308LT0-3 A5.22: 7T1H,E70T-1M H8 E70T-1 H8, PRODUCT INDEX BY AS/NZS AND AWS/ASME-SFA STANDARDS 7 --- 219 --- 221 --- 201 --- 218 ------216 217 --- 224 --- 220 PRODUCT PRODUCT INDEX STANDARDS AWS/ASME-SFA AND AS/NZS BY Miscellaneous Products Solders and Fluxes Solders Gas Welding and TIG Consumables ProductNameChromeBright (Pickling Paste) --- AS/NZS Classification Classification AWS/ASME-SFA No: Page Comweld Aluminium FluxComweld Copper and Brass FluxComweld Silver Brazing Flux No. 2Comweld G.P. Silver Brazing FluxComweld 965 Soldering Flux ------Comweld VAPAFLUX ------Comweld Nickel Bronze RodComweld Nickel Comweld Comcoat NComweld Silicon Bronze Rod (801) 1167.1 & 2: 1167.2: RCuZn-D RCuSi-AComweld 40/60 Soft SolderComweld 50/50 Soft SolderComweld 965 Solder 2: 1167.1 & RCuZn-DComweld Metal Mate Solder Kit 1834.1: 40Sn 1834.1: 50Sn 1834.1: 96.5Sn / 3.5Ag A5.8 & 27: RBCuZn-D 1834.1: A5.7: 96.5Sn / 3.5Ag RCuSi-A 206 A5.8 & 27: RBCuZn-D 207 --- 208 ------215 212 214 213 Comweld AL4043 (5% Sil.)Comweld AL4047 (10% Sil.)Comweld AL5356 (5% Mag.)Comweld Comweld G.P. Cast Iron Rod BarComweld Galvanising Rod Bronze Tobin Comweld 1167.2: R4043 1167.2:TComweld Comcoat R4047 1167.2: R5356Comweld Manganese Bronze Rod 1167.2:Comweld Comcoat C RC11 --- 1167.1 & 2: 1167.1 & 2: RCuZn-A RCuZn-C 1167.1 & 2: RCuZn-A 1167.1 & 2: A5.10: RCuZn-C R4043 A5.10: R4047 A5.10: R5356 A5.8 & 27: A5.8 & 27: --- RBCuZn-A RBCuZn-C 197 204 202 A5.8 & 27: 198 RBCuZn-A 199 A5.8 & 27: RBCuZn-C 205 203 200 Comweld LW1Comweld LW1-6Comweld CrMo1Comweld CrMo2Comweld 2209 Duplex Stainless SteelComweld 308L Stainless Steel 1167.2: R2209Comweld 309L Stainless SteelComweld 316L Stainless SteelComweld AL1100 (Pure) 1167.2: 1167.2: 1167.2: R4 R308L R6 1167.2: 1167.2: RB2 R309L 1167.2: 1167.2: RB3 R316L 1167.2: R1100 A5.9: ER2209 A5.9: ER308L A5.18: A5.9: A5.18: ER70S-4 ER309L ER70S-6 A5.28: 195 A5.9: ER80S-B2 ER316L A5.28: ER90S-B3 A5.10: R1100 192 186 188 190 193 191 194 196 ProductNameComweld Mild SteelTestComweld High Comweld Super SteelComweld LW1-3 1167.2: RG AS/NZS 1167.2: R1 1167.2: R2 Classification 1167.2: R3 A5.2: R45 Classification A5.2: AWS/ASME-SFA R60 A5.18: ER70S-2 No: Page A5.18: ER70S-3 184 189 185 187 www.cigweld.com.au 8 PRODUCT BY ALPHABETICAL ORDER www.cigweld.com.au owl L07(0 i. 172 44 51:R07198 213 214 196 197 212 77 78 73 82 R4047 72 A5.10: R1100 R4043 81 A5.10: A5.10: 79 194 76 193 75 192 74 ------ER316L --- A5.9: ER309L --- A5.9: --- ER308L A5.9: ------R4047 1167.2: R1100 R4043 1167.2: --- 1167.2: 96.5Sn/3.5Ag 1834.1: --- 67 --- 173 --- 174 50Sn 1834.1: --- 40Sn Comweld AL4047 (10%Sil.) 1834.1: Comweld AL4043 (5%Sil.) 1560-A4 R316L 2576: (Pure) 2355-A4 1167.2: Comweld AL1100 2576: R309L CuSn-C 1215-A4 1167.2: Comweld 965SolderingFlux 106 A5.6: 2576: R308L 2460-A4 EL12 1167.2: Comweld 965Solder EM12K A5.17: 2576: A5.17: 1315-A4 2360-A4 2576: Comweld 50/50SoftSolder 2576: 2560-A4 2576: Comweld 40/60SoftSolder 1860-A4 2576: Comweld 316LStainlessSteel 111 1855-A4 110 2576: Comweld 309LStainlessSteel 116 107 ER70S-2 105 1435-A4 A5.18: 2576: Comweld 308LStainlessSteel 115 113 Comweld 2209 114 117 --- Cobalarc Toolcraft 112 --- ER110S-G Cobalarc Mangcraft A5.28: ER80S-D2 A5.28: Cobalarc CR70 122 ER70S-6 ER316LSi ER70S-4 A5.18: A5.9: Cobalarc Borochrome E6200-A2 A5.18: ER309LSi 2567: A5.9: Cobalarc Austex ER308LSi ER307Si EM12K A5.9: --- Cobalarc 9e A5.9: 1858.1: ER80S-B2 ER2209 ES2-GM-W503AH EL12 A5.28: A5.9: 2717.1: Cobalarc 1e 1858.1: Cobalarc 750 120 119 118 51 ER5183 --- Cobalarc 650 ESMG-GM-W769AH A5.10: 2717.1: 50 ESD2-GM-W559AH Cobalarc 350 2717.1: ES6-GC/M-W503AH ES4-GC/M-W503AH ChromeBright (PicklingPaste) 2717.1: 2717.1: 49 Page No: Castcraft 55 48 Castcraft 100 E9018MH4R E9018-B3H4R A5.5: 52 ESB2-GM-W559AH ER5356 ER4043 A5.5: Bronzecraft AC-DC ER1100 2717.1: A5.10: A5.10: AWS/ASME-SFA A5.10: ES316LSi Autocraft SuperSteel 2717.3: Classification 47 E8018-C1H4R ES309LSi Autocraft SiliconBronze A5.5: 2717.3: E8018-B2H4R ES308LSi A5.5: Autocraft SA2 2717.3: ES307Si E11018MH4R --- 2717.3: A5.5: Autocraft SA1 ES2209 2717.3: Autocraft NiCrMo E7018-A1H4R A5.5: Autocraft Mn-Mo --- E5183 Autocraft LW1-6 2717.2: Autocraft LW1 Autocraft DeoxidisedCopper Autocraft CrMo1 E6218-M E6218-B3 1553.2: 1553.2: Autocraft 316LSi E5356 Autocraft 309LSi E4043 E1100 2717.2: E5518-C1 2717.2: 2717.2: 1553.2: Autocraft 308LSi Classification E5518-B2 1553.2: Autocraft 307Si H5R E7618-M E4818-A1. AS/NZS 1553.2: Autocraft 2209 1553.2: Arcair DCCarbons Autocraft AL5183 Autocraft AL5356 (5%Mag) Autocraft AL4043 (5%Sil) (Pure) Autocraft AL1100 Alloycraft 90-B3 Alloycraft 90 Alloycraft 80-C1 Alloycraft 80-B2 Alloycraft 70-A1 Alloycraft 110 Name Product owl oca 171&2 CZ- 58&2:RCZ- 207 199 203 RBCuZn-D A5.8&27: RBCuZn-C A5.8&27: R5356 A5.10: RCuZn-D 1167.1& 2: RCuZn-C 1167.1& 2: --- R5356 1167.2: Comweld ComcoatN Comweld ComcoatC Flux Comweld Aluminium Comweld AL5356 (5%Mag.) PRODUCT INDEXBY ALPHABETICAL - 220 --- 59 R29195 ER2209 A5.9: 123 68 ERCu A5.7: --- - 224 65 66 124 --- ENiFe-CI A5.15: ENi-CI A5.15: ERCuSi-A A5.7: - 216 --- PRODUCT BY ALPHABETICAL ORDER 9 --- 219 --- 221 --- 218 --- 201 A5.17: F6P4-EM12K 175 A5.15: ENiFe-CI 155 --- 217 → --- 2203.1: ETD-GMn/p-W503A. CM1 H5 A5.18: E70C-6M 1150 2203.1: ETD-GMp-W502A CM1 H10 A5.20: H8 E70T-1M 129 1.6mm only PRODUCT INDEX BY ALPHABETICAL BY INDEX PRODUCT Satin-Cor XP 2203.1: ETD-GCp-W502A. CM1 H10 A5.20: H8 E70T-1 129 Satincrome 309Mo-17Satincrome 316L-17Satincrome 318-17 1553.3: E309Mo-17 1553.3: E316L-17 1553.3: E318-17 A5.4: E309Mo-17 A5.4: E316L-17 A5.4: E318-17 57 58 59 Nicore 55PipeArc 6010PAutocraft SA1Satinarc 15 with Autocraft SA2Satinarc 15 with Autocraft SA1Satinarrc 4 with Autocraft SA2Satinarc 4 with 1858.1: EL12-FGH-W403A 1858.1: EM12K-FGH-W503A 1858.1:Satincraft 13 EL12-FMM-W403A 1858.1:Satincrome 308L-17 EM12K-FMM-W503A 1553.1: E4110-2 electrode classification equivalent A5.17: A5.17: F6A2-EL12 F7A2-EM12K A5.17: A5.17: F6A2-EL12 F7A4-EM12K 176 1553.3: E308L-17 176 1553.1: 175 E4113-0 175 A5.1: E6010 A5.4: E308L-17 37 A5.1: E6013 56 31 GP 6012Metal-Cor XP (*1.2mm only)Metal-Cor 5Murex Speedex 12Murex Speedex 13Murex Speedex 308L-16 2203.1: *ETP-GMn/p-W503A. CM1 H5Murex Speedex 309L-16Murex Speedex 312-16Murex Speedex 316L-16 A5.18: E70C-6M 1553.1: 1553.3: 1553.1: E4112-0 E308L-16 E4112-0 1553.3: 1553.1: E309L-16 2203.1: E4113-0 ETD-GMn/p-W505A. 150 CM1 H5 1553.3: E312-16 1553.3: E316L-16 A5.18: E70C-6M 152 A5.4: A5.1: A5.1: E308L-16 E6013 E6013 A5.4: A5.1: E309L-16 E6013 A5.4: A5.4: E312-16 E316L-16 60 61 28 30 31 62 63 Comweld VAPAFLUX 11Ferrocraft 12XPFerrocraft 16TXPFerrocraft 21Ferrocraft 22Ferrocraft 55UFerrocraft 61Ferrocraft 61 H4Ferrocraft --- 61 Ni H4Ferrocraft 7016Ferrocraft 1553.1: 1553.1: E4111-2 E4112-0 1553.1: E4816-2 H10 1553.1: E4814-2 1553.1: 1553.1: E4824-2 E4816-2 H10 1553.2: 1553.1: 1553.1: E4818-G H5 E4818-5 H5 R E4818-3 H10 1553.1: E4816-3 H10 A5.1: E7016 H8 A5.1: A5.1: E6011 E6013 A5.1: A5.1: E7016 H8 E7014 A5.1: A5.1: E7018-1 H4 R A5.1: A5.5: E7024 E7018 E7018-G H4 41 A5.1: E7016 H8 36 29 45 43 46 34 35 44 41 Comweld LW1Comweld LW1-3Comweld LW1-6Comweld Manganese Bronze RodComweld Metal Mate Solder KitComweld Mild Steel Bronze RodComweld Nickel 1167.1 & 2:Comweld Silicon Bronze Rod (801) RCuZn-CComweld Silver Brazing Flux No. 2 1834.1: 96.5Sn / 3.5AgComweld Super Steel Bronze RodTobin Comweld 1167.2: 1167.2: RCuSi-A !!67.2: R4 R3 --- 1167.1 & 2: 1167.2: RCuZn-D R6 1167.2: RG & 2: 1167.1 RCuZn-A A5.8 & 27: RBCuZn-C 1167.2: --- R2 202 A5.8 & 27: RBCuZn-D A5.7: RCuSi-A A5.18: ER70S-4 A5.18: 206 ER70S-3 A5.18: A5.8 & 27: ER70S-6 RBCuZn-A A5.2: R45 215 208 205 186 187 A5.18: 188 ER70S-2 184 189 ProductNameTComcoat Comweld Brass FluxComweld Copper and Comweld CrMo1Comweld CrMo2Comweld G.P. Cast Iron RodComweld G.P. Silver Brazing Flux --- BarComweld Galvanising TestComweld High 2: 1167.1 & RCuZn-A --- 1167.2: RC11 AS/NZS 1167.2: RB2 --- Classification 1167.2: RB3 1167.2: R1 A5.8 & 27: RBCuZn-A 205 --- Classification A5.28: AWS/ASME-SFA ER80S-B2 A5.28: ER90S-B3 No: Page A5.2: R60 190 191 200 185 www.cigweld.com.au 10 PRODUCT BY ALPHABETICAL ORDER www.cigweld.com.au edrf 531 41- 51 61 32 65 E6013 E312-17 A5.1: A5.4: 130 132 E71T-1 H8 E4113-2 A5.20: E312-17 1553.1: 144 1553.3: E71T-1 H8 A5.20: 142 E91T-1 K2MH8 139 A5.29: E81T-1 Ni2MH8 CM1H10 A5.29: ETP-GCp-W503A. 134 2203.1: 140 136 CM1H10 ETP-GCp-W502A. 2203.1: E81T1-Ni1 M E81T-1 Ni1MH4 A5.29: A5.29: 82 E71T-12 MH4 A5.20: ETP-GMp-W629AK2H5 ETP-GMp-W559ANi2H10 2203.1: 145 2203.1: E71T-1 H8 A5.20: 99 Ni1H10 ETP-GMp-W554A. E111T1-K3MH8 86 2203.1: A5.29: ETP-GMp-W554ANi1H5 2203.1: 91 CM1H5 ETP-GMp-W503A. Weldcraft 2205.1: CM1H10 ETP-GCp-W503A. Weldall 169 2203.1: 85 84 88 168 96 87 Verti-Cor XP K3H10 ETP-GMp-W768A. Verti-Cor Ultra 146 2203.1: 97 Verti-Cor 91K2H4 --- E309LT0-3 A5.22: Verti-Cor 81Ni2 95 E308LT0-3 92 A5.22: 94 93 --- Verti-Cor 81Ni1H4 E71T-5 H4 Verti-Cor A5.20: 81Ni1 --- Verti-Cor 3XPH4 ------Verti-Cor 90 3XP CM1H5 ------ETP-GCn/p-W504A. Verti-Cor 111K3H4 89 2203.1: ------3460-A1 --- 2576: --- 1315-B7 --- 2576: 1315-B7 --- 2576: --- 1845-B7 1435-B5/B7 2576: 2576: Page No: 2565-B7 2576: --- 1125-B7 1215-B7 --- 1855-B5/B7 2576: 1865-B7 2576: AWS/ASME-SFA 1955-B7 2576: 157 2576: 2576: Supre-Cor 5 Classification 156 Stoody TubeBorium 160 147 158 Stoody SuperBuildup-G/O 2460-B7 Stoody SOS309L 2576: 1440-B1 Stoody SOS308L 2576: 1715-B7 2576: 1445-B1 E71T-Ni1 Flux Stoody ‘S’ 2576: A5.20: 1125-B1 Stoody RA45-0 2576: E71T-8 --- E71T-GS Stoody Fineclad-O A5.20: A5.20: E71T-11 E70T-4 A5.20: Stoody Dynamang-O A5.20: Stoody Buildup-O Ni1H10 2360-B5/B7 ETD-GNn-W504A. 2360-B7 Stoody 965-G/O 2576: 2203.1: 2576: CM1H10 Stoody 850-O ETD-GNn-W503A. 2203.1: CM2H15 Stoody 600 ETD-GNp-W500A. CM2 Classification 2203.1: ETPS-GNn-W500A. Open ArcWire 145 2203.1: Stoody CM2 ETP-GNn-W500A. 2203.1: AS/NZS Stoody 143-O Stoody 110MC Stoody 107 Stoody 105 Stoody 104 Stoody 101HC-G/O Stoody 100HC-O Shield-Cor 8Ni Shield-Cor 8XP Shield-Cor 4XP Shield-Cor 15 Shield-Cor 11 Name Product es-o 1TPH 231 T-C-79.K 5A.9 105K 152 148 --- E110T5-K4 --- A5.29: E70T-5 H4 A5.20: --- K4H5 ETD-GCp-W769A. CM1H5 ETP-GCn/p-W504A. 2203.1: 2203.1: Verti-Cor 316LT Verti-Cor 309LT Verti-Cor 308LT Tensi-Cor 110TXPH4 Supre-Cor XPH4 PRODUCT INDEXBY ALPHABETICAL 231 T-M/79.K 5A.9 105K 4152 148 E110T5-K4MH4 A5.29: 146 --- E70T-5M H4 A5.20: --- E71T-5MJ K4H5 H4 ETD-GMp/W769A. A5.20: 2203.1: CM1H5 ETP-GMn/p-W504A. 2203.1: CM1H5 ETP-GMn/p-W504A. 2203.1: 231 T-M-53.C1H0A.0 7T1 8130 E71T-1M H8 A5.20: 140 E81T1-Ni1H4 CM1H10 A5.29: ETP-GMp-W503A. 2203.1: 134 E71T-12M H8 ETP-GCp-W554ANi1H4 A5.20: 2203.1: CM1H10 ETP-GMp-W503A. 2203.1: --- - 98 --- 52:E1L11166 164 162 E316LT1-1 A5.22: E309LT1-1 A5.22: E308LT1-1 A5.22: - 100 --- 52:E0L14164 162 E309LT1-4 A5.22: E308LT1-4 A5.22: 52:E1L14166 E316LT1-4 A5.22: PACKAGING INFORMATION 11 ABC Flange O.D.D Hub I.D.E Barrel DiameterF Width OutsideG 100mm Width Inside 57mm Engaging Hole Hole offset 16mm 45mm 40mm --- 200mm --- 104mm 52mm 55mm 45mm 270 or 300mm 11mm 135 or 207mm 44mm 400mm 52mm 100mm --- 95mm 11mm 100mm 44mm 300mm ------Spool ø100mm ø200mm ø270 or 300mm ø400mm Dimensions 4 Inch 8 Inch 12 Inch 16 Inch Spool Dimensions: MIG (GMAW) & Flux Cored (FCAW) Wires: (FCAW) & Flux Cored MIG (GMAW) Pallet Weights of Electrodes: Weights Pallet PACKAGING INFORMATION PACKAGING CIGWELD Name MiniSpool HandiSpool Spool Coil Weight RangeWeight 0.45-1kg 4.5-5kg 12.5-15kg 25-30kg SEE NEXT PAGE FOR SPOOL DIAGRAMS SEE NEXT PAGE 15kg Spools of MIG Wire15kg Spools of MIG Wire of MIG AutoPaks 150kg Wire of MIG AutoPaks 250kg Wire of MIG AutoPaks 300kg =Wire13kg Spools of MIG = =Wire25kg Coils of FCAW = per pallet 4 Packs Wire of FCAW AutoPaks 200kg 54 Spools per pallet per pallet 4 Packs Wire of FCAW AutoPaks 230kg per pallet 4 Packs = = = = = per pallet 4 Packs = 54 Spools per pallet per pallet 4 Packs = 24 Coils per pallet = 810kg 600kg 1,000kg = 1,200kg = = = 702kg 800kg 920kg 600kg 12kg Cartons Cartons15kg Standard 25kg Cartons = 72 Ctn per pallet (Skid) Dimensions: Average Pallet A = 85 Ctn per palletB = 1,080kg C = 40 Ctn per palletD = = 1,020kg = = = 1,000kg = 650mm 1,140mm 1,155mm 480mm www.cigweld.com.au 12 PACKAGING INFORMATION www.cigweld.com.au COIL: HANDISPOOLS&STANDARD SPOOLS: MINISPOOLS, SPOOL DIAGRAMS (nottoscale): PACKAGING INFORMATION COMPARABLE* CONSUMABLES BY WELDING PROCESS 13 ------___ (ER1100) (ER4043) (ER2209) (ER90S-B3) (ER80S-B2) Comweld CrMo1 Comweld CrMo2 ------(E309LT) (E308LT) (ENiFe-CI) (RC11) Stoody SOS 308L Stoody SOS 309L (E91T1-K2 M H4) (ER1100) (ER4043) (ER2209) ------___ Autocraft 2209 ___ Comweld 2209 ___ Autocraft AL1100 ___ Comweld AL1100 ___ AL4043 Autocraft ___ Comweld AL4043 (E7014)(E7024)(E7018) (ER70S-4/6) (ER70S-4/6) M) H8) (E71T-12 (E71T-1 (ER70S-2) (ER70S-4) (E70C-6M) H4) (E71T-5 (ER70S-4) (ER70S-2) (E6013)(E6013)(E6013)(E6013) (ER70S-4/6) (ER70S-4/6) (ER70S-4/6) (ER70S-4/6) (E71T-GS) (E71T-11) (E71T-GS) (E71T-11) (R60) (R60) (R60) (R60) (EniFe-CI) (E7016-1) (ER70S-2) M H4) H4 & E71T-5 (E71T-5 (ER70S-2) (E9018-M) (E308L-17) (ER308LSi) (E308LT1-1/4) (ER308L) (E316L-17)(E308L-16)(E309L-16)(E316L-16) (ER316LSi) (ER308LSi) (ER309LSi) (ER316LSi) (E316LT1-1) (E308LT1-1/4) (E309LT1-1) (E316LT1-1) (ER316L) (ER308L) (ER309L) (ER316L) MMAW GMAW FCAW GTAW (E9018-B3) (ER90S-B3) (E8018-B2) (ER80S-B2) Speedex 12 Autocraft LW1/LW1-6 Shield-Cor 15Test Comweld High Speedex 13 Autocraft LW1/LW1-6 Shield-Cor 11 Test Comweld High (E11018-M) (ER110S-G) (110T5-K4 & K4M) Castcraft 55 ___ Nicore 55 Comweld G.P. Cast Iron Ferrocraft 61Ferrocraft Autocraft Super Steel Supre-Cor 5 Comweld Super Steel Ferrocraft 22Ferrocraft Autocraft LW1/LW1-6 Metal-Cor XP/ Metal-Cor 5 Comweld LW1 Satincraft 13 21Ferrocraft Autocraft LW1/LW1-6 Autocraft LW1/LW1-6 3XP & 3XP H4 & XP Verti-Cor Shield-Cor 11 Comweld LW1 Test Comweld High Alloycraft 90 ___ 91K2H4 Verti-Cor ___ (E309Mo-17) (ER309LSi) (E309LT1-1) (ER309L) Alloycraft 110 Autocraft NiCrMo 110TXP Tensi-Cor Ferrocraft 7016Ferrocraft Autocraft Super Steel Supre-Cor 5 Comweld Super Steel Ferrocraft 12XPFerrocraft Autocraft LW1/LW1-6 Shield-Cor 15 Test Comweld High Alloycraft 80-B2 Autocraft CrMo1 Alloycraft 90-B3 Autocraft CrMo2 Speedex 308L-16Speedex 309L-16Speedex 316L-16 Autocraft 308LSi Autocraft 309LSi Autocraft 316LSi 308LT Verti-Cor 309LT Verti-Cor 316LT Verti-Cor 308L Comweld Comweld 309L Comweld 316L Satincrome 316L-17 Autocraft 316LSi 316LT Verti-Cor Comweld 316L Satincrome 308L-17 Autocraft 308LSi 308LT Verti-Cor Comweld 308L Satincrome 309Mo-17 Autocraft 309LSi 309LT Verti-Cor Comweld 309L COMPARABLE* CONSUMABLES BY WELDING PROCESS WELDING BY CONSUMABLES COMPARABLE* www.cigweld.com.au 14 COMPARABLE* HARDFACING CONSUMABLES BY PROCESS www.cigweld.com.au Note: the particularapplicationinquestion. CIGWELD representativeforadviceregardingthesuitabilityofspecificprocess/consumablecombinations Please contactyourlocal * Comparableconsumablesmaynotbeinterchangeableforallweldingapplications. recommendations. ConsultyourCIGWELDrepresentativeforaccurate Cobalarc Austex and309L/Lsi. COMPARABLE* HARDFACING CONSUMABLESBYPROCESS oaacBrcrm toyFnca ______StoodyFineclad Cobalarc Borochrome oaacMncatSod yaag______StoodyDynamang Cobalarc Mangcraft rnerf CD uorf iBoz _ ComweldSiBronze ___ AutocraftSiBronze Bronzecraft AC-DC oaacAse et-o 0L _ Comweld309L ___ Verti-Cor 309LT Cobalarc Austex oaacC7 toy11H-/ ______Stoody101HC-G/O Cobalarc CR70 oaac30Sod ue ulu toy15___ Stoody105 StoodySuperBuildup Cobalarc 350 oaac70Sod 6 / ______Stoody965G/O Stoody965G/O Cobalarc 750 Cobalarc 650 MWFA A GTAW SAW FCAW MMAW Autocraft 307si(GMAW) 26-4 (2565-B7) (2360-B5/B7) (1445B1) (1855-B5/B7) (1855-B5/B7) (2560-A4) (1435-B5/B7) (2355-A4) (1860-A4) (1855-A4) (1435-A4) (1215-B5/B7) (1215-A4) 11-4 (E309LT1-1) (1315-A4) EunC (ERCuSi-A) (ECuSn-C) _ uorf L36__ComweldAL5356 ___ AutocraftAL5356 ___ ------toyBidu- Stoody104 Stoody Build-up-O Stoody SOS309L (ER5356) 12 7 (1125B1) (1125 B7) (E309LT) can beusedinmanyofthesameapplicationsas ------(RCuSi-A) (ER5356) (ER309L) ----- PRODUCT CERTIFICATION 15 depend on the specific tests carried out. The “Fee charged”“Fee Report will The Test for a Special properties, diffusible hydrogen, etc.) x-ray soundness manufactured main line products. Of Charge”. “Issued Free require tests for weld metal composition, mechanical Conformance tests (AS/NZS & AWS).Conformance tests (AS/NZS & conformance test results. Includes for all Available requirements. extensive (eg. can be quite Tests product for certain applications may Special Test Report: Special Test in annual Shipping Society approval tests (ABS/DNV/LRS) and/or Standards tests (ABS/DNV/LRS) in annual Shipping Society approval Includes results of tests carried out to relevant Standards and specific customer Includes results of tests carried out to relevant Specifications. to that used certificate certifies that the product supplied is equivalent The Conformance Certificate: Demonstrates that the product complies to relevant Standards, to relevant Demonstrates that the product complies Regulations and Material Safety Data Sheets (MSDS): Quality Assurance Quality Assurance Certificate: PRODUCT CERTIFICATION PRODUCT The content of these certificates is agreed upon by the customer The content of these certificates is agreed time of ordering. at the and must be requested and the manufacturer Certificate Assurance / Quality Certificates showing actual chemistry fall into the Conformance report Test under the Special but Certificates showing actual mechanical values may fall group category. consult your Cigweld representative. Please EN 10204 & ISO 10474 3.1 (formerly 3.1b) Certificates Provides information on the products and the hazards associated with them to Provides information on the products and the hazards associated with them allow the safe handling and use of the products at work. MSDS describes the The identity, and chemical properties and uses of the product, physical health hazard information, precautions for use and safe handling information. Of “Issued Free Charge”. Is only issued where Conformance Certificates are not available.Is only issued where Conformance Certificates Results are derived batch testing procedures. internal from CIGWELD’s results quoted are normally The properties. chemical analysis and limited mechanical Most CIGWELD welding consumables are approved by Lloyd’s Register of Shipping (LRS), of Shipping Register by Lloyd’s are approved welding consumables Most CIGWELD of Shipping American Bureau (ABS), fabrication. and general for use in ship building (DNV) Veritas are and Det Norske party approvals third These under the supervision of consumables sizes various a series of tests on by completing annually at CIGWELD renewed society. and testing from each shipping of a surveyor mentioned to the above approvals lists the relevant CIGWELD societies, on standards/classifications American (AWS/ASME-SFA) Zealand (AS/NZS) and Australian and New as well as guide. data pages throughout this pocket the individual product from CIGWELD. available following lists Product Certification The four main certificates available, are There the most SHEET (MSDS).CONFORMANCE CERTIFICATEpopular being the obtain SAFETY DATA and the MATERIAL To (BATCH) call or fax the following numbers: on CIGWELD Product Certificates please further information PH: 1300 654 674 FAX: +61 3 9474 7391 www.cigweld.com.au 16 STORAGE, CARE & CONDITIONING OF ELECTRODES www.cigweld.com.au . Excessivemoisture inelectrodes mayproduce oneormore ofthefollowingeffects: 1.1 . hnhl ne h eomne trg odtos,originalunopenedpacksofCIGWELDelectrodes are When heldundertherecommended storage conditions*, 3.1 theweldershouldbeaware ofthefollowingpointsregarding handling: Before usingCIGWELDelectrodes, 2.1 ▲ ▲ ▲ ▲ ▲ ▲ will usuallyreturntheelectrodestotheiroriginalasmanufacturedcondition. which Electrodes indicatinganyoftheaboveshouldbereconditionedfollowingproceduressetoutinthisrecommendation, .Storage ofCIGWELDElectrodes Before Use 3. Commences Before Work 2. Introduction 1. CARE&CONDITIONINGOF ELECTRODES STORAGE, omto f“ht u”onthefluxcoating. Formation of “white fur” Blistering ofelectrodetip. Porosity inweldmetal. Introduction ofhydrogenintoweldmetal coatings willbemoreresistanttomoisturere-absorptionandfluxcoatingrehydration. Moistureresistant(MR)typeflux willgraduallyabsorbmoisture. Electrode coatingsexposedtotheatmospherehowever, generalrutiletypeelectrodes. orreducemoisturetoapredeterminedlowleveleg. hydrogen controlledtypes, eg. CIGWELDelectrodesarebaked atspecifictemperaturestoeithervirtuallyeliminateanymoisture, During manufacture, zone cracking. with increaseddangerofheataffected floor andwalls. Stacked onracksorpalletsclearofthe unheatedstoragerooms/cupboards/containers/warehouses. In weatherproof, * RecommendedStorage Conditions: indefinitely. conditionforatleast12monthsandhermeticallysealedcontainers expected toremain in “factory fresh” Productwhichshowsvisiblesignsofdamage(iewater orotherwise)shouldbereturned tothesupervisoror 2.1.3 appearwetormoistandshowsignsofrust(especially Electrodeswhichshowvisiblesignsofmechanicaldamage, 2.1.2 grindingdust paint, oil, grease, freeofmoisture, CIGWELDelectrodesshouldbekept dryandcleanatalltimes, 2.1.1 person responsibleforinspectionandpossiblereconditioningbeforeapproval foruse. on hydrogencontrolledelectrodes)shouldnotbeusedforwelding. and condensation. ▲ ▲ ▲ ▲ ▲ ▲ Undercut. Difficulty withslagremoval. Excessive spatter. High arcvoltage. Fiery unstablearc. Spalling offluxcoating. STORAGE, CARE & CONDITIONING OF ELECTRODES 17 F) above ambient temperature F) above ambient temperature F) above ambient temperature with F) above ambient temperature with ° ° ° Arcair DC Carbons AC-DC Bronzecraft 22 Ferrocraft PipeArc 6010P 61 Ni H4 Ferrocraft Speedex 16 Castcraft, Cast Iron Range 21 Ferrocraft Cobalarc, Extruded electrode Range C (50-60 C (50-60 C (50-60 ° ° ° F) and at a maximum humidity of 60% R.H. F) and at a maximum ° F) and at a maximum humidity of 60% R.H. F) and at a maximum humidity of 60% R.H. F) and at a maximum humidity of 50% ° ° /100g of Deposited Weld Metal. Weld /100g of Deposited C (140 ° 2 C (105 C (105 ° ° 5 mls H ≤ Electrodes should be kept at 10-15 kept Electrodes should be Electrodes should be kept at 10-15 Electrodes should be kept with a maximum of 60 with a maximum of a maximum of 40 a maximum of 40 : at 10-15 Electrodes should be kept following parameters are recommended: are following parameters Ferrocraft 11 Ferrocraft Section C 16TXPFerrocraft Alloycraft 80-B2Alloycraft 80-C1Alloycraft 90-B3 61 Ferrocraft Satincrome, Stainless Steel RangeSpeedex Stainless Steel Range 61 H4 Ferrocraft 7016 Ferrocraft Weldall 55U Ferrocraft Alloycraft 90 Alloycraft 110 critical applications. In practice, to any but basic applied rarely are conditioning treatments specific to be used for applications requiring when they are electrodes coated (low hydrogen) levels eg. controlled hydrogen conditions, the use of heated,at the maintained warehouses rooms/cupboards/containers/ store Section A: Speedex 12 GP 6012 Satincraft 13 Section B: Ferrocraft 12XP Ferrocraft Speedex 13 Weldcraft In high temperature baking basic coated electrodes, it is important not to exceed the changes in the recommended maximum of temperature and time as this can result in chemical coatings which will permanently impair electrode performance. the same reason, For it is not hydrogen controlled electrodes. advisable to repeatedly high temperature bake and as a result they CIGWELD hydrogen controlled electrodes have a very robust flux construction can be redried generally between 2 to 3 times. 4. Conditioning of CIGWELD Electrodes 3. Use cont. Before CIGWELD Electrodes of Storage STORAGE, ELECTRODES OF & CONDITIONING CARE .1 prior to use in sometimes given to electrodes to special treatments The term conditioning refers 4 3.3 Table Storage 3.2 or high humidity) climatic (damp or under adverse over twelve (12) months storage For www.cigweld.com.au 18 STORAGE, CARE & CONDITIONING OF ELECTRODES www.cigweld.com.au . CIGWELDElectrode Reconditioning Table 4.2 .ConditioningofCIGWELDElectrodes cont. 4. CARE&CONDITIONINGOF ELECTRODES STORAGE, for 2hoursandthereafterusefromahotboxsetat100-120 A5.1 “H aicoerneWeldall Hydrogen Controlled Electrodes -LowHydrogen Status Electrodes thatarecapableofmeeting AS/NZS 1553.1low “H Section E: Speedex range Satincrome range ercat1TPFerrocraft 61 Ferrocraft 55U Ferrocraft 7016 Ferrocraft 16TXP (480 temperature of100 Conditioning shouldbecarriedoutinventilatedairovensorhotboxes(seeparagraph6.1.2)setatastarting eto :StainlessSteelElectrodes Bronzecraft AC-DC The electrodesinthisgroupifrequiredmaybereconditionedbyheatingto250 Section D: PipeArc 6010P Ferrocraft 11 theCIGWELD Welding Consumables CelluloseElectrodes factory formoreinformation. butifrequiredpleaseconsult Reconditioningisnotrecommended, parameters. preciseoperating andactuallyrelyuponasmallpercentageofmoistureinthefluxcoatingtoobtain stored correctly, CIGWELD CelluloseCoatedelectrodesagaindonotnormallyrequirereconditioningbeforeuseif Section C: CastIronRange Castcraft, hold for1-1 eto :CastIron andBronze Electrodes if electrodesabsorbmoistureandrequirereconditioningheatto95 however The electrodesinthisgroupdonotrequirereconditioningbeforeuseifstoredcorrectly, Section B: Satincraft 13 Speedex 13 Ferrocraft 12XP GP 6012 Speedex 12 the maximumtemperatureto155 eto :General PurposeElectrodes heatto135 however ifelectrodesabsorbmoistureandrequirereconditioning, The electrodesinthisgroupnormallydonotrequirereconditioningbeforeuseifstoredcorrectly, Section A: enable evendrying. avoidingdeeplayeringof electrodessoasto Electrodesshouldbeunpacked andspacedevenlyontotraysorracks, 4.2). (275 ° ° 70 F ± 70 F ± 8 tts shouldbereconditionedbyheatingto300 status, ” 1 ° ° / 2 F) andholdfor1-2hours. F) andholdfor1-1 hours. ° C (210 ° F) andthenraisedtothecorrecttemperaturesforvarious typesofelectrodes(asin Table 1 / 2 ° C. or.*Generalpurposeelectrodescanbeoverdriedsorestrict hours. oaac ExtrudedelectrodeRange Cobalarc, Arcair DCCarbons Ferrocraft 21 Ferrocraft 22 Weldcraft ° ° 15 C ± 10 C (210-250 hydrogenclassificationand AWS ” ° 10 C ± ° C (570 ° F). ° C (200 ° 60 F ± ° 20 C ± ° 20 C ± ° 50 F ± ° F) andholding ° C ° C ° F) and STORAGE, CARE & CONDITIONING OF ELECTRODES 19 F) and holding ° F ± 60 F). ° ° F). F). ° ° ” levels of diffusible 5 C (660 C (250 ° ° C (500 ° ” or “H ” AWS hydrogen classification and 4 C (210-250 5 C ± 15 ° ° Alloycraft 80-B2 61 H4 Ferrocraft F) and a maximum humidity of 80% RH. Once opened, electrodes ° C (85-95 ° CIGWELD hermetically sealed containers, which are known to be airtight on initial ” status, by heating to 350 should be reconditioned 4 electrodes which are estimated “sufficient” estimated which are electrodes for the immediate job at hand, be from whether those electrodes and cartons. a holding oven or packets 6.1.1a. storage: CIGWELD products for heating and portable drying oven, VB1689 maximum temperature 120 Section F:“H AS/NZS 1553.1 low capable of meeting Electrodes that are Status Low Hydrogen Very - Electrodes Controlled Hydrogen A5.1 “H b. bench drying oven, VB1690 maximum temperature 260 for 2 hours and thereafter use from a hot box set at 100-120 for 2 hours and thereafter quarantined and reconditioned as in paragraph 4. as in paragraph and reconditioned quarantined should be used within a maximum of 4 hours.should be used within a maximum of 4 Thereafter,“H if Alloycraft 80-C1Alloycraft 90 Alloycraft 110 Alloycraft 70-A1Section G: opening may, good workshop practice is adopted, where for critical welding without be used reconditioning, use, provided the containers are first opened immediately prior to ensuring that (high temperature or high humidity) climatic conditions the electrodes are not used in adverse less than at 30-35 90-B3 Alloycraft 61 Ni H4 Ferrocraft hydrogen are a critical requirement, electrodes should be reconditioned as described in paragraph 4.2, Section F. 5. After Reconditioning 6. In Progress Work 4. cont. Electrodes of CIGWELD Conditioning STORAGE, ELECTRODES OF & CONDITIONING CARE 6.1 Once work has commenced, only those possible to draw where good workshop practice it is recommended CIGWELD electrodes which have been reconditioned and are not required for immediate use,CIGWELD electrodes which have been must be either placed in heated at ambient temperatures,storage or stored in airtight containers following the recommendations in paragraph 2. For further information regarding CIGWELD electrodes,For please contact the CIGWELD Customer Service Centre on 1300 654 674. 6.2 1 (1.1) should be absorption as in paragraph which show signs of moisture Electrodes www.cigweld.com.au 20 STORAGE, CARE & CONDITIONING OF ELECTRODES www.cigweld.com.au . eoeuigCGEDwligwrs theweldershould be aware ofthefollowingpoints Before usingCIGWELDweldingwires, 2.1 ▲ ▲ Excessivemoisture inCIGWELDfluxcored wires mayproduce oneormore ofthefollowing 1.1 (> 70%RH)itispossibleforthefluxcoretoabsorbmoisturethroughclosedseam. Underconditionsofprolongedexposure(severaldays)toahighhumidityatmosphere which runsalongthelengthofwire. CIGWELD FluxCoredweldingwiresaremanufacturedtotightsizetolerancesfromsteelstripandassuchhaveaclosedseam levels inthefinalproduct. storage andhandlingmanufacturingprocessesarecloselycontrolledtoensureverylowmoisture Raw materialselection, CIGWELD FluxCoredweldingwiresarefabricatedfromselectedhighqualityfluxcoreingredientsandlowresidualsteelstrip. Cored Arc WeldingFlux Wires CIGWELD operatortechniqueandshieldinggasquality. correct choiceofweldingconsumable, parentmetal, *The provisoinMIGand TIG weldingtoachievingaqualityweldaretheothervariables suchasequipmentset-up, reliablehydrogenlevelsandsoundweldmetal. welding consumablewillprovide*consistent, dryandfreeofairbornecontaminantsthe Whensolidweldingwiresandrodsarekept clean, grease orotherhydrocarbons. oiland rust, original packsareopenedandthisisnormallylimitedtosurfacecontaminationmainlyintheformofcondensation, Generally solidweldingwiresandrodsasusedforMIG TIG weldingwillnotpickupmoistureorcontaminantsuntilthe Rods Solid Weldingand WiresCIGWELD ▲ ▲ ▲ Recommended Storage andCare ofCIGWELD Welding Wires andRods: 2. Before Work Commences Before Work 2. Introduction 1. CARE&CONDITIONINGOF ELECTRODES STORAGE, Porosity inweld metal. Introduction ofhydrogenintoweldmetal .. rdc hc hw iil in fdmg ie water orotherwise)shouldbereturned Productwhichshowsvisiblesignsofdamage(i.e. 2.1.4 In some caseswherepackaginghasbeendamagedeitherintransitorduring 2.1.3 Welding wireswhichshowvisiblesignsofmechanicaldamageordisplayexcessive surface grease,2.1.2 freeofmoisture, CIGWELDweldingwiresshouldbekept dryandcleanatalltimes, condensationandotherairborneparticles. grindingdust, paint, oil, 2.1.1 regarding handling: effects: zone cracking. with increaseddangerofheataffected Gas Tungsten(GTAW Arc Welding/ TIG) Cored(FCAW) Arc WeldingFlux Gas Metal Arc Welding (GMAW /MIG) to thesupervisororpersonresponsibleforinspectionand approval foruse. in thewelddepositfromthisoxidefilmmayoccur. Increasesinhydrogenlevels whichcancausepoorfeedabilityandcurrentpickup. film, storage/handling thesurfaceofouterlayerswireandrodmayformanoxide rust shouldnotbeusedforwelding. ▲ ▲ ▲ ▲ Excessive spatter. High arcvoltage. Fiery unstablearc. Undercut. STORAGE, CARE & CONDITIONING OF ELECTRODES 21 tself - Wrap the wire with any Vapour Phase Inhibitor (VPI) paper supplied. Vapour Wrap the wire with any - - Replace the wire in the original thick plastic bag and seal with an elastic band. and store as in paragraph 3. into the original resealable cardboard packet - Pack and rods are used on the job. the welding consumable should be protected (a) In the case of FCAW and MIG welding at all times from contaminants, such as moisture and airborne particles, by either unit or by using PVC,enclosing the wire in a sealed wirefeeder spool leather or canvas welding machines.covers which are standard on most MIG cleaning of the Periodic by appropriate means. underside of spool covers is recommended workshop practice where possible to draw TIG welding it is recommended good (b) For “sufficient” only those welding rods which are estimated immediate job at hand, for the those welding rods not required for immediate use, in their original should be either kept the or stored in airtight containers at ambient temperatures following resealable packets recommendations in paragraph 3. (a) Overnight: Wires should be covered with spool covers or if in areas of adverse weather or climatic conditions the wire should be stored as below. (b) Extended periods: Wires which are not used for periods in excess of three days* off at the should be first removed from the welding machine ensuring that the wire is cut wirefeeder unit**. in their original packaging as follows: Wires should then be repacked are expected to remain in “factory fresh”“factory in expected to remain are for at least 12 months. condition Conditions: * Recommended Storage In weather proof, storage rooms/cupboards/containers/warehouses. unheated on racks Stacked floor and walls. or pallets clear of the heated, (50-60°F) above ambient maintained at 10-15°C rooms/cupboards/containers/warehouses store of 60% R.H is recommended: (105°F) and at a maximum humidity (with a maximum of 40°C temperature the same day or; (a) either the welding consumable is used is left on or near the welding machine overnight or for (b) a portion of the welding consumable an extended period of time. 4.1.1 when welding wires following points are recommended as good workshop practice The 4.1.2 FCAW and MIG welding wires left on welding machines: For 4. In Progress Work 3. Use Before Wires Welding CIGWELD of Storage STORAGE, ELECTRODES OF & CONDITIONING CARE For further information regarding CIGWELD electrodes,For please contact the CIGWELD Customer Service Centre on 1300 654 674. * Maximum exposure time will be dependant on prevailing atmospheric conditions (i.e..* Maximum exposure time will be dependant on prevailing and humidity). Temperature is done so no contaminated wire comes into contact with the clean wire on the spool or coil.**This rollers deform the surface of Feed the wire, which normally runs through a spring steel conduit which are from time to time cleaned out with compressed air, which i contains oil, or hydrocarbon containing mineral spirits. 3.2 conditions, or high humidity) climatic (damp or under adverse over twelve (12) months storage For the use of 4.1 After opening, consumed in two ways; normally and Rods are Wires Welding CIGWELD 3.1 conditions*, storage recommended held under the When CIGWELD welding wires original unopened packs of www.cigweld.com.au 22 WELDING POSITION SYMBOLS www.cigweld.com.au WELDING POSITIONSYMBOLS For filletandbuttweldingapplications-GMAW andFCAW wires: For hard surfacingapplications-electrodes andtubularwires: For filletandbuttweldingapplications-manualelectrodes: Welding Applications onad&Dwhn Downhand Downhand& Downhand & l oiinlAlPstoa xetDownhand AllPositional Except All Positional l oiinlFa HVFillet Flat All Positional etclU vredHorizontal Overhead Vertical Up oiotlHorizontal Horizontal Vertical Down MUREX WELDING POSITION SYMBOLS & HEADING BAR ICONS 23 DOWN VERTICAL VERTICAL VERTICAL Copper Coated Wire Direct Current Direct negative electrode Open Current Voltage Open Circuit rating Voltage Weld Metal Weld hardness – 45 OCV DC OCV VERTICAL HORIZONTAL HORIZONTAL/ Direct Current Direct positive electrode Melting point Direct Current Direct negative or positive Alternating or Current Direct positive electrode Alternating or Current Direct negative electrode Requires gas Requires shielding ° – + 000 DC DC +/– Alternating and Current Direct Alternating or Current Direct Thermal conductivity Direct Current Alternating Current Requires no gas Requires shielding OVERHEAD DOWNHAND % AC 00 HEADING BAR ICONS HEADING BAR MUREX WELDING POSITION SYMBOLS POSITION WELDING MUREX DC www.cigweld.com.au 24 SHIPPING SOCIETY APPROVALS www.cigweld.com.au

CIGWELD product AS/NZS AWS Shielding gas for ABS LRSSHIPPING SOCIETY APPROVALS DNV Class Class Approvals Grade Grade Grade

Manual Arc Electrodes Ferrocraft 11 1553.1: E4111-2 A5.1: E6011 - 3 / A5.1 E6011 3, 3Y 3 GP6012 1553.1: E4112-0 A5.1: E6013 - 2 2 2 Ferrocraft 12XP 1553.1: E4112-0 A5.1: E6013 - 2, 2Y / A5.1 E6013 2, 2Y 2 Satincraft 13 1553.1: E4113-0 A5.1: E6013 - 2 / A5.1 6013 2 2 Weldcraft 1553.1: E4113-2 A5.1: E6013 - 3 3 3 Ferrocraft 21 1553.1: E4814-2 A5.1: E7014 - 3 / A5.1 E7014 3 3 Ferrocraft 22 1553.1: E4824-2 A5.1: E7024 - 2, 2Y / E7024 3 3 PipeArc 6010P 1553.1: E4110-2 A5.1: E6010 - 3 / A5.1 E6010 3 3 Ferrocraft 16TXP 1553.1: E4816-2 A5.1: E7016 - 3H10, 3Y 3, 3YH15 3YH10 Ferrocraft 55U 1553.1: E4816-2 A5.1: E7016 - - 3, 3YH15 3YH10 Ferrocraft 7016 1553.1: E4816-3 A5.1: E7016 - 3H10, 3Y 3YH10 3YH10 Ferrocraft 61 1553.1: E4818-3 A5.1: E7018 - 3H15, 3Y / A5.1 E7018 3, 3YH15 3YH10 Ferrocraft 61 H4 1553.1: E4818-1 A5.1: E7018-1 - 3H5, 3Y, 3, 3YH5 3YH5 Ferrocraft 61 Ni H4 1553.2: E4818-G A5.5: E7018-G - - 3, 3YH15 - Alloycraft 80-C1 1553.2: E5518-C1 A5.5: E8018-C1 - A5.5 E8018-C1 - - Satincrome 308L-17 1553.3: E308L-17 A5.4: E308L-17 - A5.4: E308L-17 - - Satincrome 309Mo-17 1553.3: E309Mo-17 A5.4: E309Mo-17 - A5.4: E309Mo-17 - - Satincrome 316L-17 1553.3: E316L-17 A5.4: E316L-17 - A5.4: E316L-17 - - Gas Metal Arc Welding (MIG) Wires

Autocraft LW1 2717:.1: ES4-GC/M-W503AH A5.18: ER70S-4 CO2, Argon + 25%CO2 3SA 3S IIIYMS Autocraft LW1-6 2717:.1: ES6-GC/M-W503AH A5.18: ER70S-6 CO2, Argon + 25%CO2 3S, 3YSA 3S, 3YS IIIYMS Autocraft AL5356 2717.2: E5356 A5.10: ER5356 Argon A5.10: ER5356 A5.10: ER5356 A5.10:ER5356 CI

SHIPPING SOCIETY APPROVALS 25

owl L3616.:R36A.0 55 51:R36-- - R5356 A5.10: - R5356 A5.10: R5356 1167.2: AL5356 Comweld

Gas Tungsten Arc (TIG) rods (TIG) Arc Tungsten Gas

Metal-Cor 5 2203.1: ETD-GMn/p-W505A CM1 H5 A5.18: E70C-6M H4 Argon + 20% CO2 4SA, 4YSA H5 3S, 4YS H4 IVYMS H5 IVYMS H4 4YS 3S, H5 4YSA 4SA, CO2 20% + Argon H4 E70C-6M A5.18: H5 CM1 ETD-GMn/p-W505A 2203.1: 5 Metal-Cor

ea-o P20.:EDGnpW0AC1H 51:E0-MH ro 0 O S,3S S Y IIIYMS 3YS 3S, 3YSA 3SA, CO2 20% + Argon H4 E70C-6M A5.18: H5 CM1 ETD-GMn/p-W503A 2203.1: xP Metal-Cor

(2.4mm only) 2203.1: ETP-GMn/p-W504A CM1 H5 A5.20: E70T-5M H4 Argon + 20% CO2 4SA, 4YSA H5 3S, 4YS H5 4YS 3S, H5 4YSA 4SA, CO2 20% + Argon H4 E70T-5M A5.20: H5 CM1 ETP-GMn/p-W504A 2203.1: only) (2.4mm

urcrX 420.:EPGnpW0AC1H 52:E0- 4C24A YAH S Y 5- H5 4YS 3S, H5 4YSA 4SA, CO2 H4 E70T-5 A5.20: H5 CM1 ETP-GCn/p-W504A 2203.1: H4 XP Suprecor

2203.1: ETP-GMn/p-W505A CM1 H5 A5.20: E71T-5M H4 Argon + 20% CO2 3SA, 3YSA H 3S, 3YS H IIIYMS H IIIYMS H 3YS 3S, H 3YSA 3SA, CO2 20% + Argon H4 E71T-5M A5.20: H5 CM1 ETP-GMn/p-W505A 2203.1:

Suprecor 5 2203.1: ETP-GCn/p-W505A CM1 H5 A5.20: E71T-5 H4 CO2 3SA, 3YSA H 3S, 3YS H IIIYMS H IIIYMS H 3YS 3S, H 3YSA 3SA, CO2 H4 E71T-5 A5.20: H5 CM1 ETP-GCn/p-W505A 2203.1: 5 Suprecor

2203.1: ETP-GCp-W554A Ni1 H5 A5.29: E81T-1 Ni1 M H4 Argon + 20% CO2 4YSA H5 3S, 3YS H5 3YS 3S, H5 4YSA CO2 20% + Argon H4 M Ni1 E81T-1 A5.29: H5 Ni1 ETP-GCp-W554A 2203.1:

Verticor81 Ni1 H4 2203.1: ETP-GMp-W554A Ni1 H5 A5.29: E81T-1 Ni1 H4 CO2 4YSA H5 4Y4OS H10 4Y4OS H5 4YSA CO2 H4 Ni1 E81T-1 A5.29: H5 Ni1 ETP-GMp-W554A 2203.1: H4 Ni1 Verticor81

Verticor 3XP H4 2203.1: ETP-GMp-W503A CM1 H4 A5.20: E71T-12M H4 Argon + 20% CO2 3SA, 3YSA H5 3S, 3YS H5 3YS 3S, H5 3YSA 3SA, CO2 20% + Argon H4 E71T-12M A5.20: H4 CM1 ETP-GMp-W503A 2203.1: H4 3XP Verticor

2203.1: ETP-GMp-W503A CM1 H10 A5.20: E71T-12M H8 3SA, 3YSA H 3S, 3YS IIIYMS H IIIYMS 3YS 3S, H 3YSA 3SA, H8 E71T-12M A5.20: H10 CM1 ETP-GMp-W503A 2203.1:

Verticor 3XP 2203.1: ETP-GCp-W503A CM1 H10 A5.20: E71T-1 H8 Argon + 20% CO2 3S, 3YS H10 3YS 3S, CO2 20% + Argon H8 E71T-1 A5.20: H10 CM1 ETP-GCp-W503A 2203.1: 3XP Verticor

Verticor Ultra 2203.1: ETP-GCp-W502A CM1 H10 A5.20: E71T-1H8 CO2 2YSA H10 2YS H10 IIYMS H IIYMS H10 2YS H10 2YSA CO2 E71T-1H8 A5.20: H10 CM1 ETP-GCp-W502A 2203.1: Ultra Verticor

231 T-M-53 M 1 52:E1-MH ro 0 O S YA3,3SIIIYMS 3YS 3S, 3YSA 3SA CO2 20% + Argon H8 E71T-1M A5.20: H10 CM1 ETP-GMp-W503A 2203.1:

Verticor XP 2203.1: ETP-GCp-W503A CM1 H10 A5.20: E71T-1H8 CO2 3SA 3YSA 3S, 3YS H10 IIIYMS H10 IIIYMS H10 3YS 3S, 3YSA 3SA CO2 E71T-1H8 A5.20: H10 CM1 ETP-GCp-W503A 2203.1: XP Verticor

A Y 7T12SF 2YS E70T-1 3YA 3A,

aicrX 231 T-C-52 M 1 52:E0-H CO2 E70T-1H8 A5.20: H10 CM1 ETD-GCp-W502A 2203.1: XP Satincor S- 2S SH0 2YSAH10 2SAH10,

Flux Cored Arc (FC) Welding Wires Welding (FC) Arc Cored Flux

ls ls prvl rd rd Grade Grade Grade Approvals Class Class

CIGWELD product CIGWELD SNSASSiliggsfrASLSDNV LRS ABS for gas Shielding AWS AS/NZS SHIPPING SOCIETY APPROVALS SOCIETY SHIPPING www.cigweld.com.au 26 MILD STEEL & IRON POWDER ELECTRODES 27 28 32 33 34 35 36 30 31 29 37 Page No Page MILD STEEL & IRON POWDER ELECTRODES POWDER IRON & STEEL MILD Description 21 Ferrocraft 22 Ferrocraft 11 Ferrocraft PipeArc 6010P GP 6012 12XP Ferrocraft Speedex 13 Speedex 12 Satincraft 13 Weldcraft www.cigweld.com.au 45 DC GP 6012 OCV AC

▲ General Purpose Versatile Electrode. APPROVALS: ▲ High Operator Appeal! Lloyds Register of Shipping Grade 2. American Bureau of Shipping Grade 2. ▲ All Positional Welding Capabilities. Det Norske Veritas Grade 2. ▲ Ideal for the Vertical-Down Welding of TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: Thin Steel Sections. Yield Stress 430 MPa ▲ Quite, Smooth Arc Action. Tensile Strength 490 MPa ▲ Excellent for welding joints with poor fit- Elongation 29% up. CVN Impact Values 80J av @ 0°C. Classifications: TYPICAL ALL WELD METAL ANALYSIS: C: 0.07% Mn: 0.45% Si: 0.30% AS/NZS 1553.1: E4112-0. AWS/ASME-SFA A5.1: E6013. All positional - welding Description and Applications: GP 6012 is a versatile, user friendly, G.P. electrode, suitable for welding in all positions. GP 6012 has a unique flux coating that offers exceptional welder appeal and makes for easy welding of the most difficult jobs. Features include: ✦ Quick freezing, self releasing slag for exceptional control when welding in the vertical-down and other difficult positions. ✦ Excellent slag detachability under high heat build-up conditions. ✦ Superb for welding joints with poor fit-up (gaps and misalignment etc). MILD STEEL AND IRON POWDER ELECTRODES AND IRON POWDER MILD STEEL ✦ Easy arc starting and stability on low voltage (greater than 45 O.C.V.) AC current welding machines. ✦ Medium penetrating arc, useful for welding thin and light gauge steels. ✦ Impressive touch welding capabilities. Due to GP 6012’s host of versatile features it is suitable for a wide range of welding applications in the light to medium structural steel industry including, ✦ Wrought iron furniture, ✦ Mild steel plate, sheet metal and galvanised iron sheet, ✦ Rolling stock and railway maintenance work, ✦ Square or rectangular hollow tube sections (RHS etc), ✦ Pipes and low pressure pipelines, ✦ Ducting, hoppers and tanks, ✦ Plus a wide range of G.P. welding applications such as, gates, security grills, barbecues, trolleys, letter boxes, trestles, billy carts, shelved storage units etc. Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ or DC- polarity. Electrode Approx No. Current Packet Carton Part No Size mm Length mm Rods/kg Range (amps) 2.5 300 55 55–80 5kg 15kg – 3 x 5kg 611142 3.2 380 30 90–130 5kg 15kg – 3 x 5kg 611143 4.0 380 19 130–180 5kg 15kg – 3 x 5kg 611144

28 www.cigweld.com.au 45 DC MILD STEEL AND IRON POWDER ELECTRODES FERROCRAFT 12XP OCV AC

▲ General Purpose “XP series” Electrode. APPROVALS: ▲ Easy Striking - Hot or Cold! Lloyds Register of Shipping Grade 2, 2Y. American Bureau of Shipping Grade 2, 2Y. ▲ Xtra smooth Performance (XP). Det Norske Veritas Grade 2. ▲ Versatile - All Positional Capabilities. American Bureau of Shipping AWS A5.1 E6013. ▲ Ideal for Vertical Down Fillet Welding. TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: ▲ RED flux colour for easy I.D. Yield Stress 460 MPa Tensile Strength 500 MPa Classifications: Elongation 27% AS/NZS 1553.1: E4112-0. CVN Impact Values 75J av @ 0°C. AWS/ASME-SFA A5.1: E6013. TYPICAL ALL WELD METAL ANALYSIS: Description and Applications: C: 0.07% Mn: 0.60% Si: 0.50% Ferrocraft 12XP is an Xtra smooth Performance (XP) general purpose electrode manufactured at CIGWELD’s Welding All positional - welding Consumables Plant. It offers smooth, stable running and superb fillet shapes in all welding positions including vertical- down/up and overhead. Ferrocraft 12XP is recommended for all your general purpose repair, maintenance and fabrication welding jobs around the home, workshop, farm, fabshop and jobbing shop. It is the ideal vertical-down fillet welding electrode producing a fast freezing viscous slag. Typical applications of Ferrocraft 12XP include the all positional fillet welding of steel furniture, plates, fences, gates, pipes and tanks etc. Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ or DC- polarity. Electrode Approx Current Packet Carton Easyweld Part No Size mm Length mm Rods/Kg Range (amps) Handipak half pack 2.5kg 15kg – 6 x 2.5kg 612231 2.0 300 95 40–70 90 Rods 322128 2.5 300 55 60–100 5kg 15kg – 3 x 5kg 611232 2.5 300 55 60–100 half pack 2.5kg 15kg – 6 x 2.5kg 612232 1kg 322129 3.2 380 30 90–130 5kg 15kg – 3 x 5kg 611233 3.2 380 30 90–130 half pack 2.5kg 15kg – 6 x 2.5kg 612233 1kg 322138 4.0 380 19 130–180 5kg 15kg – 3 x 5kg 611234 Easyweld Blister Pack: 10 x 2.5mm/5 x 3.2mm rod Ferrocraft 12XP Blister Pack 322213

www.cigweld.com.au 29 30 MILD STEEL AND IRON POWDER ELECTRODES www.cigweld.com.au PRTN AAEES&PCAIGDETAILS:OPERATING PARAMETERS &PACKAGING ✮ ✮ ✮ ✮ ✮ ✮ ✮ ✮ ✮ EDN POSITIONS WELDING m)Aprg Polarity Amperage Ø (mm) SPEEDEX 12 ONADHRZNA ETCLOEHA HORIZONTAL/ OVERHEAD VERTICAL HORIZONTAL DOWNHAND . 3-8 AC /DCelectrode +/- AC /DCelectrode+/- 130-180 AC /DCelectrode+/- 90-130 90-130 4.0 55-80 3.2 55-80 3.2 2.5 2.5 RHS tubing. wrought iron, galvanisediron, metal, sheet Suitable forweldingmildsteel, rating orgreater.O.C.V. For useonweldingmachineswitha45 detachingslag. self Quick freezing, Excellent formisalignedjoints. arc withlowspatterloss. Speedex™ 12produces aquietsmooth Ideal fortheweldingofthinsteel. positions includingverticaldown. For filletandbuttweldinginall E4112/E6013 electrode. Speedex™ 12isauserfriendly akyr rjcs frames etc. back yard projects, ornamentaliron work, trailers, gates, Uses forSpeedex™12includetanks, .m 5g SP1240 SP12321 SP12132 SP1232 SP12251 SP12125 SP1225 0.45% Mn: 4.0mm (5kg) 3.2mm (1kg) 3.2mm (2.5kg) 3.2mm (5kg) 29% 2.5mm (1kg) 2.5mm (2.5kg) 2.5mm (5kg) 430MPa 490MPa PART NUMBERS: 80Jav@0°C E6013. 0.30% Si: 0.07% C: CHEMICAL ANALYSIS(TYPICAL): E4112-0. CVN Impact Values Elongation Tensile Strength Yield Stress MECHANICAL PROPERTIES (TYPICAL): AWS A5.1: AS/NZS 1553.1: CLASSIFICATIONS: 5 i 8 k 15kg 15kg 5kg 15kg 5kg 380 5kg 380 45A min 300 45A min 45A min C egh(m kCarton Pk Length(mm) OCV 380 2.5kg 15kg –6x2.5kg 15kg 2.5kg –6x2.5kg 15kg 2.5kg 380 300 VERTICAL OCV 45 VERTICAL DOWN DC AC 45 DC MILD STEEL AND IRON POWDER ELECTRODES SATINCRAFT 13 OCV AC

▲ General Purpose, Rutile Type Electrode. APPROVALS: ▲ Outstanding Operator Appeal! Lloyds Register of Shipping Grade 2. American Bureau of Shipping Grade 2. ▲ Versatile - All Positional Capabilities. Det Norske Veritas Grade 2. ▲ Smooth Mitre Fillet Welds with Low American Bureau of Shipping AWS A5.1 E6013. Spatter. TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: ▲ BLUE flux colour for instant I.D. Yield Stress 460 MPa Classifications: Tensile Strength 520 MPa Elongation 28% AS/NZS 1553.1: E4113-0. CVN Impact Values 60J av @ 0°C. AWS/ASME-SFA A5.1: E6013. TYPICAL ALL WELD METAL ANALYSIS: Description and Applications: C: 0.07% Mn: 0.60% Si: 0.50% Flat, horizontal-vertical, vertical-up and overhead - you can weld in any position with Satincraft 13. All positional - except That’s the beauty of Australia’s most popular G.P. electrode. vertical down Operating with either AC (min 45 O.C.V.) or DC current, Satincraft 13 produces smooth professional mitre fillet welds in all positions (except vertical-down) with very low spatter levels, positive re-strike (hot or cold) and self-releasing slag. Applications include the general workshop, field and structural welding of mild or galvanised steel components such as pipes, tanks, frames, fences and gates etc. Satincraft 13 is particularly recommended for the lap and fillet welding of thin walled galvanised and mild steels where the low spatter levels and excellent edge wetting produce superior results. Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ or DC- polarity. Electrode Approx No. Current Packet Carton Easyweld Part No Size mm Length mm Rods/kg Range (amps) Handipaks 2.5 300 53 55–90 5kg 15kg – 3 x 5kg 611182 2.5 300 53 55–90 half pack 2.5kg 15kg – 6 x 2.5kg 612182 1kg 610182 50 rod 322135 3.2 380 29 90–135 5kg 15kg – 3 x 5kg 611183 half pack 2.5kg 15kg – 6 x 2.5kg 612183 1kg 610183 25 25 rod 322136 4.0 380 20 135–180 5kg 15kg – 3 x 5kg 611184 Easyweld Blister Pack: 10 x 2.5mm/5 x 3.2mm rod Satincraft Blue Blister Pak 322203

www.cigweld.com.au 31 45 DC WELDCRAFT OCV AC ▲ Rutile - Basic Type Electrode. APPROVALS: ▲ Higher Radiographic Quality. Lloyds Register of Shipping Grade 3. ▲ American Bureau of Shipping Grade 3. Improved Grade 2 Impact Properties. Det Norske Veritas Grade 3. ▲ Versatile “Out-Of-Position” Capabilities. TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: Classifications: Yield Stress 420 MPa AS/NZS 1553.1: E4113-2. Tensile Strength 490 MPa AWS/ASME-SFA A5.1: E6013. Elongation 28% CVN Impact Values 60J av @ -20°C. Description and Applications: TYPICAL ALL WELD METAL ANALYSIS: Weldcraft is a popular, rutile - basic type electrode which C: 0.07% Mn: 0.60% Si: 0.50% combines excellent all positional welding capabilities (except vertical-down) with improved radiographic weld deposit soundness and impact toughness. All positional - except Weldcraft gives better control of the weld pool in vertical-up vertical down and overhead welding applications. As a direct result superior weld profile, edge wetting, penetration and slag lift are consistently achieved. Weld contours in the flat and horizontal-vertical positions are slightly convex and free from undercut. Weldcraft is suitable for “on site” and workshop welding where better mechanical properties are required and the work cannot be re-positioned to allow welding in the downhand. The electrode is recommended for welding joints subjected to radiographic examination in pressure vessel, ship building, bridge and storage tank MILD STEEL AND IRON POWDER ELECTRODES AND IRON POWDER MILD STEEL fabrications. Packaging and Operating Data: AC (minimum 50 O.C.V.), DC+ or DC- polarity. Electrode Approx No. Current Packet Carton Part No Size mm Length mm Rods/kg Range (amps) 2.5 300 51 60–95 5kg 15kg – 3 x 5kg 611202 3.2 380 27 95–135 5kg 15kg – 3 x 5kg 611203 4.0 380 17 130–185 5kg 15kg – 3 x 5kg 611204

32 www.cigweld.com.au MILD STEEL AND IRON POWDER ELECTRODES 33 AC DC 45 VERTICAL OCV OCV Length (mm) Pk Carton 45A min45A min45A min 300 380 380 5kg 5kg 5kg 15kg 15kg 15kg CHEMICAL ANALYSIS (TYPICAL): CHEMICAL ANALYSIS C: 0.08%Si: 0.35% NUMBERS: PART 2.5mm3.2mm4.0mm Mn: 0.43% SP1325 SP1332 SP1340 CLASSIFICATIONS: AS/NZS 1553.1:AWS A5.1: (TYPICAL): MECHANICAL PROPERTIES StressYield StrengthTensile ElongationValuesCVN Impact E4113-0. E6013. 60J av @ 0°C 500 MPa 430 MPa 28% Self-lifting slag with low spatter loss. Self-lifting slag for Speedex™ 13 is recommended steel and welding thin sections of mild galvanised steels. Easy to re-start. Speedex™ 13 is ideal for general purpose work such as frames, tanks, work. gates and light structural Speedex™ 13 is an easy running Speedex™ 13 purpose E4113/E6013 general electrode. in all fillet and butt welding For vertical down. positions except 2.53.24.0 60-90 90-135 135-180 /DC electrode +/- AC /DC electrode +/- AC /DC electrode +/- AC DOWNHAND HORIZONTAL VERTICAL OVERHEAD HORIZONTAL/ Ø (mm) Amperage Polarity SPEEDEX 13 SPEEDEX ✮ ✮ ✮ ✮ ✮ ✮ WELDING POSITIONS OPERATING PARAMETERS & PACKAGING PARAMETERS OPERATING DETAILS: www.cigweld.com.au 45 DC FERROCRAFT 21 OCV AC

▲ Rutile Type, Medium Iron Powder APPROVALS: Electrode. Lloyds Register of Shipping Grade 3. ▲ Excellent Operator Appeal! American Bureau of Shipping Grade 3. ▲ Det Norske Veritas Grade 3. Versatile - All Positional Capabilities. American Bureau of Shipping AWS A5.1 E7014. ▲ Easy Striking - Hot or Cold! TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: ▲ Ideal for Vertical Down Fillet Welding. Yield Stress 430 MPa ▲ Reliable Impact Toughness to -20°C. Tensile Strength 500 MPa Elongation 30% Classifications: CVN Impact Values. 90J av @ -20°C. AS/NZS 1553.1: E4814-2. TYPICAL ALL WELD METAL ANALYSIS: AWS/ASME-SFA A5.1: E7014. C: 0.06% Mn: 0.65% Si: 0.30% Description and Applications: # Ferrocraft 21 is a popular rutile type, medium iron powder All positional - welding electrode developed and manufactured in Australia by CIGWELD. It offers many features including smooth stable AC / DC running on low O.C.V. welding machines, excellent fillet shapes in all welding positions (including vertical-down/up and overhead) and a higher electrode efficiency of 110%. In addition, Ferrocraft 21 produces good radiographic quality, a self releasing slag and improved “Grade 2” (min 47J av @ - 20°C) impact properties.

Ferrocraft 21 is suitable for workshop or ‘on-site’ repair, maintenance and fabrication welding jobs

MILD STEEL AND IRON POWDER ELECTRODES AND IRON POWDER MILD STEEL where the iron powder addition gives improved usability over conventional E4112 rutile type electrodes. It is the ideal vertical-down fillet welding electrode for thinner steel sections using “Touch Welding” techniques. It produces a controllable fast freezing slag with outstanding slag lift and minimum undercut.

Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ or DC- polarity. Electrode Approx No. Current Packet Carton Easyweld Part No Size mm Length mm Rods/kg Range (amps) Handipaks 2.5 300 50 55–100 5kg 15kg – 3 x 5kg 611242 2.5 300 50 55–100 50 rod 322130 3.2 380 26 95–140 5kg 15kg – 3 x 5kg 611243 4.0 380 17 140–195 5kg 15kg – 3 x 5kg 611244 5.0 450 9 200-260 5kg 15kg – 3 x 5kg 611245 Easyweld Blister Pack: 10 x 2.5mm/5 x 3.2mm rod Ferrocraft 21 Blister Pack 322205 # –5.0mm Ferrocraft 21 is not recommended for out-of-position (ie vertical or overhead) welding applications.

34 www.cigweld.com.au 45 DC MILD STEEL AND IRON POWDER ELECTRODES FERROCRAFT 22 OCV AC

▲ Rutile Type High Iron Powder Electrode. APPROVALS: ▲ High Productivity Fillet and Butt Welding Lloyd’s Register of Shipping Grade 2Y. in All Downhand Positions. American Bureau of Shipping Grade 2. Det Norske Veritas Grade 2. ▲ Self Releasing Slag. American Bureau of Shipping AWS A5.1 E7024. Classifications: TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: AS/NZS 1553.1: E4824-0. Yield Stress 440 MPa AWS/ASME-SFA A5.1: E7024. Tensile Strength 512 MPa Elongation 25% Description and Applications: CVN Impact Values 60J av @ 0°C. Ferrocraft 22 is a rutile type high iron powder electrode for the higher productivity fillet and butt welding of mild steel in TYPICAL ALL WELD METAL ANALYSIS: all downhand ( flat and horizontal-vertical ) positions. C: 0.05% Mn: 0.75% Si: 0.25% Slag lift and “side wall” wash at weld toes are superb and welding speeds are approximately double those of conventional electrodes of equal size and length. Ferrocraft 22 is recommended for high production welding where large standing fillet welds are required. It is the ideal electrode for heavy structural welding applications such as tanks, frames, girders and beams, ship structures and rolling stock and general fabrication in the workshop or on-site.

Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ or DC- polarity. Electrode Approx No. Current Packet Carton Part No Size mm Length mm Rods/kg Range (amps) 2.5 350 34 85-120 5kg 15kg – 3 x 5kg 611252 3.2 380 18 130–170 5kg 15kg – 3 x 5kg 611253 4.0 450 11 185–235 5kg 15kg – 3 x 5kg 611254 5.0 450 7 260–320 5kg 15kg – 3 x 5kg 611255 # - Ferrocraft 22 is formulated to operate with AC (min 45 O.C.V.), DC+ or DC- polarity. The preferred polarity for DC fillet welding is DC+.

www.cigweld.com.au 35 65 DC FERROCRAFT 11 OCV AC ▲ Cellulose Pipe Welding Electrode. APPROVALS: ▲ All Positional, AC / DC Capabilities. Lloyds Register of Shipping Grade 3, 3Y. ▲ American Bureau of Shipping Grade 3. High Penetration, Root Pass Applications. Det Norske Veritas Grade 3. ▲ WHITE flux colour for easy I.D. American Bureau of Shipping AWS A5.1 E6011. Classifications: TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: AS/NZS 1553.1: E4111-2. Yield Stress 415 MPa AWS/ASME-SFA A5.1: E6011. Tensile Strength 500 MPa Elongation 28% Description and Applications: CVN Impact Values 90J av @ -20°C. Ferrocraft 11 is a cellulose electrode suitable for high TYPICAL ALL WELD METAL ANALYSIS: penetration welding applications using both AC and DC power C: 0.12% Mn: 0.47% Si: 0.10% sources. S: 0.007% P: 0.011% The deep penetration and fast freezing weld metal of Ferrocraft 11 make it ideal for the all positional (including vertical up/down and overhead) root pass welding of full All positional - welding penetration joints. A small iron powder addition to the Ferrocraft 11 flux coating gives it improved arc stability and smoother arc transfer. Ferrocraft 11 is recommended for root pass welding where the ‘stovepipe’ or ‘flick’ techniques can be used to achieve full root penetration. Typical applications include the root, hot, fill and capping pass welding of pipelines, pressure vessels, storage tanks, workshop and field constructions.

MILD STEEL AND IRON POWDER ELECTRODES AND IRON POWDER MILD STEEL Packaging and Operating Data: AC (minimum 65 O.C.V.), DC+ or DC- polarity. Electrode Approx No. Current Packet Carton Part No Size mm Length mm Rods/kg Range (amps) 2.5 300 62 65–85 5kg 15kg – 3 x 5kg 611132 3.2 380 33 95–125 5kg 15kg – 3 x 5kg 611133 4.0 380 22 130–160 5kg 15kg – 3 x 5kg 611134

36 www.cigweld.com.au DC MILD STEEL AND IRON POWDER ELECTRODES PIPEARC 6010P +

▲ User Friendly Pipe Welding Electrode. APPROVALS: ▲ Quieter, Forceful, Deep Penetrating Arc. American Bureau of Shipping AWS A5.1 E6010. ▲ Lower Spatter Levels and Easy Slag Removal. American Bureau of Shipping Grade 3. Det Norske Veritas Grade 3. ▲ Finer Ripples with Consistent Bead Shape. Lloyd’s Register of Shipping Grade 3. ▲ Excellent Reverse Bead Formation on Butts. TYPICAL ALL WELD METAL ANALYSIS: ▲ Versatile “Out-of-Position” Capabilities. C: 0.11% Mn: 0.46% Si: 0.15% ▲ Batch Numbered for On-the-Job Traceability. S: 0.011% P: 0.012% TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: Classifications: Yield Stress 400 MPa AS/NZS 1553.1: E4110-2. Tensile Strength 510 MPa AWS/ASME-SFA A5.1: E6010. Elongation 30% CVN Impact Values 65J av @ -20°C. Description and Applications: 40J av @ -30°C. PipeArc 6010P is a user friendly, high cellulose type electrode for welding mild steel in all welding positions. PipeArc 6010P exhibits The results quoted in this data sheet are obtained from the a quiet and forceful deep penetrating arc, quick freezing slag, listed Shipping Societies (ABS, DNV, LRS) Conformance Tests extra low spatter levels and easy slag removal. and Procedures. Actual weld metal mechanical properties PipeArc 6010P is designed specifically for pipe line welding using achieved with PipeArc 6010P are influenced by many Direct Current Electrode Positive (DC+). It can be used for the root, factors including, base metal analysis, welding parameters / fill and capping pass welding of full penetration joints in a wide heat input used, number of weld passes and run placement range of steels using “stovepipe” and “flick” techniques. Root etc. On the job mechanical tests may produce different passes (root runs) in single “V” butt preparations completed with results. PipeArc 6010P produce full and uniform penetration with excellent reverse bead formation. This electrode can be used for a wide range of applications such as, site fabrication work in the oil, LPG and LNG gas industries, All positional - welding shipbuilding, maintenance and general purpose work. PipeArc 6010P is used to weld out (root, fill and cap) steel pipes such as API 5L, 5LX grades X42 to X52. For the welding of “V” butt (groove weld) joints in higher strength steels, including 5LX grades X60, X65 and X70, PipeArc 6010P is recommended for root pass welding only. The fill and capping passes should be completed with PipeArc 7010P for X60 & X65 grades and PipeArc 8010P for X70 grades. Packaging and Operating Data: DC+ (Direct Current Electrode Positive) polarity. Electrode Approx No. Current Packet Carton Part No Size mm Length mm Rods/kg Range (amps) 2.5 300 66 45–85 5kg 15kg – 3 x 5kg 615602 3.2 350 39 70–125 5kg 15kg – 3 x 5kg 615603 4.0 350 25 120-190 5kg 15kg – 3 x 5kg 615604 4.8 350 18 160-250 5kg 15kg – 3 x 5kg 615605

www.cigweld.com.au 37 38 HYDROGEN CONTROLLED ELECTRODES 39 43 44 42 Page No Page HYDROGEN CONTROLLED ELECTRODES CONTROLLED HYDROGEN Description Storage and Reconditioning of Electrodes and Reconditioning Storage Hermetically Sealed 16TXP - Ferrocraft 7016 Ferrocraft 40 41 Ferrocraft 55U Ferrocraft 61 Ferrocraft Hermetically Sealed 61 H4 - Ferrocraft Sealed 61 Ni H4 - Hermetically Ferrocraft SealedA1- Hermetically Alloycraft 70 SealedAlloycraft 80-B2 - Hermetically SealedAlloycraft 80-C1 - Hermetically SealedAlloycraft 90-B3 - Hermetically SealedAlloycraft 90 - Hermetically SealedAlloycraft 110 - Hermetically 45 46 47 48 49 50 51 52 www.cigweld.com.au FERROCRAFT AND ALLOYCRAFT Advice on Storage and Reconditioning of CIGWELD Hydrogen Controlled Electrodes.

Storage Environments: Undamaged packs/cartons of Ferrocraft and Alloycraft electrodes stored at 50% R.H. or less and kept at 10-15°C (50- 60°F) above ambient temperature with a maximum of 40°C (105°F) stored off the ground and away from walls in cupboards, containers or warehouses are expected to maintain their designated hydrogen levels indefinitely.

Moisture Re-absorption: Cardboard packs/cartons of Ferrocraft and Alloycraft may lose their designated hydrogen status due to moisture re- absorption from poor storage environments. Where electrodes have been exposed to moisture or where hydrogen control is important, the following procedures are recommended for reconditioning.

Hermetically Sealed: Hermetically sealed, hydrogen controlled electrodes are air tight sealed to maintain product in an original “FACTORY FRESH” condition for an indefinite period provided the seal is unbroken. HYDROGEN CONTROLLED ELECTRODES Reconditioning and Hydrogen/Moisture Requirements:

AS/NZS 1553.1 low "H10" hydrogen status and AS/NZS 1553.1 very low "H5" hydrogen status and AWS A5.1 "H8" hydrogen status. AWS A5.1 "H4" very low hydrogen status. FERROCRAFT 16TXP FERROCRAFT 61 H4 FERROCRAFT 7016 FERROCRAFT 61 Ni H4 FERROCRAFT 55U ALLOYCRAFT 70-A1 FERROCRAFT 61 ALLOYCRAFT 80-B2 ALLOYCRAFT 90 ALLOYCRAFT 110 ALLOYCRAFT 80-C1 ALLOYCRAFT 90-B3

Rebake for maximum of 2 hrs @ 300°C (570°F) in Rebake for maximum of 2 hrs @ 350°C (660°F) in a vented oven and thereafter use from a hot a vented oven and thereafter use from a hot box set at 100 - 120°C (210 - 250°F). box set at 100 - 120°C (210 - 250°F).

40 www.cigweld.com.au HYDROGEN CONTROLLED ELECTRODES 41 AC DC 50 OCV All positional - except vertical down TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: MECHANICAL WELD METAL ALL TYPICAL Stress.Yield StrengthTensile ElongationValuesCVN Impact ANALYSIS: TYPICAL ALL WELD METAL C:Mn: 0.07% 1.50%S: 0.010% P: 0.015% 550 MPa. 460 MPa. AS3752: 90 J av @ -20°C. TO HYDROGEN LEVELS TYPICAL DIFFUSIBLE Si: 0.65% / 100gms of deposited weld metal 7.0–7.5 mls of hydrogen 27%. APPROVALS: Lloyds Register of ShippingAmerican Bureau of Shipping Grade 3,Veritas Det Norske H15. 3Y Grade 3H10, 3Y Grade 3Y H10. Electrode No. Approx Current Can Carton Easyweld No Part Easy operation,weld 3 Grade reliable status and low hydrogen metal properties the electrode 16TXP make of Ferrocraft jobs, ideal for maintenance welding of earth moving including the repair “buttering”equipment and the steel of of hard sections prior to the application surfacing. Hermetically Sealed Ring Pull Cans. Sealed Ring Hermetically “XP series” Electrode. Type / E7016 E4816 / Hydrogen Appeal Excellent Operator Controlled. Fewer 2.5mm Size For LONGER 350mm and Less Change-overs Electrode Wastage. 2.53.24.0 350 350 350 55 30 21 50–90 85–140 135–190 3kg 3kg 3kg 12kg – 4 x 3kg 12kg – 4 x 3kg 12kg – 4 x 3kg 613562 613563 613564 Packaging and Operating Data: and Operating Packaging Description and Applications: Description and Classifications: FERROCRAFT 16TXP – Hermetically Sealed – Hermetically 16TXP FERROCRAFT # - Ferrocraft 16TXP – Hermetically Sealed is formulated to operate with AC (50 O.C.V min), (50 O.C.V AC 16TXP – Hermetically Sealed is formulated to operate with # - Ferrocraft DC+ or DC- polarity. preferred The polarity for fillet welding and fill and capping passes is DC+. AC (minimum 50 O.C.V.),AC DC+ or DC- polarity. Size mm Length mm Rods/kg Range (amps) Handipack AS/NZS 1553.1A5.1: AWS/ASME-SFA E7016 H8. ‘XP series’, 16TXP is an Ferrocraft E4816/E7016 type hydrogen E4816-2 H10. offering controlled welding electrode from CIGWELD in all welding welding performance AC/DC exceptional positions, including vertical-up and overhead. It maintains the high level of quality,appeal already performance and operator 12XP. established with Ferrocraft performance,AC 16TXP produces excellent Ferrocraft welding machines AC particularly on portable 240V Turbo. and Easywelder 16TXP offers excellent low current Ferrocraft Turbo such as the CIGWELD Compact no undercut in the performance which is important for achieving the best bead shape whilst producing difficult vertical-up and overhead positions. is an easy-to-use,Ferrocraft E4816/E7016 type electrode for the all positional fillet and butt welding of heavier mild steel sections or joints under high restraint. It is also suitable for a wide range of welding applications on selected Carbon-Manganese, low alloy and cast steels. easy operation, The reliable Grade ideal for the electrode 16TXP make 3 weld metal properties and low hydrogen status of Ferrocraft maintenance welding jobs,‘buttering’ of steel and the including the repair of earth moving equipment sections prior to the application of hard surfacing. ▲ ▲ ▲ ▲ ▲ www.cigweld.com.au 42 HYDROGEN CONTROLLED ELECTRODES www.cigweld.com.au iem eghm osk Range(amps) Rods/kg capping passesisDC+. Theand fill preferredpolarityforfilletwelding DC+orDC-polarity.. # -Ferrocraft 7016isformulatedtooperatewith AC (55 O.C.V), Lengthmm Size mm DC+orDC-polarity.AC (minimum50O.C.V.), work. and shipbuildingequipmentrepairmaintenance bridge Typical applicationsincludepressurevesselfabrication, temperature impacttoughnessto-30°Cisrequired. recommended formorecriticalapplicationswherelow Itisalso is requiredandtheemphasisonoperatorappeal. down) filletandbuttweldingjobswhere “hydrogen control” Ferrocraft 7016isdesignedforallpositional(exceptvertical- reliable impacttoughnessto-30°C. givingexcellentallroundarcperformanceand electrode, controlled Ferrocraft 7016isaversatilehydrogen control andremove. The fullcoveringslagiseasyto E424B12H10 appearance andshape. penetratingarcwithexcellentbead and exhibitsasmooth, exceptvertical-down operator appealinallweldingpositions, Itgivesexcellent deposits weldmetalinthe550MPa class. hydrogencontrolledelectrodethat Ferrocraft 7016isabasic, E4816-3H10. E7016H8. BS EN499: AWS/ASME-SFA A5.1: AS/NZS 1553.1: ▲ ▲ ▲ ▲ Packaging andOperating Data: Description and Applications: Classifications: FERROCRAFT 7016 . 8 910105g1k k 611744 611743 15kg–3x5kg 15kg–3x5kg 5kg 5kg 120–180 90–130 19 29 380 380 4.0 3.2 Excellent Impact Toughness to-30 Ideal forFillandCappingPasses. Positions.in All Operator Appeal Excellent E7016 TypeElectrode. Fully BasicHydrogen Controlled E4816/ lcrd prxN.Cret aktCro Part No Carton Packet Current Approx No. Electrode ° C. :00%M:11%S:0.65% Si: * Reconditionedfor2hoursmaximum@300°C. metal *. 0.019% 5.0 -6.0mlsofhydrogen/100gmsdepositedweld P: 25% 1.10% Mn: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO AS3752: 480MPa 125Jav@-20°C 0.009% 570MPa S: 0.08% C: METALTYPICAL ALLWELD ANALYSIS: CVN Impact Values Grade3YH10. Elongation Tensile Strength Yield Stress AWS TYPICAL MECHANICALPROPERTIES:A5.1 E7016. 3Y. Grade3H10, Grade3YH10. American BureauofShipping Det Norske Veritas American BureauofShipping Lloyd’s RegisterofShipping APPROVALS: vertical downwelding All positional-except 100J av@-30°C OCV 50 DC AC HYDROGEN CONTROLLED ELECTRODES 43 AC DC O 70 OCV All positional - except vertical down APPROVALS: of ShippingLloyd's Register Veritas Det Norske MECHANICAL PROPERTIES: WELD METAL ALL TYPICAL Grade 3, 3YH15. StressYield StrengthTensile ElongationValuesCVN Impact Grade 3YH10. ANALYSIS: TYPICAL ALL WELD METAL C: 0.07%S: 0.007% 570 MPa. 70 J av @ -20°C. AS3752: 460 MPa. TO TYPICAL DIFFUSIBLE HYDROGEN LEVELS Mn: 0.80% P: weld 7.0 - 7.5 mls of hydrogen / 100gms of deposited 0.013% metal *. 29%. @ 300°C. * Reconditioned for 2 hours maximum Si: 0.77% Electrode No. Approx Current Packet Carton No Part Hydrogen Controlled E4816 / E7016 Type E7016 E4816 / Controlled Hydrogen Electrode. Applications. Welding Pass Ideal for Root Access. Easier Joint Thin Coated for for instant I.D. Tip Colour Purple End 2.53.24.0 350 380 380 53 31 19 40–90 60–140 90–180 5kg 5kg 5kg 15kg – 3 x 5kg 15kg – 3 x 5kg 15kg – 3 x 5kg 611492 611493 611494 Packaging and Operating Data: and Operating Packaging Description and Applications: Description and Classifications: FERROCRAFT 55U FERROCRAFT AC (minimum 70 O.C.V.),AC DC+ or DC- polarity. Size mm Length mm Rods/kg 55U is formulated to operate on low welding current to accommodate poor joint fit up and large root gaps.# - Ferrocraft electrode is The (minimum 70 O.C.V),AC suitable for DC+ or DC- polarity. polarity for ease of use in root pass welding is DC-. preferred The Where it is with DC+ polarity. necessary to maximise weld metal toughness fill and capping passes should be deposited Range (amps) Ferrocraft 55U is a basic,Ferrocraft hydrogen controlled electrode from CIGWELD offering very smooth running, excellent arc characteristics and good slag control. (except vertical Designed specifically for the all positional and plates,down) root pass welding of steel pipes Ferrocraft access.55U has a thin flux coating for easier joint When using the correct welding technique, polarity and current setting and even sound penetration beads of excellent appearance contour can be achieved. Depending on the joint properties required, 55U is suitable for fill and capping passes. Ferrocraft ▲ ▲ ▲ ▲ AS/NZS 1553.1:A5.1: AWS/ASME-SFA E7016 H8. E4816-2 H10. www.cigweld.com.au 44 HYDROGEN CONTROLLED ELECTRODES www.cigweld.com.au the workshoporonland. in onsite, ship construction andallmaintenancerepairwork; pipework, miningequipment, pressurevessels, parts, heavier steelsectionsunderhighrestraintsuchasmachinery (especially vertical-up)filletandbuttweldingapplicationson Ferrocraft 61isspecificallydesignedforallpositional manual arcelectrodes. has thehighoperatorappeal Welders demandfromtoday’s Voltage weldingmachines( Improved arccharacteristicsandstabilityonlowOpenCircuit to slightlyconvexprofile. Fillet weldshapeisexcellentandexhibitsatruemitre its type. toes andproducesverylowspatterlevelsforanelectrodeof gives improvedsidewall wash andreducedundercutatweld Ferrocraft 61 hydrogen controlledelectrodefromCIGWELD. userfriendly E4818-3H10. Ferrocraft 61isthelatestsmoothrunning, E7018. AWS/ASME-SFA A5.1: AS /NZS1553.1: ▲ ▲ ▲ ▲ iem eghm osk Range(amps) capping passesisDC+. The andfill preferredpolarityforfilletwelding DC+orDC-polarity. # -Ferrocraft 61isformulatedtooperatewith AC (55O.C.V min), Rods/kg Lengthmm Size mm DC+orDC-polarity.AC (minimum55O.C.V.), ▲ Packaging andOperating Data: Description and Applications: Classifications: FERROCRAFT 61 . 5 9–7 k 5g–3x5g611345 611344 611343 15kg–3x5kg 611342 15kg–3x5kg 15kg–3x5kg 15kg–3x5kg 5kg 5kg 5kg 5kg 195–270 145–220 95–150 65–100 9 16 24 42 450 380 380 5.0 350 4.0 3.2 2.5 Reliable ImpactProperties to-30 Excellent Out-of-Position Welding. Operator Appeal. Superb AC/DC / E7018 Type Electrode. Hydrogen Controlled E4818 Basic Coated, BATCH NUMBERIdentification. lcrd prxN.Cret aktCro Part No Carton Packet Current Approx No. Electrode ≥ 5OCV )ensureFerrocraft 61 55 O.C.V. ° C. * Reconditionedfor2hoursmaximum@300°C. metal *. 0.012% 8.5 -9.0mlsofhydrogen/100gmsdepositedweld P: 29%. 0.45% 1.45%Si: Mn: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO AS3752: 160Jav@-20°C. 450MPa. 0.010% 545MPa. S: 0.06% C: METALTYPICAL ALLWELD ANALYSIS: CVN Impact Values Grade3YH10. Elongation Tensile Strength Yield Stress. AWS TYPICAL A5.1 E7018. ALL WELD METAL MECHANICALPROPERTIES: 3Y. Grade3H15, 3YH15. Grade3, American BureauofShipping Det Norske Veritas American BureauofShipping Lloyd's RegisterofShipping APPROVALS: vertical down All positional-except 130 Jav@-30°C. OCV 55 DC AC HYDROGEN CONTROLLED ELECTRODES 45 AC DC 55 OCV 100 J av @ -40°C. 80 J av @ -50°C. All positional - except vertical down APPROVALS: Lloyd's Register of ShippingAmerican Bureau of ShippingVeritas Det Norske 3, Grade 3YH5. 3H5, Grade 3Y. Grade 3YH5. TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: MECHANICAL WELD METAL ALL TYPICAL Stress.Yield StrengthTensile ElongationValuesCVN Impact 545 MPa. ANALYSIS: TYPICAL ALL WELD METAL 450 MPa. 150 J av @ -20°C. C: 0.07%S: 0.07% 28%. AS3752: TO TYPICAL DIFFUSIBLE HYDROGEN LEVELS Mn:Si: 1.50% 0.35% weld 3.0 - 3.5 mls of hydrogen / 100gms of deposited P: 0.012% metal . C. ° Electrode No. Approx Current Can Carton No Part Recommended for critical DC welding Recommended applications. Batch Number Identification. Highly Basic,Type / E7018 E4818 electrode. controlled Hydrogen flux coating. resistant Advanced moisture / H4”“H5 low Very hydrogen diffusible class. impact for reliable C-Mn weld deposit to -40 properties AS: H5 Hydrogen status straight from the hermetically sealed can. resistant "R" classification of < or = 10mls of diffusible Hydrogen / 100 grams of deposited weld metal after 9 hours exposure to 27˚C and 80% relative humidity. 4.0 350 17 145–220 3kg 12kg – 4 x 3kg 614344 2.53.2 350 350 42 26 65–100 95–150 3kg 3kg 12kg – 4 x 3kg 12kg – 4 x 3kg 614342 614343 FERROCRAFT 61 H4 – Hermetically Sealed – Hermetically 61 H4 FERROCRAFT Packaging and Operating Data: and Operating Packaging Classifications: Applications: Description and AC (minimum 75 O.C.V.),AC DC+ or DC- polarity. Size mm Length mm Rods/kg Range (amps) Ferrocraft 61 H4 is a highly basic hydrogen controlled 61 H4 is a Ferrocraft and weld deposit electrode offering excellent weldability mechanical properties. 61 H4 is the first choice for Ferrocraft weld deposit critical welding applications where reliable impact toughness to -40˚C is required. are individually BATCH 61 H4 electrodes Ferrocraft NUMBERED for total "on the job traceability". advanced The 61 H4 ensures moisture resistant flux coating of Ferrocraft cold cracking in two excellent resistance to hydrogen induced important ways. -AWS: 61 H4 meets the very low Ferrocraft Firstly H4 and - moisture AS1553.1 H4 meets the 61 Secondly Ferrocraft ▲ ▲ AS /NZS 1553.1: AWS/ASME-SFA E4818-5 H5R. A5.1: E7018-1 H4R. ▲ ▲ ▲ ▲ www.cigweld.com.au 46 HYDROGEN CONTROLLED ELECTRODES www.cigweld.com.au iem eghm osk Range(amps) Rods/kg Lengthmm Size mm DC+orDC-polarity.AC (minimum75O.C.V.), SecondlyFerrocraft 61NiH4meetsthe AS1553.1 moistureresistant "R"classificationof

www.cigweld.com.au 55 45 SATINCROME 308L-17 OCV

▲ Rutile Type, Stainless Steel Electrode. COMPARABLE CIGWELD PRODUCTS: ▲ Outstanding Operator Appeal! Autocraft 308LSi GMAW wire AWS A5.9: ER308LSi. ▲ Now with Improved Slag Lift! Comweld 308L Gas/TIG wire ▲ All Positional (except vertical down) AWS A5.9: ER308L. Welding Capabilities. Shieldcrome 308LT & FCAW wires AWS A5.22: E308LT1-1/4 ▲ Advanced Moisture Resistant Flux Coating. APPROVALS: American Bureau of Shipping AWS A5.4: E308L-17. Classifications: TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: AS/NZS 1553.3: E308L-17. 0.2% Proof Stress 500 MPa AWS/ASME-SFA A5.4: E308L-17. Tensile Strength 630 MPa Description and Applications: Elongation 40% CVN Impact Values 75J av @ +20°C. Satincrome 308L-17 is a smooth running, rutile type stainless steel electrode manufactured by TYPICAL ALL WELD METAL ANALYSIS: CIGWELD for the all positional (except C: 0.025% Mn: 0.76% Si: 0.87% vertical-down) fillet and butt welding of 19Cr/10Ni Cr: 20.4% Ni: 9.8% S: 0.010% type stainless steels. P: 0.017%

The features of Satincrome 308L-17 include high FERRITE NUMBER: AC arc stability, sound radiographic quality, 3.0 - 10.0 FN* smooth arc transfer characteristics, very low * - using Severn Gauge spatter levels and excellent bead shape and contour. The advanced moisture resistant (MR) STAINLESS STEEL AND SPECIAL ELECTRODES STEEL STAINLESS flux coating provides improved resistance to All positional - except start-of-run porosity. Slag lift of Satincrome 308L-17 vertical down is enhanced in all welding positions, it is self peeling and non-spitting.

Applications of Satincrome 308L-17 include the single and multi-pass welding of 19Cr/10Ni type stainless steel grades including 201, 202, 301, 302, 303, 304, 304L, 305, 308 etc.

Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ polarity. Electrode Approx No. Current Packet Carton Part No Size mm Length mm Rods/kg Range (amps) 2.5 300 47 40–70 2.5kg 15kg – 6 x 2.5kg 611602 3.2 350 28 75–110 2.5kg 15kg – 6 x 2.5kg 611603 4.0 350 18 110–150 2.5kg 15kg – 6 x 2.5kg 611604

56 www.cigweld.com.au 45 STAINLESS STEEL AND SPECIAL ELECTRODES SATINCROME 309Mo-17 OCV ▲ Rutile Type, Stainless Steel Electrode. COMPARABLE CIGWELD PRODUCTS: ▲ Outstanding Operator Appeal! Autocraft 309LSi GMAW wire AWS A5.9: ER309LSi. ▲ Now with Improved Slag Lift! Comweld 309L Gas/TIG wire ▲ All Positional (except vertical down) AWS A5.9: ER309L. Welding Capabilities. Shieldcrome 309LT & FCAW wires AWS A5.22: E309LT1-1 ▲ Advanced Moisture Resistant Flux Coating. APPROVALS: American Bureau of Shipping AWS A5.4: E309Mo-17. Classifications: TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: AS/NZS 1553.3: E309Mo-17. 0.2% Proof Stress 500 MPa AWS/ASME-SFA A5.4: E309Mo-17. Tensile Strength 620 MPa Description and Applications: Elongation 35% CVN Impact Values 60 J av @ +20°C. Satincrome 309Mo-17 is a rutile type, high alloy stainless steel electrode manufactured by TYPICAL ALL WELD METAL ANALYSIS: CIGWELD for the all positional (except C: 0.05% Mn: 0.75% Si: 0.9% vertical-down) fillet and butt welding of 24Cr/13Ni Cr: 23.0% Ni: 13.0% Mo: 2.2% type stainless steels. S: 0.012% P: 0.017%

The features of Satincrome 309Mo-17 include high FERRITE NUMBER: AC arc stability, sound radiographic quality, 15.0 - 20.0 FN* smooth arc transfer characteristics, very low * - using Severn Gauge spatter levels and excellent bead shape and contour. The advanced moisture resistant (MR) flux coating provides improved resistance to All positional - except start-of-run porosity. vertical down Slag lift of Satincrome 309Mo-17 is enhanced in all welding positions, it is self peeling and non-spitting.

Applications of Satincrome 309Mo-17 include the single and multi-pass welding of matching 309 and 309L stainless steels. Satincrome 309Mo-17 is also suitable for the dissimilar welding of other “300 series” austenitic stainless steels and selected “400 series” ferritic grades to mild or low alloy steels such as 403, 405, 410, 416, 420, 430, 430F-Se, 446 etc and BHP 3CR12. Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ polarity. Electrode Approx No. Current Packet Carton Part No Size mm Length mm Rods/kg Range (amps) 2.5 300 52 40–70 2.5kg 15kg – 6 x 2.5kg 611692 3.2 350 30 75–110 2.5kg 15kg – 6 x 2.5kg 611693 4.0 350 19 110–150 2.5kg 15kg – 6 x 2.5kg 611694

www.cigweld.com.au 57 45 SATINCROME 316L-17 OCV

▲ Rutile Type, Stainless Steel Electrode. COMPARABLE CIGWELD PRODUCTS: ▲ Autocraft 316LSi GMAW wire Outstanding Operator Appeal! AWS A5.9: ER316LSi ▲ Now with Improved Slag Lift! Comweld 316L Gas/TIG wire ▲ All Positional (except vertical down) AWS A5.9: ER316L. Welding Capabilities. Shieldcrome 316LT & FCAW wires AWS A5.20: E316LT1-1 ▲ Advanced Moisture Resistant Flux APPROVALS: Coating. American Bureau of Shipping AWS A5.4: E316L-17. Classifications: TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: AS/NZS 1553.3: E316L-17. 0.2% Proof Stress 480 MPa AWS/ASME-SFA A5.4: E316L-17. Tensile Strength. 600 MPa Description and Applications: Elongation 40% CVN Impact Values 30 J av @ -120°C. Satincrome 316L-17 is a low carbon, rutile type stainless steel electrode manufactured by CIGWELD for the all positional TYPICAL ALL WELD METAL ANALYSIS: (except vertical-down) fillet and butt welding of 19Cr/10Ni C: 0.025% Mn: 0.8% Si: 0.85% type stainless steels. The features of Satincrome 316L-17 Cr: 19.4% Ni: 11.5% Mo: 2.5% include high AC arc stability, sound radiographic quality, S: 0.011% P: 0.017% smooth arc transfer characteristics, very low spatter levels and excellent bead shape and contour. The advanced moisture FERRITE NUMBER: resistant (MR) flux coating provides improved resistance to 3.0 - 10.0 FN* start-of-run porosity. Slag lift of Satincrome 316L-17 is * - using Severn Gauge enhanced in all welding positions, it is self peeling and non- spitting. Applications of Satincrome 316L-17 include the single All positional - except STAINLESS STEEL AND SPECIAL ELECTRODES STEEL STAINLESS and multi-pass welding of matching Molybdenum bearing vertical down stainless steels, 316 and 316L. Satincrome 316L-17 is also suitable for the general purpose welding of other “300 series” austenitic stainless steels including 301, 302, 303 and 304/304L, 305, 3CR12 types. The 2.5% Molybdenum content gives increased resistance to pitting corrosion and raises the creep strength for higher temperature applications. Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ polarity. Electrode Approx No. Current Packet Carton Easyweld Part No Size mm Length mm Rods/kg Range (amps) Handipack 2.0 300 87 35–55 2.5kg 15kg – 6 x 2.5kg 611661 2.5 300 46 40–70 2.5kg 15kg – 6 x 2.5kg 611662 3.2 350 28 75–110 2.5kg 15kg – 6 x 2.5kg 611663 4.0 350 18 110–150 2.5kg 15kg – 6 x 2.5kg 611664 Easyweld Blister Pack: 10 x 2.5mm/5 x 3.2mm rod Satincrome 316L-17 Blister Pack 322215

58 www.cigweld.com.au 45 STAINLESS STEEL AND SPECIAL ELECTRODES SATINCROME 318-17 OCV

(Supersedes Satincraft 318-16) TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: ▲ Rutile Type, Stainless Steel Electrode. 0.2% Proof Stress 490 MPa ▲ Tensile Strength 610 MPa Outstanding Operator Appeal! Elongation 36% ▲ Now with Improved Slag Lift! TYPICAL ALL WELD METAL ANALYSIS: ▲ All Positional (except vertical down) C: 0.04% Mn: 0.8% Si: 0.90% Welding Capabilities. Cr: 19.0% Ni: 12.0% Mo: 2.3% ▲ Advanced Moisture Resistant Flux Nb: 0.35% S: 0.017% P: 0.024% Coating. FERRITE NUMBER: 5.0 - 10.0 FN* Classifications: * - using Severn Gauge AS/NZS 1553.3: E318-17. AWS/ASME-SFA A5.4: E318-17. All positional - except Description and Applications: vertical down Satincrome 318-17 is a Niobium stabilised, rutile type stainless steel electrode manufactured by CIGWELD for the all positional (except vertical-down) fillet and butt welding of stabilised and unstabilised 19Cr/10Ni type stainless steels, such as 316, 318 and 321.

The features of Satincrome 318-17 include high AC arc stability, sound radiographic quality, smooth arc transfer characteristics, very low spatter levels and excellent bead shape and contour. The advanced moisture resistant (MR) flux coating provides improved resistance to start-of-run porosity. Slag lift of Satincrome 318-17 is enhanced in all welding positions, it is self peeling and non-spitting.

The Molybdenum content of Satincrome 318-17 gives improved resistance to pitting corrosion and the Niobium addition gives improved resistance to intergranular corrosion and good strength retention at elevated temperatures up to ≈ 700°C.

Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ polarity. Electrode Approx No. Current Packet Carton Easyweld Part No Size mm Length mm Rods/kg Range (amps) Handipaks 2.5kg 15kg – 6 x 2.5kg 611652 2.5 300 46 40–70 20 rod 322105 3.2 350 28 75–110 2.5kg 15kg – 6 x 2.5kg 611653

www.cigweld.com.au 59 45 SPEEDEX 308L-16 OCV

CLASSIFICATIONS: AS/NZS 1553.3: E308L-16. AWS A5.4: E308L-16. ✮ Speedex™ 308L-16 is a E308L-16 type stainless steel electrode. MECHANICAL PROPERTIES (TYPICAL): ✮ Designed for fillet & butt welding in Yield Stress 500 MPa all positions except Tensile Strength 630 MPa vertical-down. Elongation 40% ✮ Speedex™ 308L-16 offers low spatter CVN Impact Values 75J av @ +20°C levels with smooth running. ✮ Ideal for welding 304 and 304L CHEMICAL ANALYSIS (TYPICAL): stainless steel grades. C: 0.03% Cr: 20 % ✮ Applications for Speedex™ Mn: 0.76% Ni: 10% 308L-16 include stainless steel tanks, Si: 0.87% vessels, componentry. PART NUMBERS: Speedex™ 308L-16 is a E308L-16 type 2.5mm SPS30825 stainless steel electrode developed for the fillet 3.2mm SPS30832 & butt welding of 304 & 304L stainless steel 4.0mm SPS30840 grades. Speedex™ 308L-16 offers low spatter levels with smooth running. Applications for Speedex™ 308L-16 include STAINLESS STEEL AND SPECIAL ELECTRODES STEEL STAINLESS the welding of stainless steel pipes, tanks and vessels.

WELDING POSITIONS

DOWNHAND HORIZONTAL VERTICAL OVERHEAD HORIZONTAL/ VERTICAL

OPERATING PARAMETERS & PACKAGING DETAILS: Ø (mm) Amperage Polarity OCV Length (mm) Pk Carton 2.5 40-70 AC /DC electrode positive 45A min 300 2.5kg 15kg 3.2 75-110 AC /DC electrode positive 45A min 350 2.5kg 15kg 4.0 110-150 AC /DC electrode positive 45A min 350 2.5kg 15kg

60 www.cigweld.com.au 45 STAINLESS STEEL AND SPECIAL ELECTRODES SPEEDEX 309L-16 OCV

CLASSIFICATIONS: AS/NZS 1553.3: E309L-16. AWS A5.4: E309L-16. ✮ Speedex™ 309L-16 is a E309L-16 type stainless steel electrode. MECHANICAL PROPERTIES (TYPICAL): ✮ Designed for fillet & butt welding in Yield Stress 500 MPa all positions except Tensile Strength 620 MPa vertical down. Elongation 35% ✮ Speedex™ 309L-16 is a smoothing CVN Impact Values 60J av @ +20°C running electrode producing low spatter levels. CHEMICAL ANALYSIS (TYPICAL): ✮ Ideal for the welding of matching 309 C: 0.03% Cr: 23 % and 309L grades of stainless steel & Mn: 0.75% Ni: 13% dissimilar steels. Si: 0.9% ✮ Also suitable as an intermediate PART NUMBERS: buffer layer prior to hardfacing or as a stainless steel overlay on mild steel. 2.5mm SPS30925 3.2mm SPS30932 4.0mm SPS30940 Speedex™ 309L-16 is a E309L-16 type stainless steel electrode designed for fillet & butt welding of matching 309 & 309L grades of stainless steel. Speedex™ 309L-16 offers low spatter levels and smooth running. Applications for Speedex 309L-16 include the welding of matching stainless steel grades and used as an intermediate buffer layer prior to hardfacing. It is also recommended for the dissimilar joining of mild steel to stainless steel

WELDING POSITIONS

DOWNHAND HORIZONTAL VERTICAL OVERHEAD HORIZONTAL/ VERTICAL

OPERATING PARAMETERS & PACKAGING DETAILS: Ø (mm) Amperage Polarity OCV Length (mm) Pk Carton 2.5 40-70 AC /DC electrode positive 45A min 300 2.5kg 15kg 3.2 75-110 AC /DC electrode positive 45A min 350 2.5kg 15kg 4.0 110-150 AC /DC electrode positive 45A min 350 2.5kg 15kg

www.cigweld.com.au 61 45 SPEEDEX 316L-16 OCV

CLASSIFICATIONS: AS/NZS 1553.3: E316L-16. AWS A5.4: E316L-16. ✮ Speedex™ 316L-16 is a E316L-16 type stainless steel electrode. MECHANICAL PROPERTIES (TYPICAL): ✮ Designed for fillet and butt welding in Yield Stress 480 MPa all positions except vertical-down. Tensile Strength 630 MPa ✮ Speedex™ 316L-16 produces low Elongation 40% spatter levels as well as smooth CVN Impact Values 30J av @ -120°C running. ✮ For the welding of matching 316 and CHEMICAL ANALYSIS (TYPICAL): 316L stainless steel grades. C: 0.03% Cr: 19.5 % Mn: 0.8% Ni: 11.5% Si: 0.85% Mo: 2.5% Speedex™ 316L-16 is a E308L-16 type stainless steel electrode designed for fillet & butt welding of PART NUMBERS: matching 316 & 316L stainless steel grades. 2.5mm SPS31625 Speedex™ 316L-16 offers low spatter levels with smooth running. 3.2mm SPS31632 Applications for Speedex™ 316L-16 include the 4.0mm SPS31640 welding of matching grades used in pipes, tanks, 5.0mm SPS31650 vessels and componentry. STAINLESS STEEL AND SPECIAL ELECTRODES STEEL STAINLESS WELDING POSITIONS

DOWNHAND HORIZONTAL VERTICAL OVERHEAD HORIZONTAL/ VERTICAL

OPERATING PARAMETERS & PACKAGING DETAILS: Ø (mm) Amperage Polarity OCV Length (mm) Pk Carton 2.5 40-70 AC /DC electrode positive 45A min 300 2.5kg 15kg 3.2 75-110 AC /DC electrode positive 45A min 350 2.5kg 15kg 4.0 110-150 AC /DC electrode positive 45A min 350 2.5kg 15kg 5.0 145-210 AC /DC electrode positive 45A min 350 2.5kg 15kg

62 www.cigweld.com.au 45 STAINLESS STEEL AND SPECIAL ELECTRODES SPEEDEX 312-16 OCV

CLASSIFICATIONS: AS/NZS 1553.3: E312-16. AWS A5.4: E312-16. ✮ Speedex™ 312-16 is a E312-16 type stainless steel electrode designed for MECHANICAL PROPERTIES (TYPICAL): fillet & butt welding in all positions Yield Stress 635 MPa except vertical down. Tensile Strength 785 MPa ✮ Speedex™ 312-16 produces low Elongation 25% spatter levels as well as smooth CVN Impact Values 30J av @ +20°C running. ✮ Applications include the joining of CHEMICAL ANALYSIS (TYPICAL): stainless steels to mild steel and the C: 0.10% Cr: 26.5% welding of “unknown” steels. Mn: 0.62% Ni: 9.15% Si: 0.89% Speedex™ 312-16 is designed for repair and maintenance applications on tool and die steels and PART NUMBERS: steels of unknown compositions. 2.5mm SPS31225 Speedex™ 312-16 is also recommended for joining 3.2mm SPS31232 dissimilar steels such as mild steel to stainless steel. 4.0mm SPS31240 WELDING POSITIONS

DOWNHAND HORIZONTAL VERTICAL OVERHEAD HORIZONTAL/ VERTICAL

OPERATING PARAMETERS & PACKAGING DETAILS: Ø (mm) Amperage Polarity OCV Length (mm) Pk Carton 2.5 40-80 AC /DC electrode positive 45A min 300 2.5kg 15kg 3.2 75-110 AC /DC electrode positive 45A min 350 2.5kg 15kg 4.0 110-150 AC /DC electrode positive 45A min 350 2.5kg 15kg

www.cigweld.com.au 63 45 WELDALL OCV

▲ Easy-to-Use Rutile Type, High Alloy TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: Electrode. 0.2% Proof Stress 630 MPa ▲ Outstanding Operator Appeal! Tensile Strength 780 MPa ▲ Elongation 25% WELDS ALL Steels! CVN Impact Values 30 J av @ +20°C. ▲ Ideal for Repair & Maintenance Jobs. TYPICAL ALL WELD METAL ANALYSIS: ▲ Easy Arc Starting and Excellent C: 0.11% Mn: 0.60% Si: 0.88% Stability on Low O.C.V. Welding Cr: 27.0% Ni: 9.10% S: 0.011% Machines. P: 0.020% ▲ Not Recommended for Welding Cast Irons. All positional - except vertical down Classifications: AS/NZS 1553.3 E312-17. AWS/ASME-SFA A5.4: E312-17. Description and Applications: WELDALL is a highly alloyed stainless steel electrode which deposits a strong and ductile duplex austenite-ferrite weld metal extremely resistant to cracking. WELDALL has a host of features which make it suitable for the welding of all types of steels. These include; ✦ Easy arc starting and excellent stability on low Open Circuit Voltage (O.C.V) welding machines such as the CIGWELD Easywelder EC.

STAINLESS STEEL AND SPECIAL ELECTRODES STEEL STAINLESS ✦ Rutile type flux coating gives smooth, stable running in all positions (except vertical down) especially on low current settings. ✦ High ferrite ( ≈ 40%) austenitic stainless steel deposit gives excellent resistance to hot cracking, even when diluted with carbon, austenitic and high alloy steels. ✦ Weld deposit gives excellent resistance to corrosion and oxidation. WELDALL is recommended for the repair and maintenance of all steels, particularly those of unknown composition. It is suitable for; ✦ Joining dissimilar steels, such as stainless steel to carbon steel. ✦ Repairing die or tool steels. ✦ Use as a protective overlay against corrosion. ✦ Use as an intermediate or buffer layer prior to hard surfacing.

Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ polarity. Electrode Approx No. Current Packet Carton Easyweld Part No Size mm Length mm Rods/kg Range (amps) Handipaks 2.5 300 57 40–80 2.5kg 15kg – 6 x 2.5kg 611702 20 rod 322101 3.2 350 30 75–110 2.5kg 15kg – 6 x 2.5kg 611703 15 rod 322102 4.0 350 20 110–150 2.5kg 15kg – 6 x 2.5kg 611704 Easyweld Blister Pack: 10 x 2.5mm/5 x 3.2mm rod Weldall Blister Pack 322216

64 www.cigweld.com.au 45 STAINLESS STEEL AND SPECIAL ELECTRODES CASTCRAFT 55 OCV –

▲ Maintenance Welding of S.G. Cast Irons. CORE WIRE: ▲ Joins Cast Iron to Steel. Nickel Iron (55% Ni, 45% Fe) ▲ Lime Fluorspar / Graphite Coating. TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: Tensile Strength 500 MPa ▲ Higher Strength Nickel / Iron Deposit. Hardness. 220 HV30 ▲ Easy starting and Stable Running on TYPICAL ALL WELD METAL ANALYSIS: Portable 240V Welding Machines. C: 0.95% Mn: 0.65% Si: 0.25% Classifications: Al: 0.25% Ni: 53% Fe: Bal AWS/ASME-SFA A5.15: ENiFe-CI. COMPARABLE CIGWELD PRODUCTS: Nicore 55 Cast Iron Flux Cored Wire Description and Applications: AWS A5.15: ENiFe-CI. Castcraft 55 is a basic, graphite coated Nickel / Iron electrode manufactured by CIGWELD for the All downhand welding higher strength repair and maintenance welding of Spheroidal Graphite (S.G.) irons, austenitic cast irons, meehanites and a wide range of grey cast irons. It produces a soft stable arc with minimal penetration and spatter and is very tolerant to parent metal contaminants such as oil and dirt. The ductile Nickel / Iron weld deposit is machinable with the higher strength required for welding S.G. irons. Where higher joint strength is important, Castcraft 55 may be used for root and fill passes followed by capping passes with Castcraft 100 for a smoother surface finish.

Procedure for Welding Oil Contaminated Cast Iron: For welding oil impregnated cast iron an increased arc length of up to ≈ 6mm is recommended to reduce the porosity in the weld deposit (caused by the oil) to an acceptable level. For heavy oil contamination, preheating the cast iron up to 200°C will also help to reduce porosity levels. Packaging and Operating Data: AC (minimum 45 O.C.V.), DC- polarity. Electrode Approx No. Current Packet Carton Part No Size mm Length mm Rods/kg Range (amps) 2.5 300 49 35-85 2.5kg 15kg – 6 x 2.5kg 611722 3.2 350 31 75–120 2.5kg 15kg – 6 x 2.5kg 611723

www.cigweld.com.au 65 45 CASTCRAFT 100 OCV

▲ Maintenance Welding of Cast Irons. CORE WIRE: ▲ Lime Fluorspar / Graphite Coating. Nickel (98% Ni) ▲ Soft, Ductile Nickel Deposit. TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: Tensile Strength 400 MPa ▲ Easy starting and Stable Running on Hardness 170 HV Portable 240V Welding Machines. 30 TYPICAL ALL WELD METAL ANALYSIS: ▲ Smoother Weld Deposit Surface Finish. C: 1.0% Mn: 0.05% Fe: 0.5% Classifications: Si: 0.1% Al: 0.2% Ni: Bal AWS/ASME-SFA A5.15: ENi-CI. All downhand welding Description and Applications: Castcraft 100 is a basic, graphite coated electrode manufactured by CIGWELD for the repair and maintenance of a wide range of cast iron components.

It produces a soft stable arc with minimal penetration and spatter and is very tolerant to parent metal contaminants such as oil and dirt. The ductile Nickel based weld deposit is readily machinable with good colour match to most cast irons.

Applications of Castcraft 100 include the repair and reclamation of engine blocks, cylinder heads, differential housings, gear boxes, pump and machine housings and cast iron pulleys etc. In some applications Castcraft 100 is STAINLESS STEEL AND SPECIAL ELECTRODES STEEL STAINLESS preferred to Castcraft 55 because of the better ‘wetting’ action of the high nickel weld deposit.

Procedure for Welding Oil Contaminated Cast Iron: For welding oil impregnated cast iron an increased arc length of up to ≈ 6mm is recommended to reduce the porosity in the weld deposit (caused by the oil) to an acceptable level. For heavy oil contamination, preheating the cast iron up to 200°C will also help to reduce porosity levels. Packaging and Operating Data: AC (minimum 45 O.C.V.), DC- polarity. Electrode Approx No. Current Packet Carton Easyweld Part No Size mm Length mm Rods/kg Range (amps) Handipaks 2.5 300 49 55–85 2.5kg 15kg – 6 x 2.5kg 611732 20 rod 322110 3.2 350 31 75–120 2.5kg 15kg – 6 x 2.5kg 611733 15 rod 322111 Easyweld Blister Pack: 10 x 2.5mm/5 x 3.2mm rod Castcraft 100 Blister Pack 322217

66 www.cigweld.com.au 45 STAINLESS STEEL AND SPECIAL ELECTRODES BRONZECRAFT AC-DC OCV ▲ For Welding Copper and Copper Alloys. TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: ▲ Also for Joining Copper and Copper 0.2% Proof Stress 315 MPa Alloys to Steel. Tensile Strength 460 MPa Elongation 22% ▲ Easy to use, High Quality Weld Hardness. 120 HV30 Deposit Appearance. TYPICAL ALL WELD METAL ANALYSIS: Classifications: Mn: 0.02% Sn: 7.50% Al: 0.008% AS/NZS 2576: E 6200 - A2 P: 0.26% Fe: 0.20% Cu: Bal AWS/ASME-SFA A5.6: E CuSn - C COMPARABLE CIGWELD PRODUCTS: Autocraft Silicon Bronze Copper Alloy MIG Wire Description and Applications: AWS A5.7: ERCuSi-A. Fully extruded phosphor bronze electrode Comweld Silicon Bronze Copper Alloy TIG Wire containing approximately 7% tin. AWS A5.7: RCuSi-A. The covering is a fully extruded graphite / lime fluorspar type giving an extremely soft arc action similar to the CASTCRAFT series. All positional - except vertical down The BRONZECRAFT AC-DC electrode deposits dense, sound weld metal comparable in physical properties and colour to phosphor bronze. Suitable for welding copper and copper base alloys. Building up parts in gun-metal, phosphor bronze, aluminium bronze and silicon bronze alloys. ✦ Bronze ship propellers ✦ Copper bus-bars ✦ Copper to steel ✦ Bearing surfaces ✦ Impeller blades Suitable also for some cast irons. Packaging and Operating Data: AC (minimum 45 O.C.V.), DC- polarity. Electrode Approx No. Current Packet Carton Part No Size mm Length mm Rods/kg Range (amps) 3.2 350 30 70–110 2.5kg 15kg – 6 x 2.5kg 611783

www.cigweld.com.au 67 ARCAIR® DC GOUGING CARBONS ▲ Fast, Clean, Smooth, hassle-free Gouging. ▲ Able to Remove Metal from a Wide Range of Common Ferrous & Non-Ferrous Metals. ▲ Designed for DC Operation. ▲ Superior arc stability.

Description and Applications: CIGWELD Arcair DC gouging carbons are made by mixing carbon/graphite with a binder, baking, and then coating with a controlled thickness of copper. Carbons are available in three types; Pointed, Jointed and Flat. ✦ Pointed carbons are the standard all purpose gouging electrode. Controlled copper coating improves electrical conductivity providing more efficient, cooler operation and helps maintain electrode diameter at the point of the arc. ✦ Jointed carbons have the added benefit of working without stub loss, with each rod having a female socket and matching male tang. They can be used with semi and fully automatic torches. ✦ Flat carbons are specially designed for close tolerance metal removal and scarfing applications, producing a rectangular groove.

Air-carbon arc gouging is done in the downhand, vertical, horizontal and overhead position with a stick out of 180mm and an electrode angle of approximately 35 degrees, depending on the application. The groove width obtained will be approximately 3mm wider than the carbon size. The gouging action occurs when the arc is struck, removing molten metal as the electrode is moved along the workpiece. A slow travel speed produces a deep groove, a fast travel speed produces a shallow groove. The air flow must be turned on before gouging commences. The operator must ensure that adequate eye (shade 12-14), ear STAINLESS STEEL AND SPECIAL ELECTRODES STEEL STAINLESS and clothing protection is worn.

Severing (cutting) is a form of gouging where the operator holds the electrode at a steeper travel angle (70 - 80°) to the workpiece and moves the arc in a sawing motion (Figure 1). A gouging carbon can cut non-ferrous materials 1.5 times its own thickness.

Washing is a form of gouging that allows the removal of metal from large areas, hardfacing deposits and riser pads on castings. An arc is struck and then the electrode is weaved from side to side using a travel angle of 15 - 70° to the workpiece, depending on the required depth of the gouge. (Figure 2)

Bevelling can be achieved by using a travel angle of 90 degrees and a work angle equal to the bevel angle (Figure 3).

68 www.cigweld.com.au STAINLESS STEEL AND SPECIAL ELECTRODES ARCAIR® DC GOUGING CARBONS

CIGWELD Arcair gouging carbons are used for the efficient gouging, back gouging, plate edge preparation, touching up and removal of old or defective hardfacing and stainless steel weld deposits. They are used for reworking plates, dies, castings, pipes, armour plating etc. They gouge and sever ferrous and non-ferrous metals such as carbon steel, low alloy steel, stainless steel, cast iron, nickel alloys (nickel less than 80%), magnesium alloys and aluminium on DCEP. Copper alloys, aluminium bronze alloys and aluminium nickel bronze alloys can be gouged using DCEN.

Air carbon-arc gouging is used in many industries such as agriculture, automotive, heavy fabrication, construction, foundries, maintenance and repair shops, mining and quarrying, military, shipyards, power plants, railroads, steel mills to name a few.

Conditioning Data: If carbons are damp, they should be redried at 180°C for 10 hours, otherwise they may shatter.

HIGH EFFICIENCY GOUGING CARBONS: Arcair’s high efficiency gouging carbon takes carbon technology and performance to a new level. Formulated with a reduced carbon content and increased copper coating they can carry a current up to 800 amps (an increased carrying capacity of 25%) while giving up to 10% greater metal removal. The improved outer strength of these carbons allows for additional stick out length and the fluted exterior adds to the improved current flow and carrying capacity.

Packaging and Operating Data: CIGWELD Size Rods per Current range Air Pressure Part No. (mm) pack (Amps) (kPa) (L/min) POINTED 22043003 6.5 x 305 50 300 - 400 550 - 690 450 22053003 8 x 305 50 350 - 450 550 - 690 450 22063003 9.5 x 305 50 450 - 600 550 - 690 450 JOINTED 24104003 16 x 430 100 1000 - 1250 550 - 690 930 24124003 19 x 430 100 1250 - 1600 550 - 690 930 FLAT 35033003 15 x 5 x 305 50 450 - 600 550 - 690 450

HIGH 22155006 9.5 50 450-800 550-690 450 EFFICIENCY

www.cigweld.com.au 69 70 COBALARC HARDFACING CONSUMABLES COBALARC & STOODY HARDFACING CONSUMABLES Description Page No Cobalarc Austex 72 Cobalarc Mangcraft 73 Cobalarc 350 74 Cobalarc 650 75 Cobalarc 750 76 Cobalarc Toolcraft 77 Cobalarc CR70 78 Cobalarc Borochrome 79 Cobalarc 1e 80 Cobalarc 9e 81 Stoody Tube Borium AC-DC (Cobalarc 4) 82 Stoody Dynamang-O (Cobalarc Mang Nickel-O) 84 Stoody Buildup-O (Cobalarc 250-O) 85 Stoody Super Buildup-G/O (Cobalarc 350-G/O) 86 Stoody 965-G/O (Cobalarc 650-G/O) 87 Stoody 850-O 88 Stoody 101 HC-G/O (Cobalarc Coarseclad-G/O (1.2, 1.6)) 89 Stoody 100 HC-O (Cobalarc Coarseclad-O (2.4 & 2.8)) 90 Stoody Fineclad-O (Cobalarc Fineclad-O) 91 Stoody 110 MC (Cobalarc Crome Mang-O) 92 Stoody 104 (Cobalarc 104-SA) 93 Stoody 105 (Cobalarc 105-SA) 94 Stoody 107 (Cobalarc 107-SA) 95 Stoody 600 (Cobalarc Impactaclad-O) 96 Stoody 143-O (Cobalarc Abrasoclad-O) 97 Stoody 145 Open Arc Wire 98 Stoody RA45-0 99 Stoody ‘S’ Flux 100

www.cigweld.com.au 71 50 DC COBALARC AUSTEX 400 OCV AC

▲ Metal Enriched, Rutile Type Electrode. TYPICAL ALL WELD METAL DEPOSIT ANALYSIS: ▲ For Joining Dissimilar steels or as a Buffer C: 0.10% Mn: 1.50% Si: 0.90% Cr: 24.5% Ni: 9.3% Layer Prior to Hard Surfacing. TYPICAL WELD DEPOSIT HARDNESS: ▲ Tough, Machinable Austenitic Stainless HRC HV30 Steel Deposit. All Weld Metal Deposit 20 240 3.2mm size can be used for vertical welding by depositing Work Hardened Deposit 40 400 overlapping horizontal stringer passes. FINISHING RECOMMENDATIONS: Classifications: Machinable with Carbide Tools. AS/NZS 2576: 1315-A4. W.T.I.A.Tech Note 4: 1315-A4. Downhand & Horizontal joining and build-up applications:- Description and Applications: 3.2mm size can be used for Cobalarc AUSTEX is a metal enriched, rutile type vertical welding by depositing extruded electrode manufactured by CIGWELD. It overlapping horizontal stringer produces a smooth arc action and higher passes. deposition rates than conventional stainless steel electrodes. Deposited weld metal has high strength and toughness in combination with excellent corrosion resistance and tolerance to dilution. Under heavy impact weld deposits will work harden. Typical applications of Cobalarc AUSTEX include the joining of dissimilar steels, in particular austenitic manganese steels or stainless steels to mild steel and deposition as a buffer layer prior to hard surfacing. The high tolerance to dilution makes Cobalarc AUSTEX ideal for crack repairs on high carbon steel components or manganese steel castings. Packaging and Operating Data: AC (50 O.C.V.), DC+ or DC– polarity. Electrode No. of Electrodes Current Packet Carton Part No COBALARC & STOODY HARDFACING CONSUMABLES HARDFACING & STOODY COBALARC Size mm Length mm per kg. Range (amps) 3.2 380 20 105–140 5kg 15kg – 3 x 5kg 613973 4.0 380 13 140–180 5kg 15kg – 3 x 5kg 613974 5.0 450 7 170-210 5kg 15kg – 3 x 5kg 613975

72 www.cigweld.com.au 55 DC COBALARC HARDFACING CONSUMABLES COBALARC MANGCRAFT 425 OCV AC

▲ Austenitic Manganese Steel Electrode TYPICAL ALL WELD METAL DEPOSIT ANALYSIS: for Building Up & Reinforcing 11-14% C: 0.60% Mn: 12.0% Si: 0.10% Manganese Steel Components. TYPICAL WELD DEPOSIT HARDNESS: ▲ Tough and Impact Resistant. HRC HV30 ▲ Work Hardens Under Impact. All Weld Metal Deposit 15 --- Work Hardened Deposit 43 425 Classifications: FINISHING RECOMMENDATIONS: AS/NZS 2576: 1215 - A4. Machinable with Carbide Tools. W.T.I.A.Tech Note 4: 1215 - A4. COMPARABLE CIGWELD PRODUCTS: Description and Applications: Stoody Dynamang-O tubular wire Cobalarc MANGCRAFT is a smooth running AS/NZS 2576: 1215-B7 electrode depositing austenitic manganese steel weld metal. The deposits are extremely tough Downhand & Horizontal with high resistance to impact. They will work build-up applications harden under impact loading giving added abrasion resistance.

Mangcraft is used for rebuilding austenitic manganese steel components either to finished dimensions or prior to applying an overlay of more abrasion resistant material.

Typical components include dredge bucket lips, swing hammers, grizzleys, bucket teeth, blow bars, crusher jaws, liners and concaves. Keep austenitic manganese steels cool during welding. Do not preheat. Use intermittent or staggered weld runs and water quench at frequent intervals if necessary. Packaging and Operating Data: AC (55 O.C.V.), DC+ or DC– polarity. Electrode No. of Electrodes Current Packet Carton Part No Size mm Length mm per kg. Range (amps) 4.0 380 17 130–170 5kg 15kg – 3 x 5kg 611504 5.0 450 10 150–200 5kg 15kg – 3 x 5kg 611505

www.cigweld.com.au 73 50 DC COBALARC 350 OCV AC

▲ Metal Enriched, Rutile Type Electrode. TYPICAL ALL WELD METAL DEPOSIT ANALYSIS: ▲ For Re-building Worn Steel Components. C: 0.07% Mn: 0.85% Si: 0.30% Cr: 1.85% Mo: 0.5% ▲ Tough, Machinable Low Carbon TYPICAL WELD DEPOSIT HARDNESS: Martensitic Steel Deposit. HRC HV30 ▲ For the manual arc build-up and Single Layer on Mild Steel 28 290 surfacing of steel gear, shafts, rails, shovel All Weld Metal Deposit 35 350 pads, track links, rolls and wheels etc. FINISHING RECOMMENDATIONS: 3.2mm and 4.0mm sizes can be used for vertical welding by Machinable. depositing overlapping horizontal stringer passes. COMPARABLE CIGWELD PRODUCTS: Classifications: Stoody Super Build up-O tubular wire AS/NZS 2576: 1435-A4. AS/NZS 2576: 1435-B5/B7 W.T.I.A.Tech Note 4: 1435-A4. Downhand & Horizontal surfacing and build-up Description and Applications: applications:- Cobalarc 350 is a metal enriched, rutile type 3.2mm and 4.0mm sizes can electrode recommended for the multi-layer be used for vertical welding by build-up and surfacing of steel components depositing overlapping subjected to metal-to-metal wear and horizontal stringer passes. compressive loading. COBALARC HARDFACING CONSUMABLES HARDFACING COBALARC Depositing a tough, air hardening low carbon martensitic steel weld deposit Cobalarc 350 is recommended for the manual arc build-up and surfacing of steel gears, shafts, rails, shovel pads, track links, rolls and wheels etc. Packaging and Operating Data: AC (minimum 55 O.C.V.), DC+ or DC– polarity. Electrode No. of Electrodes Current Packet Carton Part No Size mm Length mm per kg. Range (amps) 3.2 380 25 100–150 5kg 15kg – 3 x 5kg 611443 4.0 380 16 140–200 5kg 15kg – 3 x 5kg 611444 4.0 380 16 140–200 1kg 12kg – 12 x 1kg 610444

74 www.cigweld.com.au 50 DC COBALARC HARDFACING CONSUMABLES COBALARC 650 640 OCV AC

▲ Basic Type Manual Arc Welding Electrode. TYPICAL ALL WELD METAL DEPOSIT ANALYSIS: ▲ Resistant to Hard Particle Abrasion C: 0.58% Mn: 1.1% Si: 0.6% Cr: 5.3% Mo: 0.25% and Moderate Impact Loading. TYPICAL WELD DEPOSIT HARDNESS: ▲ Air Hardening, Crack Free, HRC HV30 Martensitic Steel Deposit - 650 HV30 Single Layer on Mild Steel 55 600 All Weld Metal Deposit 57 640 Classifications: FINISHING RECOMMENDATIONS: AS/NZS 2576: 1855-A4. Not Machinable / Grinding only. W.T.I.A.Tech Note 4: 1855-A4. COMPARABLE CIGWELD PRODUCTS: Stoody 965 G/O tubular wire AS/NZS 2576: 1855-B5/B7 Description and Applications: Stoody 850-O tubular wire Cobalarc 650 is a basic electrode for the hard AS/NZS 2576: 1865-B7 surfacing of steel components subjected to wet or dry hard particle abrasion and low to moderate impact loading. Downhand & Horizontal surfacing applications: - The air hardening, low alloy steel deposit of Cobalarc 650 remains crack free on most steels 3.2mm and 4.0mm sizes can under normal welding conditions and is therefore be used for vertical welding by recommended for hard surfacing components depositing overlapping subject to flexing during service. horizontal stringer passes. The basic flux coating gives excellent resistance to rust, mill scale, dirt and oil on the surface being hardfaced. Typical applications include the surfacing of agricultural points, shares and tynes, grader and dozer blades, conveyor screws and post hole augers etc. Packaging and Operating Data: AC (minimum 55 O.C.V.), DC+ or DC– polarity. Electrode No. of Electrodes Current Packet Carton Part No Size mm Length mm per kg. Range (amps) 3.2 380 31 105–135 5kg 15kg – 3 x 5kg 611463 4.0 380 21 140–180 5kg 15kg – 3 x 5kg 611464

www.cigweld.com.au 75 45 COBALARC 750 800 OCV ▲ Rutile type, AC/DC Hard Surfacing TYPICAL ALL WELD METAL DEPOSIT ANALYSIS: Electrode. C: 0.60% Mn: 0.46% Si: 0.75% Cr: 5.9% Mo: 0.40% ▲ Resistant to Hard Particle Abrasion. TYPICAL WELD DEPOSIT HARDNESS: ▲ Air Hardening, Crack Free, HRC HV30 Martensitic Steel Deposit - 750 HV30 Single Layer on Mild Steel 64 800 ▲ Easy Arc Starting and Stable Running Two Layers on Mild Steel* 62 750 on Portable AC Welding Sets ( ≥ 45 O.C.V. ). *Not recommended for multi-pass welding heavier than 3 layers FINISHING RECOMMENDATIONS: Not Machinable / Grinding only. Classifications: COMPARABLE CIGWELD PRODUCTS: AS/NZS 2576: 1860-A4. Cobalarc 650 manual arc electrode W.T.I.A.Tech Note 4: 1860-A4. AS/NZS 2576: 1855-A4 Stoody 965-G/O tubular wire Description and Applications: AS/NZS 2576: 1855-B5/B7 Cobalarc 750 is a NEW smooth running, rutile Stoody 850-O tubular wire type electrode specifically designed for AC hard AS/NZS 2576: 1865-B7 surfacing applications in the workshop or on the land. Downhand & Horizontal It gives smooth stable arcing on AC or DC welding hard surfacing applications:- machines and is particularly suitable for surfacing COBALARC HARDFACING CONSUMABLES HARDFACING COBALARC 3.2mm and 4.0mm sizes can with portable AC welding sets (with ≥ 45 Open Circuit Volts) such as the CIGWELD Easywelder. be used for vertical welding by depositing overlapping Cobalarc 750 should be used with a touch welding horizontal stringer passes. or short arc technique and 1-2 layers are recommended for maximum deposit hardness. When hard surfacing high carbon or low alloy steel components a buffer or buttering layer of Ferrocraft 16TXP or Ferrocraft 7016 is recommended prior to depositing Cobalarc 750. Typical applications include the surfacing of agricultural equipment and components including points, shares, post hole augers, ripper teeth and tynes etc. Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ polarity. Electrode No. of Electrodes Current Packet Carton Part No Size mm Length mm per kg. Range (amps) 3.2 380 26 95–130 5kg 15kg – 3 x 5kg 611473 4.0 380 17 120–170 5kg 15kg – 3 x 5kg 611474 Easyweld Blister Pack: 10 x 3.2mm rod Cobalarc 750 Blister Pack 322218

76 www.cigweld.com.au 55 COBALARC HARDFACING CONSUMABLES COBALARC TOOLCRAFT 700 OCV

▲ Versatile Manual Arc Welding Electrode. TYPICAL ALL WELD METAL DEPOSIT ANALYSIS: ▲ Secondary Hardening, Shock Resistant C: 0.58% Mn: 0.10% Si: 0.20% Properties. Cr: 5.5% Mo: 6.8% ▲ Crack Free Cr-Mo Steel Deposit for TYPICAL WELD DEPOSIT HARDNESS: Repairing Blades, Dies, Punches etc. HRC HV30 Single Layer on Mild Steel 55 600 ▲ Also Suitable for General Hard Surfacing All Weld Metal Deposit 60 700 in Low Stress Abrasion Conditions. FINISHING RECOMMENDATIONS: 3.2mm size can be used for vertical welding by depositing Not Machinable / Grinding only. overlapping horizontal stringer passes. Classifications: Downhand & Horizontal surfacing applications:- AS/NZS 2576: 1560-A4. 3.2mm size can be used for W.T.I.A.Tech Note 4: 1560-A4. vertical welding by depositing overlapping horizontal stringer Description and Applications: passes. Cobalarc Toolcraft is a versatile electrode for welding on mild, carbon and low alloy steels. The weld deposit has excellent abrasion / shock resistance and secondary hardness retention to 500°C. The air hardening, low alloy Cr–Mo steel deposit of Cobalarc Toolcraft remains crack free on most steels under normal welding conditions and deposits can be ground to produce a long-lasting cutting edge. Typical applications include the maintenance/repair of guillotine blades, cutting knives, punches, axes, lathe tools, chisels and debarking hammers. Cobalarc Toolcraft is also suitable for general hard surfacing applications under low stress abrasion conditions.

Deposit Annealing and Hardening: Cobalarc Toolcraft deposits can be annealed by slow heating to 800°C, holding at temperature for one hour followed by furnace cooling. For deposit re-hardening to ≈ 60 HRc preheat slowly to 800 - 850°C then rapidly to 1250 - 1300°C, hold at temperature for ≈ 10 minutes and then quench in oil. For full hardness, temper twice at 520 - 530°C for one hour. Packaging and Operating Data: AC (minimum 45 O.C.V.), DC+ polarity. Electrode No. of Electrodes Current Packet Carton Part No Size mm Length mm per kg. Range (amps) 2.5 300 54 60–90 20 rods 322115 3.2 380 28 90–125 5kg 15kg – 3 x 5kg 611523

www.cigweld.com.au 77 50 COBALARC CR70 590 OCV

▲ Highly Alloyed Manual Arc Electrode. TYPICAL WELD DEPOSIT ANALYSIS: Single Layer on Mild Steel: ▲ High Chromium Carbide Iron Deposit. C: 3.3% Mn: 1.5% Si: 1.0% Cr: 25% ▲ Primary Chromium Iron Carbides in a All Weld Metal Deposit: Single Layer. C: 4.0% Mn: 1.8% Si: 1.2% Cr: 31% ▲ Ideal for Coarse Abrasion and Low to TYPICAL WELD DEPOSIT HARDNESS: Moderate Impact Loading. HRC HV30 ▲ Single Layer on Mild Steel 55 600 Typical applications of Cobalarc CR70 All Weld Metal Deposit 59 690 include the hard surfacing of crusher Deposits contain Chromium Carbides with hardness up to cones and mantles, swing hammers, 1,500 HV. bucket teeth and lips, dozer end plates FINISHING RECOMMENDATIONS: and sugar mill rolls etc. Grinding only. 3.2mm and 4.0mm sizes can be used for vertical welding by depositing overlapping horizontal stringer passes. COMPARABLE CIGWELD PRODUCTS: Stoody 100 HC-G/O tubular wire Classifications: AS/NZS 2576: 2360-B5/B7 AS/NZS 2576: 2355-A4. W.T.I.A.Tech Note 4: 2355-A4. Downhand & Horizontal Description and Applications: surfacing applications:- 3.2mm and 4.0mm sizes can Cobalarc CR70 is a popular high alloy extruded be used for vertical welding by COBALARC HARDFACING CONSUMABLES HARDFACING COBALARC hard surfacing electrode manufactured by depositing overlapping CIGWELD. The weld deposit of Cobalarc CR70 horizontal stringer passes. produces a high level of primary chromium carbides resistant to coarse abrasion (in particular gouging abrasion) and moderate impact loading at temperatures up to ≈ 650°C. Weld deposits can be finished by grinding and are best limited to two layers because of relief checking. Typical applications of Cobalarc CR70 include the hard surfacing of crusher cones and mantles, swing hammers, bucket teeth and lips, dozer end plates and sugar mill rolls etc. Packaging and Operating Data: AC (minimum 50 O.C.V.), DC+ polarity. Electrode No. of Electrodes Current Packet Carton Part No Size mm Length mm per kg. Range (amps) 3.2 380 18 90–140 5kg 15kg – 3 x 5kg 613493 4.0 380 11 130–200 5kg 15kg – 3 x 5kg 613494 5.0 450 6 180–250 5kg 15kg – 3 x 5kg 613495

78 www.cigweld.com.au 50 COBALARC HARDFACING CONSUMABLES COBALARC BOROCHROME 700 OCV

▲ Highly Alloyed Manual Arc Electrode. TYPICAL WELD DEPOSIT ANALYSIS: ▲ Martensitic Chromium Carbide Iron Single Layer on Mild Steel: C: 2.7% Mn: 0.4% Si: 1.8% Deposit. Cr: 20.0% V: 1.4% B: 1.0% ▲ Ideal for Fine Particle (Wet or Dry) All Weld Metal Deposit: Abrasion and Low Impact Loading. C: 3.2% Mn: 0.4% Si: 2.4% ▲ Primary Chromium Iron Carbides in a Hard, Cr: 24.0% V: 1.7% B: 1.2% Martensitic Matrix. TYPICAL WELD DEPOSIT HARDNESS: HRC HV30 Single Layer on Mild Steel 58 660 Classifications: All Weld Metal Deposit 60 700 AS/NZS 2576: 2560-A4. Deposits contain Chromium Carbides with hardness up to 1,500 HV. W.T.I.A.Tech Note 4: 2560-A4. FINISHING RECOMMENDATIONS: Description and Applications: Grinding only. Cobalarc BOROCHROME is a popular high alloy extruded hardsurfacing electrode manufactured COMPARABLE CIGWELD PRODUCTS: by CIGWELD. The addition of nominally 1% Boron Stoody FINECLAD-O tubular wire to Cobalarc BOROCHROME produces an ultra fine, AS/NZS 2576: 2565-B7 martensitic matrix in the weld deposit particularly resistant to wet or dry abrasive or erosive media. Downhand & Horizontal Weld deposits can be finished by grinding and are surfacing applications best limited to two layers because of relief checking. Typical applications of Cobalarc BOROCHROME include the hard surfacing of sand chutes, dredge components, ripper shanks, screens, grizzly bars, scraper blades and bucket lips and teeth.

Packaging and Operating Data: AC (minimum 50 O.C.V.), DC+ polarity. Electrode No. of Electrodes Current Packet Carton Part No Size mm Length mm per kg. Range (amps) 4.0 380 11 140-180 5kg 15kg – 3 x 5kg 613964 5.0 450 6 170–210 5kg 15kg – 3 x 5kg 613965

www.cigweld.com.au 79 55 COBALARC 1e 730 OCV

▲ Highly Alloyed Extruded Electrode. TYPICAL WELD DEPOSIT ANALYSIS: ▲ High Chromium Carbide Iron Deposit. All Weld Metal Deposit: C: 5.00% Mn: 1.10% Si: 1.3% Cr: 35.0% ▲ Ideal for Coarse Abrasion and Low to Moderate Impact Loading. TYPICAL WELD DEPOSIT HARDNESS: ▲ For wear resistant overlays on austenitic HRC HV30 manganese steels. Single Layer on Mild Steel 58 660 All Weld Metal Deposit 61 730 Deposits contain complex chromium carbides with hardness Classifications: up to 1,500 HV. AS/NZS 2576: 2360-A4. W.T.I.A.Tech Note 4: 2360-A4. FINISHING RECOMMENDATIONS: Grinding only.

Description and Applications: COMPARABLE CIGWELD PRODUCTS: Cobalarc 1e electrodes deposit an abrasion resistant weld Cobalarc CR70 extruded electrode deposit specially formulated for use on austenitic manganese AS/NZ 2576: 2355-A4 steels. It is ideal for service involving abrasion combined with heavy impact. Stoody 100 HC-G/O tubular wire AS/NZ 2576: 2360-B7 For hardfacing 11-14% manganese steel items such as swing hammers, crusher jaws, bucket lips and teeth, grizzleys, COBALARC HARDFACING CONSUMABLES HARDFACING COBALARC gyratory and cone crusher parts, shovel dipper gums, etc. Downhand & Horizontal surfacing applications. Relief checking of the deposit is normal so the build-up is best limited to two layers.

Packaging and Operating Data: AC (minimum 50 O.C.V.), DC+ polarity. Electrode No. of Electrodes Current Packet Carton Part No Size mm Length mm per kg. Range (amps) 4.0 380 10 130-190 5kg 15kg - 3 x 5kg 613210 5.0 450 5 180-260 5kg 15kg - 3 x 5kg 613235

80 www.cigweld.com.au 55 COBALARC HARDFACING CONSUMABLES COBALARC 9e OCV

▲ Highly Alloyed Extruded Electrode TYPICAL WELD DEPOSIT ANALYSIS: ▲ Versatile, Complex Carbide Iron Deposit. Single Layer on Mild Steel: C: 4.8% Mn: 1.1% Si: 1.4% Cr: 30.0% ▲ Resistant to both Coarse and Fine Ni: 0.5% Mo: 1.7% V: 0.2% Abrasion and Moderate to Heavy Impact TYPICAL WELD DEPOSIT HARDNESS: Loading. HRC HV30 ▲ Typical applications include the hard Single Layer on Mild Steel 58 660 surfacing of railway ballast tampers, All Weld Metal Deposit 63 780 dredge buckets and lips, earth moving Deposits contain complex Chromium Carbides with equipment, power shovels, rolling mill hardness up to 1,500 HV. guides, sizing screens, ripper teeth and FINISHING RECOMMENDATIONS: crushing equipment. Grinding only.

COMPARABLE CIGWELD PRODUCT: Classifications: Stoody 143-O tubular wire AS/NZS 2576: 2460-A4. W.T.I.A.Tech Note 4: 2460-A4. Downhand & Horizontal Description and Applications: surfacing applications:- 5.0mm and 6.3mm sizes can Cobalarc 9e is the most versatile extruded hard surfacing be used for vertical surfacing electrode in the CIGWELD range. by depositing overlapping horizontal stringer passes. The complex chromium rich carbides in Cobalarc 9e make it highly resistant to both coarse and fine abrasion while retaining the toughness to withstand moderate to heavy impact. Typical applications of Cobalarc 9e include the hard surfacing of railway ballast tampers, dredge buckets and lips, earth moving equipment, power shovels, rolling mill guides, sizing screens, ripper teeth and crushing equipment.

Packaging and Operating Data: AC (minimum 50 O.C.V.), DC+ polarity. Electrode No. of Electrodes Current Packet Carton Part No Size mm Length mm per kg. Range (amps) 3.2 380 17 90–140 5kg 15kg – 3 x 5kg 613350 4.0 380 10 130–190 5kg 15kg – 3 x 5kg 613360 5.0 450 5 180–260 5kg 15kg – 3 x 5kg 613370

www.cigweld.com.au 81 55 STOODY TUBE BORIUM AC/DC 730 OCV

Replaces Cobalarc 4 OPERATIONAL CHARACTERISTICS/WELDING PARAMETERS: ▲ Highly Alloyed Tubular Electrode. Diameter 4.0mm 4.8mm 6.4mm ▲ Partially Dissolved Tungsten Carbides Mesh Size 20-30 20-30 10-30 Position Flat Flat Flat bonded in an Iron Rich Matrix. ▲ Resistant to Extreme Abrasion and Low TYPICAL WELD DEPOSIT ANALYSIS*: Impact Loading. Single Layer on Mild Steel: C: 3.1% Mn: 0.9% W: 44% Cr: 6% Classifications: All Weld Metal Deposit: C: 3.7% Mn: 1.0% W: 53% Cr: 7% AS/NZS 2576: 3460-A4. W.T.I.A.Tech Note 4: 3460-A4. TYPICAL WELD DEPOSIT HARDNESS: HRC HV30 Description and Applications: Single Layer on Mild Steel 62 750 Stoody AC-DC Tube Borium is a tubular hard surfacing electrode All Weld Metal Deposit 64 800 which deposits a highly wear resistant weld metal consisting Deposits contain Tungsten Carbides with hardness up to of very hard partially dissolved tungsten carbides in an iron 2,200 HV. rich matrix. * Actual weld deposit consists of undissolved Tungsten Carbide particles in a eutectic matrix of C-W-Cr-Fe. The analysis of the Stoody AC-DC Tube Borium coated electrode is manufactured matrix will vary with the proportion of Tungsten Carbides by metering crushed tungsten carbide particles of controlled dissolved during welding.

COBALARC HARDFACING CONSUMABLES HARDFACING COBALARC mesh size into steel tubes. It receives a thin graphitic coating. The tungsten carbide particles are available in a variety of sizes FINISHING RECOMMENDATIONS: – fine mesh size increases wear resistance and coarse improves Grinding only. cutting efficiency. Downhand & Horizontal Typical applications include: hard surfacing of fan and pump surfacing applications. impellors, pug mill augers and knives, furrowing shovels, scraper/ mixer blades, rasp bars, muller plows, sand and gravel chutes, feed screws, ripper tynes, subsoiler points and tool joints.

Stoody AC-DC Tube Borium should not be used in applications involving heavy impact or shock loading.

Packaging and Operating Data: AC (minimum 50 O.C.V.), DC+ polarity. Electrode No. of Electrodes Current Packet Carton Part No Size mm Length mm per kg. Range (amps) 5.5 350 9 120-150 4.5kg vack pack 10229500 NOTE: one size only

82 www.cigweld.com.au 83 84 STOODY HARDFACING CONSUMABLES www.cigweld.com.au ....Tc oe4 1215-B7. TechW.T.I.A. Note 4: AS/NZS ▲ ▲ ▲ ▲ (Replaces Cobalarc MangNickel-O) DC Electrode Positive. bars anddredgepumpcuttersetc. blow gyratorymantles, jawandhammercrushers, Typical applicationsincludetherepairofManganesesteelcrusherrolls, service underhighimpactloading. checking anddepositswillworkhardenduring multi-layered toanythicknesswithoutrelief StoodyDynamang-Ocanbe loading. elongation andareextremelyresistanttoimpact Resultant welddepositshavehighstrengthand mining industries. steel componentsusedinthequarryingand for therepairandjoiningofmatchingManganese wire depositingamanganesesteelweldmetal Stoody Dynamang-Oisahighalloytubular ieDa urn VlaeEetoePc yePc egtPartNo Pack Weight Pack Type Electrode Voltage Current Dia. Wire P Description and Applications: Classifications: STOODY DYNAMANG-O ackaging andOperating Data: mRne(ms ag vls Stickout mm Range(volts) Range(amps) mm . 7–7 52 04 ol2k 11249900 11446700 27kg 15kg Coil Spool 20–45 12–25 25–28 23–27 275–375 200–250 2.8 1.6 horizontal stringerpasses. surfacing bydepositingoverlapping 1.6mm sizecanbeusedforvertical bars anddredge pumpcutters etc. blow gyratory mantles, hammer crushers, jawand Manganese steelcrusherrolls, Typical applicationsincludetherepair of Manganese SteelDeposit. Work Hardening Tough, Austenitic Tubular Hardfacing Wire.Self Shielded(-O), 56 1215-B7. 2576: SNS27:1215-A4 AS/NZS 2576: Cobalarc Mangcraftextrudedelectrode COMPARABLE CIGWELDPRODUCTS: ● RECOMMENDED SHIELDINGGAS: 21% Machinable asDeposited. FINISHING RECOMMENDATIONS: 615MPa 810MPa TYPICAL WELD DEPOSITHARDNESS: 0.37% Elongation Si: Tensile Strength 2.50% Cr: Yield Stress 13.40% Mn: TYPICAL WELD DEPOSITPROPERTIES: 2.7% Ni: 0.90% C: METALDEPOSIT ANALYSIS:TYPICAL ALLWELD okHree 2410 220 42 17 Work Hardened All Weld MetalDeposit Open arcorweldinggradeCO DC + passes. overlapping horizontalstringer vertical surfacingbydepositing 1.6mm sizecanbeusedfor surfacing applications:- Downhand &Horizontal 2 HR S115 C1 ISO14175: C HV 30 STOODY HARDFACING CONSUMABLES 85 + DC ISO14175: C1 HRC HV30 2 300 TYPICAL ALL WELD TYPICAL ALL DEPOSIT ANALYSIS: C: 0.10%Cr: 1.00% Mn:WELD DEPOSIT HARDNESS: TYPICAL 2.00% Mo: 0.25% Si: 0.50% Fe: bal Steel Single Layer on Mild FINISHING RECOMMENDATIONS: Machinable. 28 GASES: RECOMMENDED SHIELDING grade CO • Open arc or welding CIGWELD PRODUCTS: COMPARABLE 290 Cobalarc 350 extruded electrode AS/NZS 2576:1435-A4 Stoody Super Build Up-G/O AS/NZS 2576:1435-B5/B7 Self shielded (-O),Self shielded wire. build-up tubular Tough, pearlitic machinable low carbon steel deposit. loading. compressive Resistant to high prior to hardfacing. Ideal as an underbase worn steel components. re-building For 2.4 200-350 24-28 20-30 Coil 27kg 11183600 mm Range (amps) Range (volts) (ESO) mm Stickout 2.8#2.8#2.8# 300-450 300-450 300-450 26-30 26-30 26-30 20-35 20-35 20-35 Coil Half Pack Drum 90kg 27kg 226kg 11813100 11000100 11869900 STOODY BUILDUP-O STOODY Packaging and Operating Data: and Operating Packaging Classifications: Applications: Description and Replaces Cobalarc 250-O) Cobalarc Replaces #Indent items DC electrode positive. DC electrode Wire diameter Current Voltage Electrode Type Pack Weight Pack No Part AS/NZS 2576: Note 4:W.T.I.A.Tech 1125-B7. wire developed for the Stoody Buildup-O is an open arc tubular to high compressive re-building of steel components subjected 1125-B7. loading and plastic deformation. ‘as welded’ condition, Producing excellent machinability in the be multi-layered and weld deposits of Stoody Buildup-O can readily hot forged. applications of Stoody Buildup-O include the semi or fully Typical automatic build-up of steel rolls, wheels, sprockets, shafts and track links. ( ▲ ▲ ▲ ▲ ▲ www.cigweld.com.au 86 STOODY HARDFACING CONSUMABLES www.cigweld.com.au h eiatmtcbidu n ufcn fseltakrls de hes rc as rv pokt,pn,linksandother components subjectedtoabrasionand/ormetal-to-metalwear. pins, drivesprockets, trackpads, idlerwheels, the semi-automaticbuild-upandsurfacingofsteeltrackrolls, eoiigatuh airhardeninglowcarbonmartensiticsteelwelddeposit, Depositing atough, ▲ ▲ ▲ ▲ ▲ (Replaces Cobalarc 350-G/O) DC Electrode Positive. Stoody SuperBuildup-G/O 1.2mm subjected tometal-to-metalwearandcompressiveloading. SNS27:1435-B5 1435-B5 TechW.T.I.A. Note4: AS/NZS 2576: Packaging andOperating Data: Description and Applications: Classifications: ieDa urn VlaeRcmeddPc yePc egtPartNo Pack Weight Pack Type Recommended Voltage Current Dia. Wire STOODY SUPERBUILDUP-G/O mRne(ms ag vls Stickout (ESO)mm Range(volts) Range(amps) mm . 4–5 32 52 po 5g11946200 11423600 15kg 15kg Spool Spool 15–25 15–20 23–26 18–24 140–250 120–220 1.6 1.2 which require ashieldinggas. 1.2mm and1.6mmwires are B5typewires stringer passes. surfacing bydepositingoverlappinghorizontal 1.2mm and1.6mmsizescanbeusedforvertical to-metal wear. components subjecttoabrasion and/ormetal- linksandother pins, drivesprockets, track pads, idlerwheels, steel track rolls, Recommended forthebuild-upandsurfacingof Steel Deposit. MachinableLowCarbonMartensitic Tough, Hardfacing Wires. Tubular Gas (-G)andSelfShielded(-O), Stoody SuperBuildup-G/O 1.2mm &1.6mm is atubularhardsurfacingwiredesignedforthere-buildingorofsteelcomponents is idealforallpositionalsurfacingapplicationswith Transmig 250and275powerplants. SNS27:1435-A4 AS/NZS 2576: Cobalarc 350extrudedelectrode COMPARABLE CIGWELDPRODUCTS: ● ● 1.2mm &1.6mmSuperBuildup–G RECOMMENDED SHIELDINGGASES: Carbidetoolsrecommended. Machinable. balance Fe: FINISHING RECOMMENDATIONS: 0.4% Si: 0.5% Mo: 1.5% Mn: TYPICAL WELD DEPOSITHARDNESS: 2.0% Cr: 0.20% C: METALDEPOSIT ANALYSIS:TYPICAL ALLWELD l edMtlDpst4 390 300 40 30 All Weld MetalDeposit Single LayeronMildSteel Ar +10-25%CO Ar +1-3%O Stoody SuperBuildup-G/O 400 2 2 reuvln IO47:M21 ISO14175: or equivalent horizontal stringerpasses. by depositingoverlapping be usedforverticalsurfacing 1.2mm and1.6mmsizescan build-up applications:- Downhand &Horizontal DC + HR S115 M13 ISO14175: is recommendedfor C HV 30 STOODY HARDFACING CONSUMABLES 87 30 HV C HR ISO14175: M13 ISO14175: C1 is a B7 type open arc + DC 2 Downhand & Horizontal build-up applications:- 1.2mm and 1.6mm sizes can be used for vertical surfacing by depositing overlapping horizontal stringer passes. Stoody 965-O or equivalent 2 + 1-3% O Open arc or welding grade CO Ar 2.4mm 965-O Single Layer on Mild SteelSingle Layer on Mild Metal DepositWeld All 55 60 600 700 ● CIGWELD PRODUCTS: COMPARABLE Cobalarc 650 extruded electrode AS/NZS 2576: 1855-A4 TYPICAL ALL WELD METAL ALL WELD TYPICAL ANALYSIS: DEPOSIT METAL C: 0.60%Cr: 6.20% DEPOSIT HARDNESS: WELD TYPICAL Mn: 1.70% Fe: balance Si: 1.40% FINISHING RECOMMENDATIONS: Not Machinable. Grinding only. RECOMMENDED SHIELDING GASES: 1.2mm & 1.6mm 965-G ● wires are B5 type wires which require a shielding gas. 2.4mm 1.2mm & 1.6mm 2.4mm* Stoody 965-G 2576: 1855-B5 1855-B7. 1.2mm and 1.6mm wires are B5 type are 1.2mm and 1.6mm wires gas. a shielding which require wires wire arc 2.4mm size is a B7 type open no shielding gas. which requires Typical applications include the surfacing applications Typical points,of agricultural and shares tynes, cutter heads, sand dredge dredge and tumblers,rollers conveyor screws, lips,bucket etc. be used for 1.2mm and 1.6mm sizes can vertical surfacing by depositing overlapping horizontal stringer passes. Gas (-G) and Self Shielded (-O), and Self Shielded Gas (-G) Tubular Wires. Hardfacing Air Hardening, Free, Crack Martensitic Steel Deposit. and Abrasion Particle Resistant to Hard Impact Loading. Moderate 1.61.62.4 140–250 140-250 200–350 23–26 23-26 24–28 20–25 20-25 20–30 Spool Handispool Coil 4.5kg 15kg 11945700 11501500 27kg 11946100 1.2 120–220 18–24 15–20 Spool 15kg 11423100 mm Range (amps) Range (volts) (ESO) mm Stickout STOODY 965-G/O STOODY Wire Wire Dia Current Voltage Recommended Type Pack Weight Pack No Part Packaging and Operating Data: and Operating Packaging Description and Applications: Description and Classifications: W.T.I.A.Tech Note 4:W.T.I.A.Tech 1855-B5 1855-B7. DC Electrode Positive. DC Electrode * - 1.2mm and 1.6mm to wet or dry hard particle abrasion and Stoody 965-G/O is a tubular hard surfacing wire for surfacing components subjected low to moderate impact loading. of Stoody 965-G/O remains crack free on air hardening martensitic steel weld deposit The the surfacing of components subject to most steels under normal welding conditions and is therefore recommended for flexing during service. 210,Transmig is ideal for all positional surfacing applications with the 1.2mm Stoody 965-G/O 275 and 350 power sources. of agricultural points, applications include the surfacing Typical shares and tynes, sand dredge cutter heads, and dredge rollers tumblers, conveyor screws, lips, bucket etc. ▲ AS/NZS ▲ ▲ (Replaces Cobalarc 650-G/O) Cobalarc (Replaces ▲ ▲ ▲ wire which requires no shielding gas. www.cigweld.com.au 88 STOODY HARDFACING CONSUMABLES www.cigweld.com.au ....Tc oe4 1865-B7. TechW.T.I.A. Note4: ▲ ▲ ▲ ▲ ▲ DC Electrode Positive /elevators andsugarmillscraperplates. caneharvestercutters dredgebuckets, conveyorscrews, points, miningandmaterialshandlingequipmentincludingtynes, Typical applicationsincludethehardsurfacingofagricultural, 1.2mm Stoody850-Oisidealforallpositionalsurfacingapplicationswiththe Transmig 250and275powerplant. heavy impactorshockloading. Stoody850-Oshouldnotbeusedinapplicationsinvolving Weld depositsareairhardeningandpronetofinereliefchecking. fine(wetordry)abrasionandlowimpactloading. resistance tosevere, Stoody 850-Oisaselfshielded(oropenarc)hardsurfacingwirewhichdepositshighcarbonmartensiticsteelforexcellent AS/NZS Packaging andOperating Data: Description and Applications: Classifications: ieDaCret otg eomne akTp akWih PartNo Pack Weight Pack Type Recommended Voltage Current Dia Wire STOODY 850-O mRne(ms ag vls Stickout (ESO)mm Range(volts) Range(amps) mm . 2–2 82 52 po 5g11945500 15kg Spool 15–20 18–24 120–220 1.2 horizontal stringerpasses. surfacing bydepositingoverlapping 1.2mm sizecanbeusedforvertical and sugarmillscraper plates. caneharvestercutters/elevators buckets, dredge conveyorscrews, points, tynes, materials handlingequipmentincluding miningand surfacing ofagricultural, Typical applicationsincludethehard Impact Loading. Resistant toSevere Abrasion andLow Martensitic SteelDeposit. Crack Prone HighCarbon, Air Hardening, Wire. Tubular Hardfacing Self Shielded(-O), 56 1865-B7. 2576: ● ● RECOMMENDED SHIELDINGGAS: Grinding only. 1.5% B: FINISHING RECOMMENDATIONS: 0.9% Si: 3.5% Mo: 0.6% Mn: TYPICAL WELD DEPOSITHARDNESS: 6.5% Cr: 0.95% C: METALDEPOSIT ANALYSIS:TYPICAL ALLWELD l edMtlDpst6 830 750 65 62 All Weld MetalDeposit Single LayeronMildSteel S115 C1 ISO14175: Open arcorweldinggradeCO passes. overlapping horizontalstringer vertical surfacingbydepositing 1.2mm sizecanbeusedfor surfacing applications:- Downhand &Horizontal 2 DC + HR C HV 30 STOODY HARDFACING CONSUMABLES 89 30 HV C HR ISO14175: C1 + DC 2 Downhand & Horizontal surfacing applications:- 1.2mm size is suitable for vertical-up surfacing using a wide weaving technique. Spool 15kg 11304700 or equivalent ISO14175: M13 Handispool 4.5kg 11945600 2 Ar+ 1-3% O Open arc or welding grade CO RECOMMENDED SHIELDING GAS: 1.2mm 101 HC-G ● ● CIGWELD PRODUCTS: COMPARABLE Cobalarc CR70 extruded electrode AS/NZS 2576: 2355-A4 TYPICAL WELD TYPICAL DEPOSIT ANALYSIS: on Mild Steel: Single Layer C: 4.0% Metal Deposit: Weld All C: 5.2% Mn: 0.7% DEPOSIT HARDNESS: WELD TYPICAL Mn: 0.7% Si: 0.7% Si: 0.7% Cr: 14.0% Cr: 19.0% FINISHING RECOMMENDATIONS: Grinding only. Single Layer on Mild SteelSingle Layer on Mild Metal DepositWeld All Carbides with hardness up to Deposits contain Chromium 1,500 HV (80 HRc). 55 60 600 700 1.6mm 101 HC-O C. ° 1.2mm* 1.6mm* For high impact applications Stoody 101 HC-G/O deposits should be restricted to one layer. to Stoody 101 HC-G/O deposits should be restricted high impact applications For 2576: 2360-B5 2360-B7. 1.2mm size is suitable for vertical-up surfacing using a wide weaving technique. High Alloy, Wire. Hardfacing Tubular Deposit. Iron - Carbide High Chromium Applications. Engaging Ground For to and Low Abrasion Resistant to Severe Impact Loading. Moderate include the hard applications Typical cones and mantles, surfacing of crusher swing hammers, buckets, earthmoving and scarifier points and sugar harvesting milling equipment. 1.21.6 150–200 200–260 22–26 24–28 12–20 15–25 Spool 15kg 11436300 mm Range (amps)Range (volts) (ESO) mm Stickout STOODY 101 HC-G/O 101 STOODY Wire Wire Dia Current Voltage Recommended Type Pack Weight Pack No Part Packaging and Operating Data: and Operating Packaging Weld Deposit Microstructure: Weld Description and Applications: Description and Classifications: Weld deposits can be finished by grinding and relief checking is normal.Weld applications of Stoody 101 HC-G/O include Typical the hard surfacing of crusher cones and mantles, swing hammers, earthmoving buckets, scarifier points and sugar harvesting and milling equipment. DC Electrode Positive. DC Electrode Two layers of Stoody 101 HC-G/O onto a mild steel component will produce approximately 25 - 30% primary chromium iron Two impact applications. carbides in a carbide-ferrite matrix ideal for severe abrasion and low to moderate AS/NZS requires a shielding gas. * 1.2mm 101 HC-G is a B5 type wire which no shielding gas. 1.6mm 101 HC-O is a B7 type wire which requires Stoody 101 HC-G/O is a high alloy tubular hardfacing wire depositing a high chromium carbide iron particularly resistant to severe coarse (large particle) abrasion. weld deposit of The Stoody 101 HC-G/O produces a high level of primary chromium carbides resistant to coarse abrasion (in particular gouging abrasion) at temperatures up to 650 ▲ (Replaces Cobalarc Coarseclad-G/O 1.2 & 1.6mm) Coarseclad-G/O Cobalarc (Replaces ▲ ▲ ▲ ▲ W.T.I.A.Tech Note 4:W.T.I.A.Tech 2360-B5 2360-B7. www.cigweld.com.au 90 STOODY HARDFACING CONSUMABLES www.cigweld.com.au ....Tc oe4 2360-B7. TechW.T.I.A. Note4: DC Electrode Positive. carbides inacarbide-ferritematrixidealforcoarseabrasionandlowtomoderateimpactapplications. Two layersofStoody100HC-O ontoamildsteelcomponentwillproduceapproximately30%-35%primarychromiumiron temperatures upto650 abrasion (inparticulargougingabrasion)at primary chromiumcarbidesresistanttocoarse Stoody 100HC-Oproducesahighlevelof The welddepositof (large particle)abrasion. carbide ironparticularlyresistanttocoarse hardfacing wiredepositingahighchromium Stoody 100HC-Oisahighalloytubular AS/NZS ▲ ▲ ▲ ▲ ▲ (Replaces Cobalarc Coarseclad-O 2.4&2.8mm) deposits shouldberestricted totwolayers. For higherimpactapplicationsStoody100HC-O manufacture. Alsosuitableforsinglelayerwearplate rippers. bladesand earthmovingbuckets, hammers, swing surfacing ofcrusherconesandmantles, Stoody 100HC-Oincludethehard Typical applicationsof relief checkingisnormal. Weld depositscanbefinishedbygrindingand ieDaee urn VlaeRcmeddPc yePc egtPartNo Pack Weight Pack Type Recommended Voltage Current Diameter Wire Packaging andOperating Data: Weld DepositMicrostructure: Description and Applications: Classifications: STOODY 100HC-O Single Layer. Primary Chromium Iron Carbidesin Low toModerate ImpactLoading. Resistant toCoarse Abrasion and For Ground Engaging Applications. Deposit. High Chromium CarbideIron Hardfacing Wire. Tubular Self Shielded(-O), mRne(ms ag vls Stickout (ESO)mm Range(volts) Range(amps) mm . 0-5 73 55 rm26g11235400 11001000 11313400 226kg 27kg 27kg Drum Coil Coil 35-55 35–55 35–55 27-33 27–33 25–30 300-450 300–450 250–350 2.8 2.8 2.4 56 2360-B7. 2576: ° C. SNS27:2355-A4 AS/NZS 2576: Cobalarc CR70extrudedelectrode COMPARABLE CIGWELDPRODUCTS: ● ● RECOMMENDED SHIELDINGGAS: Grinding only. FINISHING RECOMMENDATIONS: 1% Mo: 25% Cr: 0.7% Mo: 1.5% Si: 20% Cr: 1.5% Mn: 1.0% TYPICAL Si: WELD DEPOSITHARDNESS: 1.0% Mn: 4.5% C: All Weld MetalDeposit: 4.0% C: Single LayeronMildSteel: DEPOSIT ANALYSIS:TYPICAL WELD l edMtlDpst6 780 600 63 1,500 HV(80HRc). 55 Deposits containChromiumCarbideswithhardnessupto All Weld MetalDeposit Single LayeronMildSteel S115 C1 ISO14175: Open arcorweldinggradeCO HR applications Downhand surfacing 2 DC C + HV 30 STOODY HARDFACING CONSUMABLES 91 30 HV C HR + DC 2 Downhand & Horizontal surfacing applications:- 1.6mm size can be used for vertical surfacing by depositing overlapping horizontal stringer passes. Open arc or welding grade CO ISO14175: C1 FINISHING RECOMMENDATIONS: Grinding only. RECOMMENDED SHIELDING GAS: ● ● CIGWELD PRODUCTS: COMPARABLE Cobalarc Borochrome extruded electrode AS/NZS 2576: 2560-A4 TYPICAL WELD TYPICAL DEPOSIT ANALYSIS: on Mild Steel: Single Layer C: 3.5%Cr: 14% Metal Deposit: Weld All C: 4.8%Cr: 20% Mn: 0.3% B: 0.5% Mn: DEPOSIT HARDNESS: WELD TYPICAL 0.5% B: Si: 0.75% 0.4% Si: 0.6% Single Layer on Mild SteelSingle Layer on Mild Metal DepositWeld All hardness up to Deposits contain Chromium Carbides with 1,500 HV (80 HRc). 62 65 750 830 2576: 2565-B7. High Deposit Hardness - typically High Deposit Hardness 65 HRc. on Now available in 1.6mm size 15kg spools. Self Shielded (-O),Self Shielded Tubular Wire. Hardfacing in a Hard, Carbides Iron Chromium Martensitic Matrix. Resistant to Fine, or Dry Wet Abrasion 1.62.4 200–260 250–350 24–28 25–30 15–25 35–55 Spool Coil 15kg 27kg 11945800 11945900 mm Range (amps) Range (volts) mm Stickout STOODY FINECLAD-O STOODY Packaging and Operating Data: and Operating Packaging Weld Deposit Microstructure: Weld Classifications: Applications: Description and Replaces Cobalarc Fineclad-O) Cobalarc Replaces DC Electrode Positive. DC Electrode Wire Diameter Current Voltage Electrode Type Pack Weight Pack No Part The addition of nominally 0.8% Boron to Stoody FINECLAD-O facilitates the formation of martensite addition of nominally 0.8% Boron The in the eutectic. It also results in an ultra fine eutectic structure which in combination with the martensite fraction is to fine wet/dry abrasion and erosion. excellent resistance responsible for Stoody FINECLAD-O’s Stoody FINECLAD-O is a second generation Stoody FINECLAD-O is a second generation Cobalarc tubular wire depositing a hard to martensitic chromium carbide iron resistant severe fine abrasion. addition of nominally The an 0.8% Boron to Stoody FINECLAD-O produces ultra fine, martensitic matrix in the weld deposit or particularly resistant to wet or dry abrasive erosive media. Stoody FINECLAD-O also gives satisfactory performance under medium to coarse abrasion however this is limited to conditions of low impact loading. deposits can be finished Weld by grinding and relief checking is normal. applications of Stoody FINECLAD-O Typical include the surfacing of sand chutes, dredge components, ripper shanks, screens, grizzly bars, scraper blades, teeth and lips etc. and bucket AS/NZS ( W.T.I.A.Tech Note 4:W.T.I.A.Tech 2565-B7. ▲ ▲ ▲ ▲ ▲ www.cigweld.com.au 92 STOODY HARDFACING CONSUMABLES www.cigweld.com.au DC Electrode Positive drivetumblersanddredgepumpcuttersetc. manganese frogs, gyratorymantles, jawandhammercrushers, crusher rolls, Typical applicationsincludetherepairofmanganesesteel during serviceunderhighimpactloading. thickness withoutreliefcheckinganddepositswillworkharden Stoody110MCcanbemulti-layeredtoany to impactloading. resistance tocavitationandcorrosionareextremelyresistant good Resultant welddepositshavehighstrengthandtoughness, extensively usedinthequarryingandminingindustry. joiningorsurfacingofmanganesesteelcomponents repair, 1715-B7. manganese andhighchromiumstainlesssteelweldmetalforthe Stoody 110MCisanopenarctubularwiredepositingahigh 1715-B7. TechW.T.I.A. Note4: AS/NZS 2576: ▲ ▲ ▲ ▲ (Replaces Cobalarc Crome Mang-O) Packaging andOperating Data: Description and Applications: Classifications: lcrd urn VlaeEetoePc yePc egtPartNo Pack Weight Pack Type Electrode Voltage Current Electrode STOODY 110MC .m 5-1 22 52m po 5g11424400 15kg Spool 15-25mm 27kg 11836900 25-2820-35mm Coil 22-28 200-375 150-210 2.8mm 1.6mm ieRne(ms ag vls Stickout mm Range(volts) Range(amps) Size Suitable forheavybuild-upapplications. steel components. andsurfacingofmanganese joining Repair, high chromium stainless steeldeposits. workhardening highmanganese/ Tough, Self shielded(-0)tubularhardfacing wire. okHree 5600 220 55 17 Work Hardened All Weld MetalDeposit AS/NZS 2576:1215-B7 Stoody Dynamang-OOpen Arc Wire AS/NZS 2576:1215-A4 Cobalarc MangcraftExtrudedElectrode COMPARABLE CIGWELDPRODUCTS: • RECOMMENDED SHIELDINGGASES: Machinable-as deposited FINISHING RECOMMENDATIONS: 40% Balance Fe: 0.37% Si: 820MPa 520MPa TYPICAL WELD DEPOSITHARDNESS: Elongation 0.65% Ni: 14.7% Mn: Tensile Strength Yield Strength TYPICAL WELD DEPOSITPROPERTIES: 16.8% Cr: 0.30% C: DEPOSIT ANALYSIS:TYPICAL ALLWELD Open Arc or Welding GradeCO 400 2 HR S115 C1 ISO14175: c DC + HV 30 STOODY HARDFACING CONSUMABLES 93 Yes 30 HRC HV 300 COMPARABLE CIGWELD PRODUCTS: COMPARABLE wire Stoody Build Up-O self shielded tubular AS/NZS 2576:1125-B7 TYPICAL ALL WELD TYPICAL ALL ANALYSIS: DEPOSIT C: 0.07%Cr: 1.15% DEPOSIT HARDNESS: WELD TYPICAL Mn: 2.90% Fe: bal FINISHING RECOMMENDATIONS: Machinable. RECOMMENDED FLUX: Stoody S Si: 1.25% DEPOSIT CHARACTERISTICS: Abrasion resistanceImpact resistanceCompressive strengthHardnessSurface cross checksMagnetic Excellent Excellent Low No 29 HRc Deposit LayersMachinability Unlimited Yes All weld metal deposit All weld metal deposit 29 290 Submerged arc (-SA) tubular build-up wire. (-SA) tubular arc Submerged Tough, machinable, low carbon pearlitic steel deposit. loading. compressive Resistant to high of worn steel the unlimited build-up For components. 3.23.23.2 350-400 350-400 350-400 26-30 26-30 26-30 25-35 25-35 25-35 Coil Half Pack Drum 90kg 27kg 226kg 11040900 11820300 11039500 mm Range (amps) Range (volts) (ESO) mm Stickout STOODY 104 STOODY Packaging and Operating Data: and Operating Packaging Classifications: Applications: Description and Replaces Cobalarc 104-SA) Cobalarc Replaces Wire diameterWire Current Voltage ElectrodeType Pack Weight Pack No Part AC, positive or negative DC electrode AS/NZS 2576: Note 4:W.T.I.A.Tech 1125-B1. arc tubular wire Stoody 104 is a low alloy steel submerged subjected to developed for the rebuilding of steel components 1125-B1. high compressive loading and plastic deformation. Producing ‘as welded’ in the weld metal with excellent machinability condition, S flux, when used with Stoody Stoody 104 can be multi-layered and readily hot forged. applications of Typical arc build-up of Stoody 104/Stoody S flux include the submerged steel rolls, wheels, sprockets, shafts and track links etc. ( ▲ ▲ ▲ ▲ www.cigweld.com.au 94 STOODY HARDFACING CONSUMABLES www.cigweld.com.au nld h euligo:rles des iecrwel,arch wheels andchargingcarwheels. minecarwheels, idlers, rollers, include therebuildingof: Applications Depositsaredifficulttoflamecut. machining. wellpoweredequipmentarerequiredfor tools andrigid, Tungsten carbide an underbaseofStoody105isrecommended. Whenmorethan3layersarerequired, deposits canbeobtained. 1445-B1. Multiplelayercrack-freesteel abrasion inmetal-to-metalwear. Stoody 105isasubmergedarcwirewithverygoodresistanceto 1445-B1. W.T.I.A.Tech Note4: AS/NZS 2576: ▲ ▲ ▲ ▲ ▲ ( iedaee urn VlaeEetoePc yePc egtPart No Pack Weight Pack Type Electrode Voltage Current Wire diameter DCelectrode positiveornegative. AC, Replaces Cobalarc 105-SA) Packaging andOperating Data: Description and Applications: Classifications: STOODY 105 mRne(ms ag vls Stickout (ESO)mm Range(volts) Range(amps) mm . 5-0 63 53 rm26g11039600 11041000 226kg 90kg Drum HalfPack 25-35 25-35 26-30 28-30 350-400 350-400 3.2 3.2 For re-building wornsteelcomponents. Ideal asanunderbasepriortohardfacing. Resistant tohighcompressive loading. crack-free steeldeposit. machinable, Tough, Submerged arc tubularbuild-upwire. eoi aesThree Withdifficulty No Good Good AS/NZS 2576:1435-B5/B7 Stoody SuperBuildUp-G/O Very good AS/NZS 2576:1435-A4 Cobalarc 350extrudedelectrode COMPARABLE CIGWELDPRODUCTS: Machinability Deposit Layers Magnetic Surface crosschecks Hardness Compressive strength Impact resistance Abrasion resistance DEPOSIT CHARACTERISTICS: 1.3% Si: Stoody S RECOMMENDED FLUX: bal Fe: Machinable withdifficulty. FINISHING RECOMMENDATIONS: 0.15% V: 0.4% Mo: 2.0% Mn: TYPICAL WELD DEPOSITHARDNESS: 2.8% Cr: 0.2% C: DEPOSIT ANALYSIS:TYPICAL ALLWELD aesmxmmo idSel 5440 45 3 layersmaximumonMildSteel 450 R HV HRC 30 45HRc Yes STOODY HARDFACING CONSUMABLES 95 Yes 30 HRc HV 400 Multiple Layer on Mild Steel Multiple Layer on Mild 38 380 COMPARABLE CIGWELD PRODUCTS: COMPARABLE Cobalarc 350 extruded electrode AS/NZS 2576:1435-A4 Stoody Super Build Up-G/O AS/NZS 2576:1435-B5/B7 TYPICAL ALL WELD TYPICAL ALL ANALYSIS: DEPOSIT C: 0.14%Cr: 2.2% DEPOSIT HARDNESS: WELD TYPICAL Mn: 1.9% Mo: 0.3% Si: 0.8% Fe: bal FINISHING RECOMMENDATIONS: Machinable. RECOMMENDED FLUX: Stoody S DEPOSIT CHARACTERISTICS: Abrasion resistanceImpact resistanceCompressive strengthHardnessSurface cross checksMagnetic Good Excellent Good No 38 HRc Deposit thicknessMachinability to 20mm up Yes Submerged arc tubular build-up wire. tubular build-up arc Submerged Tough, machinable, steel deposit. crack-free loading. compressive Resistant to high prior to hardfacing. Ideal as an underbase worn steel components. re-building For 3.23.2 350-400 350-400 28-30 26-30 25-35 25-35 Half Pack Drum 90kg 226kg 11041200 11039800 mm Range (amps) Range (volts) (ESO) mm Stickout STOODY 107 STOODY Packaging and Operating Data: and Operating Packaging Classifications: Applications: Description and Replaces Cobalarc 107-SA) Cobalarc Replaces Wire Wire diameter Current Voltage Electrode Type Pack Weight Pack No Part AC, positive or negative. DC electrode AS/NZS 2576: Note 4:W.T.I.A.Tech 1440-B1. good resistance to Stoody 107 is a submerged arc wire with metal-to-metal wear, excellent impact resistance, good 1440-B1. plastic defamation. compressive strength and resistance to obtained up to 20mm Multiple layer check-free deposits can be thick. and can Deposits are readily machinable with carbide tools be flame cut. Stoody 107 can be used for both the build-up and hardfacing of rollers and idlers. Applications include the rebuilding of rollers, idlers, carbon steel crane wheels, mine car wheels and house rollers. ( ▲ ▲ ▲ ▲ ▲ www.cigweld.com.au 96 STOODY HARDFACING CONSUMABLES www.cigweld.com.au other componentssubjectedtoextremeabrasionandmoderateheavyimpact. agitatorscrewsand tampers, bucket teethandlips, Typical applicationsofStoody600includethesurfacingmillhammers, *Non stockitemavailable onindentonly. iedaee urn VlaeEetoePc yePc egtPartNo Pack Weight Pack Type Electrode Voltage Current diameter Wire DC Electrode Positive The allweldmetalmicrostructureofStoody600showsanevendispersion( relief checkingandhavegoodhardnessretentionto Weld depositsarenormallyfreefrom minimum oftwolayersStoody600isrecommendedforoptimumserviceperformance. A The uniquemicrostructureofStoody600makes itparticularlysuitableforhighstressabrasionandheavyimpactconditions. hard titaniumcarbides. 1955-B7 martensitic alloysteelcontainingahighvolumefractionoffine, Stoody 600isanewgenerationtubularwirewhichdeposits 1955-B7 TechW.T.I.A. Note4: AS/NZS 2576: ▲ ▲ ▲ ( high chromiummartensiticmatrixresistanttostressabrasionandheavyimpactloading Replaces Cobalarc Impactaclad-O) Description and Applications: Classifications: Packaging andOperating Data: Finishing Recommendations: STOODY 600 28m40502-83-5mCi 7g11814400 11929400 Coil27kg Drum226kg 30-35mm 30-35mm 26-28 26-28 400-500 400-500 *2.8mm *2.4mm .m 0-0 52 53m ol2k 11846000 11886600 Coil27kg Spool15kg 35-35mm 20-25mm 25-27 22-26 300-400 200-300 2.4mm 1.6mm mRne(ms ag vls Stickout (ESO)mm Range(volts) Range(amps) mm and heavyimpact. Excellent resistance tohighstress abrasion titaniumcarbides. containing hard, martensiticalloysteel Crack free, Self shielded(-O)tubularhardfacing wires. ≈ 500˚C Open Arc Operation Open Arc RECOMMENDED SHIELDINGGASES: Grinding Only FINISHING RECOMMENDATIONS: 5.3% Ti: 0.5% Si: 1.3% Mo: 1.6% Mn: TYPICAL WELD DEPOSITHARDNESS: 7.5% Cr: 1.7% C: DEPOSIT ANALYSIS:TYPICAL ALLWELD - aeso idSel6 690 690 670 60 60 58 3,200HV Deposits contain Titanium Carbideswithhardnessupto 3-8 layersofMildSteel Two layersofMildSteel Single LayerorMildSteel ≈ 0 yvlm)o ie hardtitaniumcarbidesina 10% byvolume)offine, 700 HR c DC + HV 30 STOODY HARDFACING CONSUMABLES 97 s + DC ISO14175: C1 HRC HV30 2 C: 3.7% Mn: 0.6% Si: 0.3% C: 5.2% Mn: 0.7% Si: 0.4% Cr: 16% Nb: 5% Cr: 22% Nb: 7.3% RECOMMENDED SHIELDING GASES: • Open arc or welding grade CO CIGWELD PRODUCTS: COMPARABLE Cobalarc 9e extruded electrode AS/NZS 2576: 2460-A4 TYPICAL ALL WELD TYPICAL ALL ANALYSIS: DEPOSIT on Mild Steel Single Layer DEPOSIT HARDNESS: WELD TYPICAL Steel Single Layer on Mild Metal DepositWeld All hardness up to Deposits contain niobium carbides with 2,400 HV. 58FINISHING RECOMMENDATIONS: 62Grinding only. 670 760 All Weld Metal Deposit Weld All 650˚C. ≈ Self shielded (-O),Self shielded wire. tubular hardfacing carbide iron / chromium Complex niobium deposit. abrasion fine or coarse Resistant to sever impact. and low to moderate in 1.6mm size on 15kg Now available spools. 1.62.8 200-300 300-450 22-26 27-33 20-25 35-55 Spool Coil 15kg 27kg 11877000 11867800 mm Range (amps) Range (volts) (ESO) mm Stickout *2.8 300-450 27-33 35-55 Drum 226kg 11857800 STOODY 143-O STOODY Packaging and Operating Data: and Operating Packaging Weld Deposit Microstructure: Weld Classifications: Applications: Description and Replaces Cobalarc Abrasoclad-O) Cobalarc Replaces The addition of nominally 7% niobium to Stoody 143-O initiates the formation of a complex niobium / chromium carbide iron addition of nominally 7% niobium The of moderate impact. structure which resists extreme high or low stress abrasion even under conditions Positive DC Electrode Wire diameter Current Voltage Electrode Type Pack Weight Pack No Part AS/NZS 2576: Note 4:W.T.I.A.Tech 2460-B7 wire depositing a Stoody 143-O is a high alloy tubular hardfacing to extreme abrasion complex chromium carbide iron resistant 2460-B7 and low to moderate impact loading. addition of nominally The a complex chromium / 7% niobium to Stoody 143-O produces is particularly resistant niobium carbide iron weld deposit which and low to moderate to severe low and high stress abrasion impact loading at temperatures up to ( ▲ ▲ ▲ ▲ *Non-stock item available on indent only. *Non-stock item available The nodular niobium rich carbide structure of Stoody 143-O is capable of withstanding higher impact loading than standard nodular niobium rich carbide structure of Stoody 143-O is capable of The chromium carbide alloy types. sensitivity means that two layers will normally be sufficient to achieve optimum low dilution The wear resistance. grinding. 143-O deposits will readily stress relief check and can only be finished by Stoody application Typical include the surfacing of conveyor screws, pug mill paddles, wear plates, fan blades, chutes / shoes and grizzly bars, coke etc. www.cigweld.com.au 98 STOODY HARDFACING CONSUMABLES www.cigweld.com.au *Non-stock itemavailable onindentonly. iedaee urn VlaeWr akTp akWih PartNo Pack Weight Pack Type Wire Voltage Current diameter Wire Conveyor Excavator Bucket Teeth, wearPlates, Mining: • ZincPots, SlagLadles, CopperLadles, Non-Ferrous Metals: • Hot CementDryers, CementScrews, CementandRefractory: • Blast SinterPlantParts, Guides, IronandSteelIndustry: • temperature abrasionresistanceupto1500˚F(816˚C). whichcontributestoitsexcellenthigh columbium (niobium), The Stoody145alloyedwirecontains elevated temperature. andhighhardnessat highcorrosionresistance, resistance, 2460-B7 withhighabrasion Stoody 145isahighlyalloyedopenarcwire, 2460-B7 W.T.I.A.Tech Note4: AS/NZS 2576: ▲ ▲ ▲ ▲ Applications: Description and Applications: Classifications: Packaging andOperating Data: STOODY 145OPEN ARC WIRE 2830502-41-2Du 2k O 11440200 11484700 226kgPOP 90kgH/P Drum Drum 19-32 19-32 28-34 28-34 300-550 300-550 *2.8 *2.8 mRne(ms ag vls Extensionmm Range(volts) Range(amps) mm . 0-5 83 93 ol2k 11414300 27kg Coil 19-32 28-34 300-550 2.8 temperatures. Produces hardness atelevated corrosion resistance. Highly abrasion resistant withexcellent deposit. Complex niobium/chromium carbideiron tubularhardfacing wire. Self shielded(-O), ces SlurryPipes. Screws, ZincScrapers. CopperBarGuides, Tin MillParts, Presses. Mixer Blades, CementFurnaceParts, Cement Cones, HotBilletHandlers. fingers, Tilt HotScreens, Coke PusherShoes, Crushers, Blades, ExhaustFan Hot Ash Elbows, SlagRakes, Furnace Parts, Description and ahnblt GrindOnly 2Maximum Yes Low 56-61HRC Upto1500˚F(816˚C) Excellent COMPARABLE CIGWELDPRODUCTS: Hot Wear Applications Deposit thickness Magnetic Machinability Surface crosschecks Hardness 2Layers Impact resistance Abrasion resistance DEPOSIT CHARACTERISTICS: Grinding Only FINISHING RECOMMENDATIONS: TYPICAL DEPOSITCHEMISTRY (WT%): :58 r 4 o .%M:.%Nb:5.1% Mn:1.0% 6.3% Mo: 24% Cr: 5.8% C: :.%V08 i07 Fe:Bal Si:0.7% V:0.8% W:1.8% DC + Yes STOODY HARDFACING CONSUMABLES 99 + DC gas mixtures 2 HRc HV30 HRc 450 or Argon + CO or 2 Single layer on cast ironSingle layer All weld metal deposit 40 45 400 440 TYPICAL WELD DEPOSIT HARDNESS: WELD TYPICAL FINISHING RECOMMENDATIONS: Grinding Only GAS: RECOMMENDED SHIELDING Open arc grade CO Welding PRODUCTS: CIGWELD COMPARABLE Stoody 117 Hardfacing wire WELDING POSITIONS: applications, roller arcing For be used Stoody RA45-O can in the flat, horizontal, vertical up and vertical down welding positions. hardfacing applications Stoody RA45-O is conventional For welding restricted to use in the flat and horizontal positions. Self shielded (-O) tubular hardfacing wire. hardfacing (-O) tubular Self shielded sheath for copper coated Seamless feeding. starting and wire outstanding arc ‘open arc’ the out-of-position Developed for rolls. surfacing of sugar mill hard surfacing deposit for Martensitic steel and wear roughness enhanced roll resistance. 2.02.8 240-300 300-350 28-35 30-35 40-50 40-50 Coil Coil 25kg 25kg 11121100 11122200 mm Range (amps) Range (volts) Extension mm STOODY RA45-O STOODY Packaging and Operating Data: and Operating Packaging Classifications: Applications: Description and Wire Wire diameter Current Voltage Wire Type Pack Weight Pack No Part AS/NZS 2576: Note 4:W.T.I.A.Tech 1845-B7 hard surfacing wire Stoody RA45-O is a seamless copper coated ‘open arc’ automatic developed primarily for the semi or fully 1845-B7 surfacing of cast iron sugar mill rolls. Stoody RA45-O can also be dioxide Argon/carbon or used with shielding gas (carbon dioxide general purpose hard mixtures) or without shielding gas for the as agricultural points, surfacing of ground engaging tools such shares and tynes, conveyor screws and post hole augers. ‘in-situ’ maintenance and pre-season conditioning of both the For cast iron sugar mill rolls, Stoody RA45-O deposits a superior resulting in improved roll wear resistant martensitic steel overlay efficiency and service life. ‘in-situ’ with long gun cables,When roller arcing torch awkward angles, high welding currents and a wet bagasse blanket, the RA45-O offers copper coated seamless sheath of Stoody in addition to outstanding arc starting and deposit penetration uninterrupted wire feeding. ▲ ▲ ▲ ▲ www.cigweld.com.au 100 STOODY HARDFACING CONSUMABLES www.cigweld.com.au toy“”Fu saalbei 2gBg Pr ubr 11008400) Fluxisavailable in22kgBags(Part Number: Stoody “S” this fluxtotherightwire. careshouldbeexercisedinthematchingof Asthedepositcomposition issignificantlyalteredfromthewirecomposition, wire). FluxisanactivefusedfluxdesignedforusewithStoodySubmerged Arc Welding Wires (otherthanthe Stoody “S” ThermaClad® Packaging andOperating Data: Description and Applications: TOY“”FLUX STOODY “S” STOODY HARDFACING CONSUMABLES 101 www.cigweld.com.au 102 GAS METAL(MIG) WIRES GAS ARC WELDING GAS METAL ARC WELDING (MIG) WIRES Description Page No Autocraft LW1 105 Autocraft Super Steel 106 Autocraft LW1-6 107 Autocraft Mn-Mo 110 Autocraft NiCrMo 111 Autocraft CrMo1 112 Autocraft 307Si 113 Autocraft 308LSi 114 Autocraft 309LSi 115 Autocraft 316LSi 116 Autocraft 2209 117 Autocraft AL1100 (Pure) 118 Autocraft AL4043 (5% Silicon) 119 Autocraft AL5356 (5% Magnesium) 120 Autocraft AL5183 122 Autocraft Deoxidised Copper 123 Autocraft Silicon Bronze 124

www.cigweld.com.au 103 104 GAS METAL ARC WELDING (MIG) WIRES www.cigweld.com.au on hr tetr h edn r,andthearclength. point whereitenterstheweldingarc, tothe CTWDincludesthewirelengthfromcontacttip, shown below. Aschematicdiagram ofCTWDis the contacttipandworkpiece. isdefinedasthedistancebetweenendof electrode stickout(ESO), Contact Tip to Work Distance(CTWD), CONTACTEXPLAINED TIPTODISTANCE(CTWD) WORK Shielding Gas CTWD also sometimesreferredtoas Ar Zone (RHZ) Heating Resistive c Length Conta c t Tip GAS METAL ARC WELDING (MIG) WIRES 105 : 2 C ° ISO14175: C1 ISO14175: M23 M 21, M24 M14 : Grade CO Welding 2 All positional welding applications C 110 J @ -20 ° 10-15%CO 2 2 or equivalent ISO14175: or equivalent ISO14175: M21, M24 Argon + 2 2 + DC + 3% O 2 Yield StressYield StrengthTensile 550 MPaElongationVal.MPa 450 CVN Impact 120 J @ -20 29%RECOMMENDED SHIELDING GAS: Ar + 10-15% CO 525 MPa 410 MPa Grade CO Welding 32% CIGWELD PRODUCTS: COMPARABLE TIG rod: Comweld LW1 A5.18:AWS/ASME-SFA ER70S-4 APPROVALS: of Shipping Register Lloyd’s of ShippingAmerican Bureau Veritas Det Norske TYPICAL WIRE ANALYSIS: C: 0.08% 3S Grade S: 3SA Grade 0.010%TO HYDROGEN LEVELS TYPICAL DIFFUSIBLE AS3752: Mn: 1.16% P: 0.015% / 100gms of deposited weld metal. 1.0 - 2.0 mls of hydrogen IIIYMS Grade TYPICAL ALL WELD MECHANICAL METAL Si: 0.70% PROPERTIES: Ar + 5% CO Ar + 15-25% CO C) and at a ° C above ambient ° 0.91.2 15–26 18–32 3.5–15 2.5–15 70–230 120–350 Spool Spool 15kg 15kg 720115 720116 mm Range (volts) (metres/min) Range (amps) For GMAW Welding of Mild & Low of Mild Welding GMAW For Alloy Steels. to Copper Resistance Increased Settings. Current Flaking at High for Use with Designed Primarily Gases. Based Shielding Argon with Short-arc, Suitable for use Modes. Transfer & Pulsed arc Spray Wire DiameterWire Voltage Speed Feed Wire CurrentType* Pack Weight Pack No Part Packaging and Operating Data: and Operating Packaging Classifications: Applications: Description and AUTOCRAFT LW1 AUTOCRAFT temperature (with a maximum of 40 maximum humidity of 60% R.H. is recommended. on racks or pallets clear Product should be stacked of the floor and walls. AS/NZS 2717.1:A5.18: AWS/ASME-SFA ER70S-4. coated is a high quality copper Autocraft LW1 ES4-GC/M-W503AH. wire welding wire manufactured using the latest drawing technology. technology state-of-the-art This ensures; - for the highest quality copper coating improved wire feeding, and electrical conductivity lower contact tip wear. Improved copper coating especially gives increased resistance to copper flaking under high current welding conditions. Autocraft LW1 Gas Metal is suitable for the all positional multi-pass Arc welding of mild, low alloy and medium strength steels, as used in general fabrication, pressure vessels and structural work. exhibits excellent Autocraft LW1 important operator appeal and very low spatter levels for welding light to medium gauge sheet, pipe and tubular steel sections. welds exhibit a mitre to Fillet smooth slightly concave profile with an even and contour. Recommendations: Storage When held under the recommended storage are Autocraft LW1 conditions unopened packs of ‘factory fresh’ condition for expected to remain in at least 12 months. or under adverse (damp storage over 12 months For or high humidity) climatic conditions the use of heated weather proof store rooms/cupboards/ containers maintained at 10-15 ▲ ▲ ▲ ▲ * Spool (ø300mm); www.cigweld.com.au 106 GAS METAL ARC WELDING (MIG) WIRES www.cigweld.com.au ▲ ▲ store rooms/cupboards/containersmaintainedat For storageover12monthsorunderadverse(damphigh humidity)climaticconditionstheuseofheatedweatherproof condition foratleast12months. Steel areexpectedtoremainin ‘factory fresh’ conditions unopenedpacksof Autocraft Super When heldundertherecommendedstorage Storage Recommendations: achieved underhighdilution. toughness andradiographicsoundnessare and heavywalled jointswheregoodweld tanks, pipes andtherootpassweldingofpipes, (MIG) weldingofrustyormillscaledplatesand ItistheidealchoiceforGasMetal Arc quality. Manganese andSiliconforimprovedwelddeposit Aluminium andZirconiuminadditionto Autocraft SuperSteelisdeoxidisedwith Titanium, mild andmediumstrengthsteels. the highqualityGasMetal Arc (MIG)weldingof deoxidised’ steelweldingwirerecommendedfor Autocraft SuperSteelisacoppercoated ‘triple ES2-GC/M-W503AH. ER70S-2. AWS/ASME-SFA A5.18: AS/NZS 2717.1: ▲ ▲ aiu uiiyo 0 ..i eomne.Productshouldbestacked onracksorpalletsclearofthefloorandwalls. isrecommended. maximum humidityof60%R.H. * Spool(ø300mm). Packaging andOperating Data: Description and Applications: Classifications: AUTOCRAFT SUPERSTEEL ieDaee otg ieFe pe urn akTp*Pc egtPart No Pack Weight Pack Type* Current Wire Feed Speed Voltage Wire Diameter Argon BasedShielding Gases. Spray &Pulsed Arc Transfer Modes. Suitable forUsewithShort-arc, Porosity. Deposit QualityandResistanceto Triple DeoxidisedforSuperior Weld For usewith Welding Grade CO Applications. Steel Wire forGMAW Welding Triple Deoxidised A LowCarbon, mRne(ot)(ersmn Range(amps) (metres/min) Range(volts) mm . 83 .-51030Sol1k 720054 15kg Spool 120-350 3.5-15 18-32 1.2 2 or 10-15 ° C above ambienttemperature(withamaximumof40 AWS A5.18 ER70S-2 AWS A5.18 Comweld SuperSteel TIG rod COMPARABLE CIGWELDPRODUCTS: ● ● ● RECOMMENDED SHIELDINGGAS: Ar+20-25%CO Using PROPERTIES: METALMECHANICAL TYPICAL ALLWELD Balance Fe: 0.08% Al: metal. 0.55% Si: 1.0 -2.0mlsofhydrogen/100gmsdepositedweld 0.008% AS3752: P: 0.06% Zr: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO 1.10% Mn: 0.007% S: 0.10% Ti: 0.05% C: TYPICAL WIREANALYSIS: lnain34% 425MPa 75Jav@-20 520MPa CVN Impact Values Elongation Tensile Strength Yield Stress Welding GradeCO Ar +1-3%O Ar +15-25%CO DC 2 + or equivalent 2 2 or equivalent applications All positionalwelding ° C ISO14175: ISO14175: ISO14175: 2 : ° C) andata C1 M13 M24 M21, GAS METAL ARC WELDING (MIG) WIRES 107 : 2 C ° Welding GradeCO Welding 2 ISO14175: C1 ISO14175: M23 M 21, M24 M14 C J @ -20 110 All positional welding applications ° 2 Argon + 20-25% CO 2 or equivalent ISO14175: or equivalent ISO14175: M21, M24 2 2 + DC + 3% O 2 Yield StressYield StrengthTensile ElongationVal.CVN Impact 550 MPa 450 MPa 120 J @ -20 29% 525 MPa 410 MPa 32% RECOMMENDED SHIELDING GAS: Ar + 10-15% CO Grade CO Welding CIGWELD PRODUCTS: COMPARABLE TIG rod: Comweld LW1-6 A5.18:AWS/ASME-SFA ER70S-6 APPROVALS*: of ShippingLloyd's Register of ShippingAmerican Bureau Veritas Det Norske Grade 111YMS Autocraft LW1-6 do not include 0.6mm Approvals * 3S, Grade 3YS Grade 3SA, 3YSA TYPICAL WIRE ANALYSIS: C: 0.07%S: 0.012%AS3752: TO HYDROGEN LEVELS TYPICAL DIFFUSIBLE / 100gms of deposited weld metal. 1.0 - 2.0 mls of hydrogen Mn: 1.55% P: 0.015% MECHANICAL PROPERTIES: WELD METAL ALL TYPICAL Si: 0.88% Ar + 5% CO Ar + 15-25% CO and 2 C) and at a maximum humidity of 60% R.H. is recommended. on racks or pallets Product should be stacked ° above ambient temperature (with a C ° Argon Based Shielding Gases. Based Shielding Argon Wide Range of Minispool, Wide Autopak Handispool and Options. Packaging A Higher Manganese / Silicon Wire Wire Silicon Manganese / A Higher of Mild & Low Welding for GMAW Alloy Steels. with CO Designed for Use Classifications: Applications: Description and AUTOCRAFT LW1-6 AUTOCRAFT clear of the floor and walls. ▲ 10-15 AS/NZS 2717.1:A5.18: AWS/ASME-SFA ER70S-6. ES6-GC/M-W503AH. is a high quality copper coated Autocraft LW1-6 Gas welding wire suitable for the all positional (GMAW) of mild and low alloy Welding Arc Metal steels, general fabrication and structural used in work. high quality copper coating ensures The problem free feeding, pick-up and smooth current minimal contact tip wear. higher silicon The ensures excellent Autocraft LW1-6 content of operator appeal, improved fillet shape / side wall at weld toes and very low spatter levels wash gauge important for welding light to medium sheet and tubular steel sections. welds Fillet with an exhibit a mitre to slightly convex profile even and smooth contour. higher The Manganese / Silicon levels give improved weld metal deoxidation when welding steels with moderate amounts of rust or mill scale. Recommendations: Storage When held under the recommended storage Autocraft LW1-6 conditions unopened packs of ‘factory fresh’ wires are expected to remain in condition for at least 12 months. storage over 12 months or under adverse For (damp or high humidity) climatic conditions the use of heated weather proof store rooms/cupboards/containers maintained at ▲ ▲ maximum of 40 www.cigweld.com.au 108 GAS METAL ARC WELDING (MIG) WIRES www.cigweld.com.au UOA cesre Sadr ye” Part Number. 720001 AUTOPAK conduitassemblykit 2. x300mmheight). Clearplastic AUTOPAK dome(510mmbasediam. 1. AUTOPAK accessories “Standard Types”. H.770mm);** AutoPak (ø650mmxH820mm). AutoPak (ø510mmx Spool(ø300mm); HandiSpool(ø200mm); * MiniSpool(ø100mm); AUTOPAK Packaging andOperating Data: AUTOCRAFT LW1-6 ieDaVlaeWr edSedCretPc ye akWih Part No Pack Weight Pack Type* Current Wire Feed Speed Voltage Wire Dia mRne(ot)(ersmn Range(amps) (metres/min) Range(volts) mm . 83 .–0180–390 2.5–10 120–350 18–34 2.5–15 100–280 721109 1.6 18–32 3.5–15 5kg 70–230 1.2 721108 16–29 3.5–15 HandiSpool 5kg 50–180 1.0 15–26 3.5–14 HandiSpool 0.9 35–100 14–22 3.5–14 0.8 12–14 0.6 ® Parts List: iiSol-Pcso 4x08g721105 4x0.8kg Mini Spool-Packs of 721104 4x0.8kg Mini Spool-Packs of adsol5g720161 5kg Handispool *uoa 5k 720125A 350kg **AutoPak uoa 5k 720124A 250kg 720123A 250kg AutoPak 720122A 250kg AutoPak AutoPak po 5g720095 15kg 720096 15kg 720094 Spool 15kg Spool Spool po 5g720090 15kg 720114 15kg Spool 720103 Spool 15kg Spool DC + 720008 GAS METAL ARC WELDING (MIG) WIRES 109 Cardboard Drum P/N: 720008 2.Assembly Kit Conduit Autopak of floor space. 2 + DC Autopak occupies only 0.2m == Less stress on wire-feed unit. Less wire slippage and burn backs. . ® 1. and Conduit Clear Plastic Dome Adaptor P/N: 720001 Steel Locking Ring Handle Pressure Ring Wire Reduced downtime free wire Straight/Twist Acceleration weight Smaller = = = Higher productivity outcomes. Improved arc starting. Greater wire accuracy in the joint. Fully Enclosed pack and pay-off system Compact and manoeuvrable = against dust, Protection dirt and moisture. = Ease of use in confined and restricted locations. The advantages of AUTOPAK of The advantages AUTOCRAFT LW1-6 AUTOCRAFT ✦ ✦ ✦ ✦ ✦ www.cigweld.com.au 110 GAS METAL ARC WELDING (MIG) WIRES www.cigweld.com.au to pipelines whereservicetemperaturesup boilersand fabrication ofpressurevessels, particularlythoseusedinthe strength steels, fillet andbuttweldingofawiderangehigher Autocraft Mn-Moissuitablefortheallpositional to itshigherdeoxidantlevels. to porositywhenweldingdirtyorrustyplatedue Itgivesexcellentresistance 550 MPa tensileclass. 1.7% Mn/0.4%Mo)steelwelddepositofthe Autocraft Mn-Moproducesalowalloy(nominally steels. Arc Welding (GMAW)ofmediumtohigh strength steel wiresuitablefortheallpositionalGasMetal lowalloy Autocraft Mn-Moisacoppercoated, ESD2-GC/M-W559AH. ER80S-D2. AWS/ASME-SFA A5.28: AS/NZS 2717.1: ▲ ▲ aiu uiiyo 0 ..i eomne.Productshouldbestacked onracksorpalletsclearofthefloorandwalls. isrecommended. maximum humidityof60%R.H. * Spool(ø300mm). store rooms/cupboards/containersmaintainedat For storageover12monthsorunderadverse(damphigh humidity)climaticconditionstheuseofheatedweatherproof ‘factory fresh’conditionforatleast12months. When heldundertherecommendedstorageconditionsunopenedpacksof Autocraft Mn-Mowiresareexpectedtoremainin Storage Recommendations: of componentssubjectedtodynamicloading. include thelowerstrengthfilletandbuttwelding ▲ ▲ Packaging andOperating Data: Description and Applications: Classifications: AUTOCRAFT Mn-Mo ieDaee otg ieFe pe urn akTp*Pc egtPart No Pack Weight Pack Type* Current Wire Feed Speed Voltage Wire Diameter ≈

For Usewith Welding Grade CO Higher Strength steels. Wire fortheGMAW Welding of A ManganeseMolybdenumSteel Argon BasedShieldingGases. Spray &Pulsed Arc Transfer Modes. Suitable forUsewithShort-arc, MPa550 TensileDeposits.Class Weld 500 mRne(ot)(ersmn Range(amps) (metres/min) Range(volts) mm . 83 .-51030Sol1k 720052 720049 15kg 15kg Spool Spool 120-350 70-230 3.5-15 3.5-15 18-32 16-28 1.2 0.9 ° r xeine.Otherapplications C areexperienced. 2 or 10-15 ° C above ambienttemperature(withamaximumof40 lnain24% 580MPa 80Jav@+20 680MPa CVN Impact Values Elongation Tensile Strength Yield Stress ● ● ● RECOMMENDED SHIELDINGGAS: PROPERTIES: METALMECHANICAL TYPICAL ALLWELD 0.017% P: 0.65% Si: metal. 1.0 -2.0mlsofhydrogen/100gmsdepositedweld AS3752: 0.011% 1.73% S: Mn: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO 0.45% Mo: 0.08% C: TYPICAL WIREANALYSIS: Welding GradeCO Ar +1-3%O Ar +15-25%CO DC 2 + reuvln S115 M13 ISO14175: or equivalent 2 2 reuvln S115 2,M24 M21, ISO14175: or equivalent Argon +20-25%CO applications All positionalwelding ° S115 C1 ISO14175: C 2 : ° C) andata GAS METAL ARC WELDING (MIG) WIRES 111 : 2 C C ° ° ISO14175: C1 All positional welding applications : + 20-25% CO Ar C J @ -29 72 2 C 50 J @ -51 ° ° or equivalent ISO14175: M21, M24 2 2 80 J @ -51 Ar + 1-3% O or equivalent ISO14175: M13 + 2 DC Ar + 15-25% CO Ar + 1-3% O Grade CO Welding Yield StressYield StrengthTensile 790 MPaElongation 730 MPaVal.CVN Impact 130 J @ -29 17% 770 MPa 707 MPa 21% RECOMMENDED SHIELDING GAS: ● ● ● TYPICAL WIRE ANALYSIS: TYPICAL C: 0.08%Ni: 1.40%V: 0.10% TO HYDROGEN LEVELS TYPICAL DIFFUSIBLE Mn: 1.40% Cr:AS3752: 0.40% / 100gms of deposited weld 1.0 - 2.0 mls of hydrogen metal. Si: 0.60% TYPICAL ALL WELD MECHANICAL METAL Mo: 0.25% PROPERTIES: The actual weld metal mechanical properties achieved with The factors Autocraft Ni Cr Mo are influenced by many including, base metal analysis, welding parameters, passes etc.shielding gas selection and number of Please welding consult your nearest CIGWELD branch for procedure recommendations. or 2 C) and at a maximum humidity of 60% R.H. is recommended. on racks or Product should be stacked ° above ambient temperature C ° 1.2 18-32 3.5-15 120-350 Spool 15kg 720053 mm Range (volts) (metres/min) Range (amps) 760 MPa Tensile Weld Class Deposits. Tensile 760 MPa with Short-arc, Suitable for Use Modes. Transfer Arc & Pulsed Spray Argon Based Shielding Gases. Based Shielding Argon A Low Alloy Steel Wire for the Gas for Wire Steel Alloy A Low High Strength of Welding Metal steels. CO Grade Welding Use with For 10-15 Wire DiameterWire Voltage Speed Feed Wire CurrentType* Pack Weight Pack No Part Packaging and Operating Data: and Operating Packaging Classifications: Applications: Description and AUTOCRAFT NiCrMo AUTOCRAFT ▲ ▲ (with a maximum of 40 AS/NZS 2717.1:A5.28: AWS/ASME-SFA ER110S-G. ESMG-GC/M-W769AH. Autocraft Ni Cr Mo. is a copper coated, low alloy Gas Metal steel wire suitable for the all positional of high strength steels. Welding Arc Autocraft Ni Cr Mo. produces a low alloy (nominally, 1.4%Ni, 0.4%Cr, 0.30%Mo, 0.10%V) steel tensile class. weld deposit of the 690 MPa Autocraft Ni Cr Mo. is suitable for the all positional of high fillet and butt welding of a wide range strength steels,quenched and particularly tempered types such as Bisalloy 80, USS-T1 types 80C etc.Welten and Autocraft Ni Cr Mo. is not to be suitable for use in weldments which are stress relieved. ‘Vanadium these applications For TXP 110 Tensicor free’ welding wires such as are recommended. Recommendations: Storage When held under the recommended storage Autocraft Ni Cr Mo. conditions unopened packs of ‘factory fresh’ wires are expected to remain in condition for at least 12 months. storage over 12 months or under adverse For (damp or high humidity) climatic conditions the use of heated weather proof store rooms/cupboards/containers maintained at ▲ ▲ * Spool (ø300mm). pallets clear of the floor and walls. www.cigweld.com.au 112 GAS METAL ARC WELDING (MIG) WIRES www.cigweld.com.au at rooms/cupboards/containers maintained use ofheatedweatherproofstore (damp orhighhumidity)climaticconditionsthe For storageover12monthsorunderadverse for atleast12months. are expectedtoremainin ‘factory fresh’condition conditions unopenedpacksof Autocraft CrMo1 When heldundertherecommendedstorage Storage Recommendations: which canbesubsequentlyheattreated. for theweldingofcasehardenablesteelsor GMA weldingofCr-Mo steeltocarbonand Autocraft CrMo1isalsosuitableforthedissimilar generation andpetrochemicalindustriesetc. temperatures (upto550 platesandcastingsusedatelevated service pipes, 1Cr-1/2Mo and11/4Cr-1/2Mo steel 1/2Cr-1/2Mo, It isrecommendedfortheGMAweldingof Molybdenum (Mo). nominally 1.25%Chromium(Cr)and0.50% Metal Arc (GMA)weldingwirealloyedwith Autocraft CrMo1isacoppercoatedsteelGas ESB2-GM-W559AH. ER80S-B2. AWS/ASME-SFA A5.28: AS/NZS 2717.1: ▲ ▲ * Spool(ø300mm). uiiyo 0 ..i eomne.Productshouldbestacked onracksorpalletsclearofthefloorandwalls. isrecommended. humidity of60%R.H. (with amaximumof40 Packaging andOperating Data: Description and Applications: Classifications: AUTOCRAFT CrMo1 ieDaee otg ieFe pe urn akTp*Pc egtPart No Pack Weight Pack Type* Current Wire Feed Speed Voltage Wire Diameter 10-15 to CarbonSteels. Dissimilar Joining ofCr-MoSteels Also Recommendedforthe Corrosive Service. Steels forElevated Temperature and Welding ofCr-MoCreep Resistant For theGasMetal Arc (GMA) mRne(ot)(ersmn Range(amps) (metres/min) Range(volts) mm . 83 .-51030Sol1k 720029 15kg Spool 120-350 3.5-15 18-32 1.2 ° C above ambienttemperature ° ° C) andatamaximum C) inthepower ● ● RECOMMENDED SHIELDINGGAS: ER80S-B2 AWS A5.28: Comweld CrMo1 TIG rod E8018-B2 AWS A5.5: Alloycraft 80-B2electrode COMPARABLE CIGWELDPRODUCTS: PROPERTIES: METALMECHANICAL TYPICAL ALLWELD metal. 0.015% P: 1.0 -2.0mlsofhydrogen/100gmsdepositedweld 0.60% Si: AS3752: Balance Fe: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO 0.50% Mo: 0.60% Mn: 0.010% S: 1.30% Cr: 0.09% C: TYPICAL WIREANALYSIS: lnain20% 60Jav@+20 600MPa 500MPa CVN Impact Values Elongation Tensile Strength 0.2% ProofStress Post weldheattreatedat620 Ar +1-3%O Ar +15-25%CO DC 2 + reuvln S115 M13 ISO14175: or equivalent 2 reuvln S115 2,M24 M21, ISO14175: or equivalent Argon +1-3%O ° C asrequiredby AWS A5.28. applications All positionalwelding ° C 2 : GAS METAL ARC WELDING (MIG) WIRES 113 C ° ISO14175: M12 Stainshield: All positional welding applications or equivalent + 35% He or equivalent ISO14175: M13 2 2 + 2 DC Ar + 1-3% O Ar + 2-5% CO Ar + 2-4% CO COMPARABLE CIGWELD PRODUCTS: COMPARABLE Coabalarc Austex AS/NZS 2576 1315-A4 RECOMMENDED SHIELDING GAS: ● ● ● TYPICAL WIRE ANALYSIS: TYPICAL C: 0.07%Cr: 18.5%S: 0.015% Mn: 8.90% Ni:FERRITE NUMBER: 8.5% Fe: Balance 10 – 15 FN Si: 0.8% TYPICAL ALL WELD MECHANICAL METAL P:PROPERTIES: 0.03% 0.2% Proof Stress StrengthTensile ElongationValuesCVN Impact 450 MPa 640 MPa 150 J av @ 20 40% 1.2 20-28 3.0-10.0 150-280 Spool 15kg 721301 0.9 16-24 4.5-15.0 70-200 Spool 15kg 721300 mm Range (volts) (metres/min) Range (amps) Series’ stainless steel grades to mild or low alloy steels Series’ stainless steel grades to mild or clad steels, 13% Mn steels New Ultrafeed matt finish. matt New Ultrafeed For the GMAW Welding of hardenable of Welding GMAW the For steels, difficult to weld Mn steels & 13% steels. Weld ) Low Carbon ( < 0.07% Extra to Deposits for Resistance Corrosion. Intergranular Arc for Improved High Silicon level Pool Weld Stability and Increased Wetting. Fluidity and Edge Wire DiameterWire Voltage Speed Feed Wire CurrentType* Pack Weight Pack No Part Packaging and Operating Data: and Operating Packaging Classifications: Applications: Description and AUTOCRAFT 307Si AUTOCRAFT These machine settings are a guide only. machine settings are a guide These Actual voltage and welding current used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc. Autocraft 307Si is a premium quality, low carbon 18% Cr, 8% Gas Ni and 8% Mn stainless steel wire for the (GMAW) of hardenable steels,Welding Arc Metal 13% Mn steels and difficult to weld steels. range of other Autocraft 307Si is also suitable for a wide welding applications including: •‘400 ‘300 Series’ and selected of the dissimilar joining • an intermediate or buttering layer in the butt welding of • a stainless steel overlay on mild or low alloy steel and • from carbide low carbon content ensures immunity The a buttering layer prior to surfacing. precipitation and intergranular corrosion when welding low carbon stainless steel grades and the higher Silicon level offers improved arc stability, bead shape and edge wetting. be PWHT without Autocraft 307Si can produced with Welds the risk of sigma-phase and loss of ductility. ▲ AS 2717.3:A5.9: AWS/ASME-SFA ES307Si. ES307Si. ▲ ▲ ▲ * Spool (ø300mm). www.cigweld.com.au 114 GAS METAL ARC WELDING (MIG) WIRES www.cigweld.com.au * Spool(ø300mm). lt hcns,rnsz,shieldinggasandoperatortechniqueetc. runsize, plate thickness, Actualvoltageandweldingcurrentusedwilldependonmachinecharacteristics, These machinesettingsareaguideonly. cryogenic applications. and 304Ltypesincorrosionresistant 409and444type stainless steelsandforthecriticalweldingof304 347, 321, 302, welding of301, Autocraft 308LSiisrecommendedforthegeneral wetting. beadshapeandedge offers improvedarcstability, stainless steelgradesandthehigherSiliconlevel intergranular corrosionwhenweldinglowcarbon ensures immunityfromcarbideprecipitationand The lowcarboncontentof Autocraft 308LSi forgings andcastings. plates, austenitic 18/8typestainlesssteelpipes, Metal Arc Welding (GMAW)ofawiderange ES308LSi. 20% Cr/10%NistainlesssteelwirefortheGas lowcarbon Autocraft 308LSiisapremiumquality, ER308LSi. AWS/ASME-SFA A5.9: AS 2717.3: ▲ ▲ ▲ ▲ Description and Applications: Classifications: AUTOCRAFT 308LSi Packaging andOperating Data: ieDaee otg ieFe pe urn akTp*Pc egtPart No Pack Weight Pack Type* Current Wire Feed Speed Voltage Wire Diameter NEW Ultrafeed MattFinish. Fluidity andEdge Wetting. Stability andIncreased Weld Pool High SiliconlevelforImproved Arc Intergranular Corrosion. Deposits forResistanceto Extra LowCarbon (<0.03%) Weld 18%Cr /8%Ni Type StainlessSteels. For theGMAW Welding of mRne(ot)(ersmn Range(amps) (metres/min) Range(volts) mm . 02 .-001020Sol1k 721272 721271 15kg 15kg Spool Spool 150-280 70-200 3.0-10.0 4.5-15.0 20-28 16-24 1.2 0.9 ● ● ● ● RECOMMENDED SHIELDINGGAS: E308LT1-1/4 AWS A5.22: Shieldcrome 308LT FCAWwires ER308L AWS A5.9: Comweld 308L TIG rod E308L-17 AWS A5.4: Satincrome 308L-17electrode COMPARABLE CIGWELDPRODUCTS: PROPERTIES: METALMECHANICAL TYPICAL ALLWELD 0.020% 0.80% P: Si: 5 –10FN Balance Fe: FERRITE NUMBER: 10.25% 2.05% Ni: Mn: 0.005% S: 19.95% Cr: 0.02% C: TYPICAL WIREANALYSIS: lnain36% 90Jav@-60 620MPa 450MPa CVN Impact Values Elongation Tensile Strength 0.2% ProofStress Ar +1-4%CO Ar +1-4%CO Ar +2-5%CO Ar +1-3%O DC 2 + 2 2 2 reuvln S115 M13 ISO14175: or equivalent or equivalent + 35%He + 1-5%H 2 or equivalent applications All positionalwelding Ar +1-3%O ISO14175: ISO14175: M12 2 ° : C M11 (1) GAS METAL ARC WELDING (MIG) WIRES 115 : 2 C M11 (1) ° M12 ISO14175: ISO14175: Argon + 1-3% O All positional welding applications or equivalent or equivalent 2 + 1-5% H + 35% He or equivalent or equivalent ISO14175: M13 2 2 2 + 2 DC Ar + 1-3% O Ar + 2-5% CO Ar + 1-4% CO Ar + 1-4% CO 0.2% Proof Stress StrengthTensile ElongationValuesCVN Impact 450 MPa 610 MPa -110 90 J av @ 36% COMPARABLE CIGWELD PRODUCTS: COMPARABLE Satincrome 309Mo-17 electrode AWS A5.4: E309Mo-17 TIG rod Comweld 309L AWS A5.9: ER309L FCAW wires Shieldcrome 309LT AWS A5.22: E309LT1-1/4 RECOMMENDED SHIELDING GAS: ● ● ● ● TYPICAL WIRE ANALYSIS: TYPICAL C: 0.02%Cr: 23.75%S: 0.005% Mn: Ni: 2.10% 13.75%FERRITE NUMBER: Fe: Balance 10 – 15 FN Si: P: 0.75% 0.020% TYPICAL ALL WELD MECHANICAL METAL PROPERTIES: 0.91.2 16-24 20-28 4.5-15.0 3.0-10.0 70-200 150-280 Spool Spool 15kg 15kg 721276 721277 mm Range (volts) (metres/min) Range (amps) The dissimilar joining of “300 series” dissimilar joining of The and “400 series”selected stainless steel grades to mild or low alloy steels, An intermediate or buttering layer in the butt welding of clad steels, A stainless steel overlay on mild or low alloy steel, ‘buttering’ layer prior to hardfacing. A For the GMAW Welding of of Welding GMAW the For Steels. Stainless Type / 12%Ni 23%Cr Weld 0.03% ) Carbon ( < Low Extra to Deposits for Resistance Corrosion. Intergranular Arc for Improved High Silicon level Pool Weld Stability and Increased Wetting. Fluidity and Edge NEW Ultrafeed Matt Finish. NEW Ultrafeed Wire DiameterWire Voltage Speed Feed Wire CurrentType* Pack Weight Pack No Part Packaging and Operating Data: and Operating Packaging Classifications: Applications: Description and AUTOCRAFT 309LSi AUTOCRAFT These machine settings are a guide only. machine settings are a guide These Actual voltage and welding current used will depend on machine characteristics, plate thickness, run size, gas and operator technique etc. shielding Autocraft 309LSi is a premium quality, low carbon the Gas 24% Cr / 13% Ni stainless steel wire for (GMAW) of matching 309L type Welding Arc Metal stainless steel. range Autocraft 309LSi is also suitable for a wide of other welding applications including; ✦ ✦ ✦ ✦ from low carbon content ensures immunity The carbide precipitation and intergranular corrosion when welding low carbon stainless steel grades and the higher Silicon level offers improved arc stability, bead shape and edge wetting. ▲ AS 2717.3:A5.9: AWS/ASME-SFA ER309LSi. ES309LSi. ▲ ▲ ▲ * Spool (ø300mm). www.cigweld.com.au 116 GAS METAL ARC WELDING (MIG) WIRES www.cigweld.com.au lt hcns,rnsz,shieldinggasandoperatortechniqueetc. runsize, plate thickness, Actualvoltageandweldingcurrentusedwilldependonmachinecharacteristics, These machinesettingsareaguideonly. beadshapeandedgewetting. stability, and thehigherSiliconleveloffersimprovedarc when weldinglowcarbonstainlesssteelgrades carbide precipitationandintergranularcorrosion The lowcarboncontentensuresimmunityfrom 410 347, and 430. 321, 304/304L, 302, steels including301, welding ofother300and400seriesstainless Autocraft 316LSiisalsosuitableforthegeneral 316L alloys. 318and inparticular316, bearing stainlesssteels; Gas Metal Arc Welding (GMAW)ofMolybdenum ES316LSi. 19% Cr/13%Ni2.5Mostainlesssteelwireforthe lowcarbon Autocraft 316LSiisapremiumquality, ER316LSi. AWS/ASME-SFA A5.9: AS 2717.3: ▲ ▲ ▲ ▲ iisol(10m;Hnisol(20m;Spool(ø300mm). Handispool(ø200mm); * Minispool(ø100mm); Packaging andOperating Data: Description and Applications: Classifications: AUTOCRAFT 316LSi ieDaVlaeWr edSedCretPc ye akWih Part No Pack Weight Pack Type* Current Wire Feed Speed Voltage Wire Dia Fluidity andEdge Wetting. Stability andIncreased Weld Pool High SiliconlevelforImproved Arc Intergranular Corrosion. Deposits forResistanceto Extra LowCarbon (<0.03%) Weld 3%Mo Type StainlessSteels. 18%Cr /8%Niand For theGMAW Welding of NEW Ultrafeed MattFinish. mRne(ot)(ersmn Range(amps) (metres/min) Range(volts) mm . 02 .–001020Sol1k 721287 722386 721286 15kg 15kg 720283 15kg Spool 5kg Spool Spool 721285 Handispool 150–280 70–200 4x1kg 70–200 Minispool(4perpack) 70–200 3.0–10.0 60–150 4.5–15.0 4.5–15.0 4.5–15.0 20–28 5.0–15.0 16–24 16–24 1.2 16–24 1.0 16–20 0.9 0.9 0.8 lnain38% 90Jav@–60 640MPa 470MPa CVN Impact Valves Elongation Tensile Strength 0.2% ProofStress ● ● ● ● RECOMMENDED SHIELDINGGAS: E316LT1-1/4 AWS A5.22: Shieldcrome 316LT FCAWwires ER316L AWS A5.9: Comweld 316L TIG rod E316L-17 AWS A5.4: Satincrome 316L-17electrode COMPARABLE CIGWELDPRODUCTS: Balance Fe: PROPERTIES: METALMECHANICAL TYPICAL ALLWELD 2.45% 0.70% Mo: Si: 5 –10FN 0.002% S: FERRITE NUMBER: 12.75% 1.52% Ni: Mn: 0.022% P: 18.85% Cr: 0.02% C: TYPICAL WIREANALYSIS: Ar +1-4%CO Ar +1-4%CO Ar +2-5%CO Ar +1-3%O DC 2 + 2 2 2 reuvln S115 M13 ISO14175: or equivalent or equivalent + 35%He + 1-5%H 2 or equivalent applications All positionalwelding Argon +1-3%O ISO14175: ISO14175: ° M12 C 2 : M11 (1) DC METAL(MIG) WIRES GAS ARC WELDING AUTOCRAFT 2209 + ▲ For the GMAW welding of TYPICAL WIRE ANALYSIS: 22%Cr/5%Ni/3%Mo duplex type C: 0.012% Mn: 1.60% Si: 0.44% stainless steels. Cr: 22.80% Ni: 8.63% Mo: 3.10% N: 0.14% P: 0.018% S: 0.007% ▲ Extra low carbon (<0.03%) Cu: 0.06% Fe: Balance corrosion resistance weld deposits. FERRITE NUMBER: ▲ Precision layer wound for improved 30- 50 FN (Procedure dependent) feedability and performance. TYPICAL ALL WELD METAL MECHANICAL ▲ New Ultrafeed matt finish. PROPERTIES: Welding grade Argon: 0.2% Proof Stress 600 MPa Classifications: Tensile Strength 765 MPa AS 2717.3: ES2209 Elongation 28% AWS/ASME-SFA A5.9: ER2209. CVN Impact Value 60J av @ -40˚C Werkstoffe No: 1.4462 80J av @ -20˚C 100J av @ +20˚C Description and Applications: COMPARABLE CIGWELD PRODUCTS: Comweld 2209 TIG rod Autocraft 2209 is a premium quality GMAW stainless steel AWS A5.9: ER 2209 welding wire suitable for the single and multi-pass fillet and butt welding of 22Cr/5Ni/3Mo type duplex stainless steels. RECOMMENDED SHIELDING GAS: Applications include the welding of duplex stainless steels ● Ar + 1-3% O2 or equivalent ISO14175: M13 (UNS S30000 series) as used for corrosion resistant applications ● Ar + 2-5% CO2 or equivalent ISO14175: M12 as an alternative to 300 series austenitic stainless steels. Some nitrogen bearing shielding gases assist in maintaining an optimum Austenite/Ferrite ratio. Consult your gas supplier for The most common duplex grades weldable with Autocraft specific details. 2209 include S39205 (2205 and Bohler A903) and S39230 (2304).

Autocraft 2209 has high resistance to intergranular and All positional welding pitting corrosion. It has especially high resistance to stress applications corrosion in chloride and hydrogen sulphide containing media. Applications include the welding of stainless steel tanks and pipes in the chemistry industry.

Packaging and Operating Data: These machine settings are a guide only. Actual voltage and welding current used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc. Wire Diameter Voltage Wire Feed Speed Current Pack Type* Pack Weight Part No mm Range (volts) (metres/min) Range (amps) 0.9 16-24 4.5-15.0 65-165 Spool 15kg 721261 1.2 20-26 3.0-10.0 180-280 Spool 15kg 721262

117 www.cigweld.com.au DC AUTOCRAFT AL1100 + ▲ For the GMAW Welding of Selected WIRE ANALYSIS LIMITS: Wrought Aluminium Alloys. Si: 0.06% Fe: 0.06% Cu: 0.005% ▲ Highest Quality - Precision Layer Wound. Mn: 0.01% Mg: 0.01% Zn: 0.03% ▲ Patented Lubrication Process for Ti: 0.01% Total others: 0.01% Superior Wire Feedability. Al: 99.88% min. * Single values are maximum allowable, unless otherwise stated. ▲ Superior Wire Cleanliness for TYPICAL ALL WELD METAL MECHANICAL Improved Resistance to Porosity. PROPERTIES: ▲ Tight Wire Diameter Control for Single-vee butt weld with 1060 Aluminium (reduced section Smooth, Consistent Arc tensile specimen): Performance. Welding grade Argon: ▲ Standard 7 kg Spools for Fewer 0.2% Proof Stress 34.5 MPa Spool Change-overs. Tensile Strength 69.0 MPa Elongation (in 2 inches) 29% Classifications: RECOMMENDED SHIELDING GAS: AS/NZS 2717.2: E1100. ● Welding Grade Argon ISO14175: I1 AWS/ASME-SFA A5.10: ER1100. ● Ar + 25% He or equivalent gases ISO14175: I3 ● He + 25% Ar or equivalent gases ISO14175: I3 Description and Applications: Autocraft AL1100 is a premium quality, pure ( 99.88% min ) Aluminium alloy recommended for the Gas Metal Arc Welding All positional welding GAS METAL ARC WELDING GAS (MIG) WIRES METAL (GMAW) of selected 1XXX series wrought Aluminium alloys. applications The lower weld deposit strength, excellent corrosion resistance and high thermal and electrical conductivity make Autocraft AL1100 ideal for the joining of selected high purity 1XXX series Aluminium alloys used extensively in electrical and chemical industry applications. Autocraft AL1100 produces a good colour match in anodised 1XXX series welded joints. See CIGWELD Aluminium Alloy Selection Chart for detailed welding consumable selection criteria for a wide range of Aluminium alloy parent metals.

Storage and Handling Recommendations: ✦ Store in a heated room with uniform temperature control and, if possible, with humidity control as well. ✦ Store unpackaged Autocraft AL series wires for long periods in a heated cabinet at 10-15°C above ambient temperature. ✦ Hold Autocraft AL series welding wires in the welding area for 24 hours before unpacking to allow its temperature to equalise with that of the surrounding area. ✦ Use dust covers on open wire feed units to protect wire during welding. Packaging and Operating Data: These machine settings are a guide only. Actual voltage and welding current used will depend on machine characteristics, plate For 1XXX, 2XXX and 4XXX type welding wires use welding current settings on the lower side of the specified range and arc voltages on the higher side. Wire Dia Voltage Wire Feed Speed Current Pack Type* Pack Weight Part No mm Range (volts) (metres/min) Range (amps) 1.6 23-28 5.0-9.5 200-350 Spool 7kg 722218 2.0 25-31 4.0-8.0 250-400 Spool 7kg 723218

* Spool (ø300mm).

118 www.cigweld.com.au DC METAL(MIG) WIRES GAS ARC WELDING AUTOCRAFT AL4043 + ▲ For GMAW Welding of Selected Wrought and WIRE ANALYSIS LIMITS: Cast Aluminium Alloys. Single values are maximum allowable, unless otherwise ▲ Highest Quality - Precision Layer Wound. stated. ▲ Si: 4.5–6.0% Fe: 0.80% Cu: 0.30% Patented Lubrication Process for Superior Wire Mn: 0.05% Mg: 0.05% Zn: 0.10% Feedability. Ti: 0.20% Total others: 0.15% ▲ Superior Wire Cleanliness for Improved Al: Balance Resistance to Porosity. TYPICAL ALL WELD METAL MECHANICAL ▲ Tight Wire Diameter Control for Smooth, PROPERTIES: Consistent Arc Performance. Single-vee butt weld with 6061-T6 Aluminium (reduced ▲ Standard 7.0 kg Spools for Fewer Spool Change- section tensile specimen) using welding grade Argon: Postweld heat overs. As welded: treated and aged: Classifications: 0.2% Proof Stress 124 MPa 276 MPa AS 2717.2: E4043. Tensile Strength 186 MPa 303 MPa AWS/ASME-SFA A5.10: ER4043. Elongation (in 2 inches) 8% 5% Description and Applications: RECOMMENDED SHIELDING GAS: Autocraft AL4043 is a premium quality Aluminium - nominal ● Welding Grade Argon ISO14175: I 5% Silicon alloy suitable for the Gas Metal Arc Welding ● Ar + 25% He or equivalent gases ISO14175: I3 (GMAW) of a wide range of cast and wrought Aluminium ● He + 25% Ar or equivalent gases ISO14175: I3 alloys. Autocraft AL4043 is used extensively for the repair welding of many aluminium alloy castings. It’s lower weld deposit strength, and excellent crack resistance make it All positional welding suitable for the GMA welding of cast ( mainly 4XX & 6XX applications series ) and wrought ( selected 1XXX, 5XXX & 6XXX series ) aluminium alloys, except where an accurate colour match is required after anodising. See CIGWELD Aluminium Alloy Selection Chart for detailed welding consumable selection criteria for a wide range of Aluminium alloy parent metals. Storage and Handling Recommendations: ✦ Store in a heated room with uniform temperature control and, if possible, with humidity control as well. ✦ Store unpackaged Autocraft AL series wires for long periods in a heated cabinet at 10-15°C above ambient temperature. ✦ Hold Autocraft AL series welding wires in the welding area for 24 hours before unpacking to allow its temperature to equalise with that of the surrounding area. ✦ Use dust covers on open wire feed units to protect wire during welding. Packaging and Operating Data: These machine settings are a guide only. Actual voltage and welding current used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc. For 5XXX type welding wires use welding current settings on the higher side of the range specified below and arc voltages on the lower side of the range. For 1XXX, 2XXX and 4XXX type welding wires use welding current settings on the lower side of the specified range and arc voltages on the higher side. Wire Dia Voltage Wire Feed Speed Current Pack Type* Pack Weight Part No mm Range (volts) (metres/min) Range (amps) 1.2 20-25 5.5-12.0 150-250 Spool 7kg 722237 1.6 23-28 5.0-9.5 200-350 Spool 7kg 722238

* Spool (ø300mm).

www.cigweld.com.au 119 DC AUTOCRAFT AL5356 + ▲ For GMAW Welding of Wrought and APPROVALS: Cast Aluminium Alloys containing Det Norske Veritas (DNV). Magnesium. Lloyds Register (LRS). ▲ Patented Lubrication Process for * with welding grade Argon Superior Wire Feedability. WIRE ANALYSIS LIMITS: ▲ Superior Surface Cleanliness for Single values are maximum allowable, unless otherwise Improved Resistance to Porosity. stated. ▲ Tight Wire Diameter Control for Si: 0.25% Fe: 0.40% Cu: 0.10% Smooth, Consistent Arc Performance. Mn: 0.05–0.2% Mg: 4.5–5.5% Cr: 0.05–0.20% ▲ Zn: 0.10% Ti: 0.06–0.20% DNV Shipping Society Approval. Total others: 0.15% Al: Balance ▲ Standard 7.0 kg Spools for Fewer TYPICAL ALL WELD METAL MECHANICAL Spool Change-overs. PROPERTIES: Single-vee butt weld with 5086 Aluminium (reduced section tensile specimen): Classifications: Welding grade Argon: AS 2717.2: E5356. 0.2% Proof Stress 130 MPa AWS/ASME-SFA A5.10: ER5356. Tensile Strength 269 MPa Elongation (in 2 inches) 17% Description and Applications: RECOMMENDED SHIELDING GAS: GAS METAL ARC WELDING GAS (MIG) WIRES METAL Autocraft AL5356 is a premium quality, Aluminium ● Welding Grade Argon ISO14175: I - nominal 5% Magnesium alloy suitable for the ● Ar + 25% He or equivalent gases ISO14175: I3 Gas Metal Arc Welding (GMAW) of a wide range of ● He + 25% Ar or equivalent gases ISO14175: I3 cast and wrought Aluminium alloys. Autocraft AL5356 is the most popular Aluminium alloy in the CIGWELD range. It produces intermediate All positional welding deposit strength and good ductility and corrosion applications resistance for the GMA welding of a wide range of 3XXX, 5XXX, 6XXX and 5XX Aluminium alloys.

See CIGWELD Aluminium Alloy Selection Chart for detailed welding consumable selection criteria for a wide range of Aluminium alloy parent metals.

Storage and Handling Recommendations: ✦ Store in a heated room with uniform temperature control and, if possible, with humidity control as well. ✦ Store unpackaged Autocraft AL series wires for long periods in a heated cabinet at 10-15°C above ambient temperature. ✦ Hold Autocraft AL series welding wires in the welding area for 24 hours before unpacking to allow its temperature to equalise with that of the surrounding area. ✦ Use dust covers on open wire feed units to protect wire during welding.

120 www.cigweld.com.au DC METAL(MIG) WIRES GAS ARC WELDING .AUTOCRAFT AL5356 CONT. + Packaging and Operating Data: These machine settings are a guide only. Actual voltage and welding current used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc. For 5XXX type welding wires use welding current settings on the higher side of the range specified below and arc voltages on the lower side of the range. For 1XXX, 2XXX and 4XXX type welding wires use welding current settings on the lower side of the specified range and arc voltages on the higher side. Wire Dia Voltage Wire Feed Speed Current Pack Type* Pack Weight Part No mm Range (volts) (metres/min) Range (amps) 0.8 14–21 6.0–20.0 50–150 Mini Spool (4 per pack) 4 x 0.5kg 721221 0.9 16–22 6.0–17.5 80–180 Spool 7kg 722226 1.0 17–23 6.0–16.5 110–220 Spool 7kg 722224 1.0 17–23 6.0–16.5 110–220 Handi Spool 2.0kg 723224 1.2 20–25 5.5–12.0 150–250 Spool 7kg 722227 * Mini Spool (ø100mm); Handi Spool (ø200mm); Spool (ø300mm).

www.cigweld.com.au 121 DC AUTOCRAFT AL5183 + ▲ For GMAW welding of wrought and cast TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: aluminium alloys containing Single-vee butt weld with 5083 Aluminium (reduced section magnesium. tensile specimen) Welding grade Argon: ▲ Superior surface cleanliness for improved 0.2% Proof Stress 152 MPa resistance to porosity. Tensile Strength 297 MPa Classifications: Elongation (in 2 inches)16% AS 2717.2: E5183. WIRE ANALYSIS LIMITS: AWS/ASME-SFA A5.10: ER5183. Single values are maximum allowable, unless otherwise stated. Description and Applications: Si: 0.40% Fe: 0.40% Cu: 0.10% Autocraft AL5183 is a premium quality Aluminium welding wire Mn: 0.5-1.0% Mg: 4.3-5.2% Cr: 0.05-0.25% that is typically used in the marine and structured industries, Zn: 0.25% Ti: 0.15% where higher strength and good fracture toughness is required. Total others: 0.15% Al: Balance Autocraft AL5183 is ideally suited to the welding of Alloy 5083. RECOMMENDED SHIELDING GAS: Autocraft AL5183 is not suitable for heat treatment. • Welding Grade Argon ISO14175: I • Ar + 25% He or equivalent gases ISO14175: I3 • He + 25% Ar or equivalent gases ISO14175: I3 APPROVALS: Det Norske Veritas (DNV) GAS METAL ARC WELDING GAS (MIG) WIRES METAL Lloyds register of Shipping American Bureau of Shipping

Packaging and Operating Data: These machine settings are a guide only. Actual voltage and welding current used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc. For 5XXX type welding wires use welding current settings on the higher side of the range specified below and arc voltages on the lower side of the range. For 1XXX, 2XXX and 4XXX type welding wires use welding current settings on the lower side of the specified range and arc voltages on the higher side. Wire Dia Voltage Wire Feed Speed Current Pack Type* Pack Weight Part No mm Range (volts) (metres/min) Range (amps) 1.0 17-23 6.0-16.5 110-220 Spool 7kg 722239 1.2 20-25 5.5-12.0 150-250 Spool 7kg 722240

* Spool (ø300mm).

122 www.cigweld.com.au DC METAL(MIG) WIRES GAS ARC WELDING AUTOCRAFT DEOXIDISED COPPER + ▲ For GMAW Joining and Overlay TYPICAL ALL WELD METAL MECHANICAL Applications. PROPERTIES: ▲ Fabricating Deoxidised Copper and Welding grade Argon: Electrolytic Pitch Copper 0.2% Proof Stress 55 MPa Components. Tensile Strength 200 MPa ▲ Elongation (in 2 inches) 30% Repair of Copper Castings. Electrical Conductivity 40% IACS ▲ Lower Strength Welding of Hardness 55 BHN Galvanised Steels and Deoxidised Weld Metal Density 7.47 x 103 kg/m3 Copper to Mild Steel Joints. TYPICAL WIRE ANALYSIS LIMITS: Mn: 0.5% Si: 0.5% P: 0.15% Classifications: Sn: 1.0% Cu: 98.0% min Others: 0.50% Single values are maximum allowable, unless otherwise stated. AWS/ASME-SFA A5.7: ERCu. RECOMMENDED SHIELDING GAS: ● Welding Grade Argon ISO14175: I Description and Applications: ● Ar + 25% He or equivalent gases ISO14175: I3 Autocraft Deoxidised Copper is a versatile 98% ● He + 25% Ar or equivalent gases ISO14175: I3 pure Copper alloy for the GMAW welding of: ✦ Deoxidised and electrolytic tough pitch All positional welding copper components applications ✦ Copper castings and galvanised steels ✦ Dissimilar mild steel to deoxidised copper joints Autocraft Deoxidised Copper should only be used for the GMAW welding of galvanised steel and for dissimilar welding of mild steel to deoxidised copper where high strength joints are not required. Typical applications include the GMAW welding of copper transformer connectors, copper bus bars, billet molds and heater elements etc. Autocraft Deoxidised Copper can also be used as a corrosion resistant overlay.

Packaging and Operating Data: These machine settings are a guide only. Actual voltage and welding current used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc. Wire Diameter Voltage Wire Feed Speed Current Pack Type* Pack Weight Part No mm Range (volts) (metres/min) Range (amps) 1.6 28-32 5.5-11.5 160-380 Spool 13kg 720260 * Spool (ø300mm).

www.cigweld.com.au 123 DC AUTOCRAFT SILICON BRONZE + ▲ For the GMAW Welding of Copper- TYPICAL WIRE ANALYSIS: Silicon Alloys including Cusilman Fe: 0.25% Mn: 1.0% Si: 3.40% and Everdur. Sn: 0.90% Zn: 0.90% Cu: Balance ▲ Used for the Lower Strength TYPICAL ALL WELD METAL MECHANICAL Welding of Steels. PROPERTIES: ▲ Extensively used in Marine and Hot Welding grade Argon: Water System Applications. 0.2% Proof Stress 170 MPa Tensile Strength 380 MPa Elongation (in 2 inches) 50% Classifications: TYPICAL WELD DEPOSIT HARDNESS WITH AWS/ASME-SFA A5.7: ERCuSi–A. Argon + 16% CO2 + 2.75% O2: HRB Description and Applications: Three Layers on Mild Steel 48 Autocraft Silicon Bronze is a Copper based wire COMPARABLE CIGWELD PRODUCTS: recommended for the Gas Metal Arc Welding Comweld Silicon Bronze rod (GMAW) of Copper-Silicon alloys used extensively AWS A5.7: ERCuSi–A in hot water systems, heat exchangers, calorifiers and marine components for their corrosion RECOMMENDED SHIELDING GAS: resistance. ● Welding Grade Argon ISO14175: I1 ● Ar + 10-15% CO2 or equiv. gases ISO14175: M21, M24, M14

GAS METAL ARC WELDING GAS (MIG) WIRES METAL Autocraft Silicon Bronze is highly recommended ● Ar + 20-25% CO2 or equiv gases ISO14175: M21, M24 for the fillet welding of galvanised steels and irons ● Ar + > 0-3% O or equiv gases ISO14175: M13 and for the lower strength ‘brazing’ of light gauge 2 ● He + 25% Ar or equivalent gases ISO14175: I3 steel sections as used in the automotive industry. It is also suitable for the MIG welding of All positional welding Copper-Zinc alloys to themselves and to steels. applications

Packaging and Operating Data: These machine settings are a guide only. Actual voltage and welding current used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc. Wire Diameter Voltage Wire Feed Speed Current Pack Type* Pack Weight Part No mm Range (volts) (metres/min) Range (amps) 0.8 15-20 4.5-10.5 65-150 Handispool 4.5kg 720159 0.9 21-26 7.5-14.5 100-250 Spool 13kg 720015 1.2 22-28 5.5-11.5 160-380 Spool 13kg 720255 * Spool (ø300mm).

124 www.cigweld.com.au GAS METAL ARC WELDING (MIG) WIRES 125 www.cigweld.com.au 126 FLUX CORED ARC WELDING (FCAW) WIRES 127 132 149 129 130 134 146 151 154 157 155 156 158 160 162 164 166 148 139 142 168 169 152 138 140 144 145 Page No Page FLUX FLUX WELDING ARC CORED WIRES (FCAW) Stoody SOS 309L Description 309LT Verti-Cor 316LT Verti-Cor Stoody SOS 308L Satin-Cor XP Satin-Cor Shield-Cor 8XP Shield-Cor 8Ni Shield-Cor 15 308LT Verti-Cor Verti-Cor XP Verti-Cor Ultra Verti-Cor Seamless 3XP H4 - Verti-Cor A1 H4 81 Verti-Cor Supre-Cor XP H4 Metal-Cor XP 110TXP H4 Tensi-Cor 136 Shield-Cor 4XP Shield-Cor 11 Verti-Cor 3XP Verti-Cor 81 Ni1 Verti-Cor 81 Ni2 Verti-Cor 111K3 H4 Verti-Cor Supre-Cor 5 Metal-Cor 5 Nicore 55 Verti-Cor 81 Ni1 H4 Verti-Cor 91 K2 H4 Verti-Cor www.cigweld.com.au 128 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au on hr tetr h edn r,andthearclength. point whereitenterstheweldingarc, tothe CTWDincludesthewirelengthfromcontacttip, shown below. Aschematicdiagram ofCTWDis the contacttipandworkpiece. isdefinedasthedistancebetweenendof electrode stickout(ESO), Contact Tip to Work Distance(CTWD), CONTACTEXPLAINED TIPTODISTANCE(CTWD) WORK Shielding Gas CTWD also sometimesreferredtoas Zone (RHZ) Heating Resistive Ar c Length Conta c t Tip DC (FCAW) WIRES CORED ARC WELDING FLUX SATIN-COR XP + ▲ Rutile Type Flux Cored Wire Formulated APPROVALS*: for Use with CO2 Shielding Gas. Lloyds Register of Shipping Grade 2YS H ▲ 1.6mm can be used with Argon + 20-25% CO2 or CO2. American Bureau of Shipping Grade 2SA H10, 2YSA H10 ▲ High Speed, Downhand Welding Applications. Det Norske Veritas II YMS * - with welding grade CO shielding gas. ▲ Excellent Operator Appeal. 2 TYPICAL ALL WELD METAL ANALYSIS: ▲ Superior Fillet Shape and Slag Lift. Using CO2 ▲ Precision Layer Wound. C: 0.04% Mn: 1.4% Si: 0.41% Using Argon + 20-25% CO2 (1.6mm only) Classifications: C: 0.05% Mn: 1.65% Si:0.61% AS 2203.1: ETD-GCp-W502A. CM1 H10. TYPICAL DIFFUSIBLE HYDROGEN LEVELS TO AS3752: AWS/ASME-SFA A5.20: E70T-1H8. 5- 6mls of hydrogen / 100gms of deposited weld metal. 1.6mm ONLY: For welded product using welding grade CO shielding gas. AS 2203.1: ETD-GCp-W502A. CM1 H10. 2 ETD-GMp-W502A. CM1 H10. TYPICAL ALL WELD METAL MECHANICAL AWS/ASME-SFA A5.20: E70T-1H8, E70T-1M H8 PROPERTIES: CO2 Argon+20-25% CO2 Description and Applications: Yield Stress. 430 MPa 465 MPa (1.6mm) Satin-Cor XP is a smooth running rutile type flux cored wire Tensile Strength 560 MPa 550 MPa recommended for the high speed fillet and butt welding of Elongation 25% 26% mild and medium strength steels using welding grade CVN Impact Values 84J av @ 0°C 70J av @ 0˚C carbon dioxide shielding gas. The 1.6mm size is formulated for use with either CO2 or Argon + 20-25% CO2. RECOMMENDED SHIELDING GASES: The fluid, full covering slag system of Satin-Cor XP gives Welding Grade Carbon Dioxide (CO2) ISO14175: C1 superior fillet shapes in all downhand (flat, horizontal and Argon + 20-25% CO2 or equivalent 1.6mm ONLY horizontal-vertical) welding positions. The smooth arc ISO14175: M21 transfer using CO2 shielding gas produces low spatter levels and the full covering slag is easy to control and self-releasing in many joint preparations. Satin-Cor XP is Packaging Data: designed for the high productivity, single and multi-pass welding of mild and medium strength steels in the flat, Wire Pack Pack horizontal and horizontal-vertical positions. It is particularly Diameter (mm) Type Weight Part No. recommended for the downhand fillet welding of structural 1.6 Spool 15kg 720904 steels of 6mm thickness or heavier. 2.4 Coil 25kg 720906 Operating Data: All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and welding grade CO2 shielding gas with a flow rate of 10-15 litres/min. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions Flat 1.6 350–450 28–33 25–30 2.4 400–550 28–33 25–35 1.6 300–400 26–30 25–30 HV Fillet

2.4 350–450 26–30 25–30 1.6 270–350 25–29 25–30 Horizontal 2.4 320–420 25–29 25–30 These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc. www.cigweld.com.au 129 DC VERTI-COR XP + ▲ Versatile, smooth running, general purpose, APPROVALS*: rutile type flux cored wire. Lloyds Register of Shipping Grade 3S 3YS H10 ▲ Now with Grade 3 Shipping Society American Bureau of Shipping Grade 3SA, 3YSA approvals on mixed gas and CO2. Det Norske Veritas III YMS ▲ Excellent Operator Appeal. *with Argon + 20-25% CO2 and CO2 shielding gases. TYPICAL ALL WELD METAL ANALYSIS: ▲ All positional capabilities. Using Argon + 20-25% CO2: C: 0.032% Mn: 1.44% Si: 0.59% Classifications: S: 0.001% P: 0.025%. Using CO : AS 2203.1: ETP-GMp-W503A. CM1 H10. 2 C: 0.029% Mn: 1.35% Si: 0.42% ETP-GCp-W503A. CM1 H10. S: 0.012% P: 0.013% AWS/ASME-SFA A5.20: E71T-1M H8; E71T-1 H8. TYPICAL DIFFUSIBLE HYDROGEN LEVELS TO AS3752: Description and Applications: 5-6 mls of hydrogen / 100gms of deposited weld metal for Verti-Cor XP is a versatile rutile type flux cored wire as manufactured product using Argon + 20-25% CO2. designed for all positional fillet and butt welding TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: applications using Argon +20-25% CO and CO shielding 2 2 Using Argon: Using CO2: gases. Verti-Cor XP is characterised by its smooth transfer + 20-25% CO arc characteristic and all positional capabilities while 2 offering smooth genuine mitre fillets in all positions. Yield Stress 550 MPa 510 MPa Tensile Strength 630 MPa 600 MPa Reliable Grade 3 impact properties on both mixed gas Elongation 26% 26% FLUX CORED ARC WELDING WIRES (FCAW) and CO2 are other attributes of Verti-Cor XP. CVN Impact Values 70J av @ 0°C. 60J av @ 0°C RECOMMENDED SHIELDING GASES: Typical Weld Metal Mechanical Properties: ● Argon + 20-25% CO or equivalent ISO14175: Actual weld metal mechanical properties achieved with 2 Verti-Cor XP are influenced by many factors including, M21, M24 base metal analysis, welding parameters/heat input used, ● Welding Grade CO2 ISO14175: C1 shielding gas selection, number of weld passes and run placement, etc. Please consult your nearest CIGWELD distributor for welding procedure recommendations. Packaging Data: Wire Pack Pack Diameter (mm) Type Weight Part No. 1.2 Spool 15kg 720915 1.2 Autopak 200kg 720915A 1.6 Spool 15kg 720917 1.6 Autopak 200kg 720917A 2.0 Spool 15kg 720595 2.0 Coil 25kg 720596

130 www.cigweld.com.au DC (FCAW) WIRES CORED ARC WELDING FLUX VERTI-COR XP CONT. + Operating Data: All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive using Argon + 20-25% CO2 shielding gas with a flow rate of 15–20 litres/min. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions 1.2 150-250 23-28 15-20 Flat 1.6 280-400 28-34 25-30 2.0 400-480 29-32 25-30 1.2 150-200 23-28 15-20 HV Fillet 1.6 250-350 28-34 25-30 2.0 350-400 27-31 25-30 1.2 120-180 22-27 15-20 Vertical up 1.6 200-250 23-27 20-25 2.0 230-280 24-28 20-25 1.2 140-180 22-27 15-20 Overhead 1.6 190-250 23-27 20-25 2.0 220-260 23-27 20-25 These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.

www.cigweld.com.au 131 DC VERTI-COR ULTRA + ▲ Rutile Type Flux Cored Wire APPROVALS*: Formulated Exclusively for CO2 Lloyds Register of Shipping Grade 2YS H10. Shielding Gas. American Bureau of Shipping Grade 2YSA H10. ▲ Versatile, All Positional Capabilities. Det Norske Veritas IIYMS H. ▲ Excellent Operator Appeal. * - with welding grade CO2 shielding gas. ▲ TYPICAL ALL WELD METAL ANALYSIS USING CO2 Low Spatter and Fume Levels. SHIELDING GAS: C: 0.04% Mn: 1.24% Si: 0.70% Ti: 0.035% B: 0.005%. Classifications: AS 2203.1: ETP-GCp-W502A. CM1 H10. TYPICAL DIFFUSIBLE HYDROGEN LEVELS TO AS3752: AWS/ASME-SFA A5.20: E71T-1H8. 5.0 - 6.0 mls of hydrogen / 100gms of deposited weld metal *. Description and Applications: * - for “as manufactured” product using welding grade CO2 shielding gas. Verti-Cor Ultra is a smooth running all positional flux cored wire which offers improved operator TYPICAL ALL WELD METAL MECHANICAL appeal and lower fume and spatter levels under PROPERTIES: welding grade carbon dioxide shielding gas. Using welding grade CO2: Yield Stress 480 MPa Verti-Cor Ultra offers significant welding Tensile Strength 560 MPa improvements compared with conventional E71T-1 Elongation 28% wires, in particular 50-60% less spatter and CVN Impact Values 80 J av @ 0°C. ≈ 20% less fume. FLUX CORED ARC WELDING WIRES (FCAW) RECOMMENDED SHIELDING GAS: ● Verti-Cor Ultra is designed for the single and Welding Grade CO2 ISO14175: C1 multi-pass welding of mild and medium strength steels in the downhand, vertical-up and overhead positions. It is recommended for general steel Packaging Data: construction and fabrication welding where the Wire Pack Pack work cannot be rotated to the downhand positions. Diameter (mm) Type Weight Part No. Typical Weld Metal Mechanical Properties: 1.2 Spool 15kg 720900 Actual weld metal mechanical properties 1.6 Spool 15kg 720902 achieved with Verti-Cor Ultra are influenced by many factors including, base metal analysis, welding parameters / heat input used, number of weld passes and run placement etc. Please consult your nearest CIGWELD branch for welding procedure recommendations.

132 www.cigweld.com.au DC (FCAW) WIRES CORED ARC WELDING FLUX VERTI-COR ULTRA CONT. + Operating Data: All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and welding grade CO2 shielding gas with a flow rate of 10–15 litres/min. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions 1.2 250-300 27-31 20-25 Flat

1.6 350-400 27-31 25-30 1.2 230-280 26-30 20-25 HV Fillet

1.6 310-360 26-30 25–30 1.2 170-220 24-28 15-20 Vertical up

1.6 200-250 24-28 15-20 1.2 160-210 24-28 15-20 Overhead

1.6 190-240 24-28 15-20 These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.

www.cigweld.com.au 133 134 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au recommendations. CIGWELD branchforweldingprocedure Pleaseconsultyournearest placement etc. numberofweldpassesandrun selection, shieldinggas parameters /heatinputused, welding basemetalanalysis, including, with Verti-Cor 3XPareinfluencedbymanyfactors Actual weldmetalmechanicalpropertiesachieved Typical Weld MetalMechanicalProperties: shielding gasesarerecommended. impact toughness Argon +20-25%CO For optimumarcperformanceandwelddeposit of mildandmediumstrengthsteels. Verti-Cor 3XPissuitableforweldingawiderange in allpositions(exceptvertical-down), flatmitrefilletweldsandexcellentslaglift transfer, Formulated togivesmooth(lowspatter)arc and overheadfilletbuttweldingapplications. vertical-up cored wiredesignedfordownhand, CM1H10. ETP-GMp-W503A. Verti-Cor 3XPisamicroalloyedrutiletypeflux E71T-12M H8. E71T-1 H8, AWS/ASME-SFA A5.20: AS 2203.1: ▲ ▲ ▲ Description and Applications: Classifications: VERTI-COR 3XP Grade 3ShippingSociety Approvals. All Positional Capabilities. Versatile, Cored Wire. RutileTypeFlux Microalloyed, T-C-53.CM1H10. ETP-GCp-W503A. 2 or CO 2 :00%M:10% i 0.42% Si: 0.007% B: 1.05% Mn: 0.035% Ti: 0.06% C: ● ● RECOMMENDED SHIELDINGGASES: CO Using Argon +20-25%CO2: TYPICAL ALL WELD METAL MECHANICALPROPERTIES: gas. productusing Argoshield 52shielding * -for “as manufactured” *. 5.0–6.0 mlsofhydrogen/100gmsdepositedweldmetal AS3752: 0.52% Si: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO 0.008% B: 1.16% Mn: IIIYMSH. Using CO 0.035% Ti: 0.07% C: Using Argon +20-25%CO2: METALTYPICAL ALLWELD ANALYSIS: 3YS H. Grade3S, 3YSA H. Grade3SA, *with Argon +20-25%CO Det Norske Veritas American BureauofShipping Lloyds RegisterofShipping APPROVALS*: lnain2%30% 460MPa 530MPa 110J av@0 28% 480MPa Impact Values CVN, 560MPa Elongation Tensile Strength Yield Stress Packaging Data: Welding GradeCO Argon +20-25%CO imtr(m yeWih Part No. Weight Type Diameter (mm) DC + iePc Pack Pack Wire . po 5g720921 720919 15kg 15kg Spool Spool 1.6 1.2 2 : 90J av@-20 2 2 or equivalent ISO14175: 2 or CO ° 2 .90Jav@0 C. ° shielding gases 75Jav@-20 C 2,M4 M21(1) M24, M21, S115 C1 ISO14175: 2 : ° C. ° C DC (FCAW) WIRES CORED ARC WELDING FLUX VERTI-COR 3XP CONT. + . Operating Data: All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argon + 20- 25% CO2 shielding gas with a flow rate of 15–20 litres/min Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions 1.2 250-300 27-31 20-25 Flat

1.6 350-400 27-31 25-30 1.2 230-280 26-30 20-25 HV Fillet

1.6 310-360 26-30 25–30 1.2 170-220 24-28 15-20 Vertical up

1.6 200-250 24-28 15-20 1.2 160-210 24-28 15-20 Overhead

1.6 190-240 24-28 15-20 These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.

www.cigweld.com.au 135 136 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au exposure totheatmosphere maintenance ofthe ‘very lowhydrogenstatus’following – The eliminationofmoisturereabsorptioninthefluxcorefor weld deposit improved resistancetohydrogeninducedcoldcrackingofthe H5diffusiblehydrogenstatusfor H4and AS: – ‘Very low AWS: consistent arcstarting – improvedcurrenttransferattheweldingtorchforsmooth, feeder – improvedwirefeedingwhicheliminates ‘bird nests’atthewire to severaluniquefeaturesandbenefitsincluding: The advanced seamlesscoppercoatedtubetechnologygivesrise releasing slag. fillet weldsinallpositionswithverylowspatterlevelsandaself- mitre gases (orequivalent) andisformulatedtogivesmooth, medium strengthsteelswith Argon +20-25%CO2shielding Verti-Cor 3XPH4issuitableforweldingawiderangeofmildto welding applications. vertical-upandoverheadfilletbutt designed fordownhand, rutiletypeFCwire Verti-Cor 3XPH4isaseamlesscoppercoated, CM1H5. ETP-GMp-W503A. E71T-12M H4. AWS/ASME-SFA A5.20: AS/NZS 2203.1: ▲ ▲ ▲ ▲ ▲ ▲ ▲ Description and Applications: Classifications: VERTI-COR 3XPH4-Seamless Grade 3ShippingSociety Approvals. Excellent Operator Appeal. hydrogen/100 gms. weldmetal of2.2mls H4 diffusiblehydrogen classwithatypical Ultra lowsplatterandfumelevels. a flatmitre filletbeadshape. allpositionalcapabilitiesproducing Rutile, feedability andcurrent pickup. Copper coatedforsmoothconsistent Next generation technologyfluxcored wire. i.(m yeWih Part No. Weight Type (mm) Dia. Argon+20-25%CO • RECOMMENDED SHIELDINGGASES: 3YS H5 3YSA H5 3S, S3A, * -with Argon +20-25%CO American BureauofShipping Lloyds RegisterofShipping APPROVALS*: CO2 shieldinggas. productusing Argon +20-25% * -for “as manufactured” 2.2 mlsofhydrogen/100gmsdepositedweldmetal*. 105Jav@-20°C TYPICAL DIFFUSIBLEHYDROGENLEVELS TO AS3752: 30% 510MPa 570MPa Using Argon +20-25%CO METALTYPICAL ALLWELD ANALYSIS: Impact Values CVN, Elongation Tensile Strength Yield Stress Using Argon +20-25%CO2: TYPICAL ALL WELD METAL MECHANICALPROPERTIES: :00% n .5 S:0.43% Si: 0.007 S: 1.25% Mn: 0.009 P: 0.05% C: Packaging Data: DC + iePc Pack Pack Wire . po 25g722919 12.5kg 12.5kg Spool Spool 1.6 1.2 2 ISO14175: . 2 : 2 shielding gascombinations. 2,2,M21(1) M21,M24, 722921 DC (FCAW) WIRES CORED ARC WELDING FLUX VERTI-COR 3XP H4 - Seamless +

Operating Data: All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argon +20-25% CO2 shielding gas with a flow rate of 15–20 litres/min Wire Current Voltage Optimum Welding Dia. (mm) Range (amps) Range (volts) CTWD Amps Volts Positions 1.2 250-300 27-31 20-25 280 31 Flat

1.6 350-400 27-31 25-30 360 31 1.2 230-280 26-30 20-25 260 28 HV Fillet

1.6 310-360 26-30 25–30 320 29 1.2 170-220 24-28 15-20 200 24 Vertical up

1.6 200-250 24-28 15-20 240 25 1.2 160-210 24-28 15-20 200 24 Overhead

1.6 190-240 24-28 15-20 220 24 These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.

www.cigweld.com.au 137 DC VERTI-COR 81 A1 H4 + ▲ Copper coated seamless wire delivering TYPICAL ALL WELD METAL ANALYSIS: very low AWS H4 class hydrogen C: 0.085% Mn: 1.05% Si: 0.52% ▲ Higher strength low alloy rutile type flux S: 0.01% Mo: 0.5% cored wire TYPICAL DIFFUSIBLE HYDROGEN LEVELS TO ▲ Formulated for Use with Argon + AS3752: 20-25% CO2 or equivalent 3< mls of hydrogen / 100gms of deposited weld metal*. ▲ *for “as manufactured” product using Argon + 20-25% CO2 Versatile, All Positional Capabilities shielding gas. ▲ Excellent Operator Appeal TYPICAL ALL WELD METAL MECHANICAL ▲ Low fume levels PROPERTIES: Using Argon + 20-25% CO2: Classifications: Yield Stress 470 MPa AS 2203.1: ETP-GMp-W553 A1 H5. Tensile Strength 630 MPa AWS/ASME-SFA A5.29: E81T1-1 A1 M H4 Elongation 22% CVN Impact Values 50J av @ -20°C Description and Applications: Verti-Cor 81 A1 H4 is a seamless copper coated rutile type flux cored RECOMMENDED SHIELDING GAS: wire suitable for the all positional welding of medium to high strength ● Argon + 20-25% CO2 or equivalent ISO14175: M21, M24 steels using Argon + 20-25% CO2. Verti-Cor 81 A1 H4 produces a low alloy (nominally 0.5% Mo) steel weld deposit of the 550 MPa tensile Packaging Data: class. Verti-Cor 81 A1 H4 is easy to use in all positions and produces smooth arc transfer characteristics, low spatter levels, mitre fillet welds Wire Pack Pack and a full covering, easily releasing slag, similar to Verti-Cor Ni1 H4. Diameter (mm) Type Weight Part No.

FLUX CORED ARC WELDING WIRES (FCAW) Verti-Cor 81 A1 H4 is suitable for the fillet and butt welding of a broad * 1.2 Spool 15kg 720557 range of higher strength steels in all welding positions except vertical down. Typical applications include the welding of creep resisting steels * 1.6 Spool 15kg 720558 used in the pressure vessel and petrochemical industries. *Non-stock item. Available on indent only. Typical Weld Metal Mechanical Properties: Actual weld metal mechanical properties achieved with Verti-Cor 81 A1 H4 are influenced by many factors including, base metal analysis, welding parameters / heat input used, shielding gas selection, number of weld passes and run placement etc. Please consult your nearest CIGWELD branch for welding procedure recommendations. Operating Data: All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argon + 20-25% CO2 shielding gas with a flow rate of 15–20 litres/min. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions 1.2 250-300 27-31 20-25 Flat 1.6 350-400 27-31 25-30 1.2 230-280 26-30 20-25 HV Fillet 1.6 310-360 26-30 25–30 1.2 170-220 24-28 15-20 Vertical up 1.6 200-250 24-28 15-20 1.2 160-210 24-28 15-20 Overhead 1.6 190-240 24-28 15-20 These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.

138 www.cigweld.com.au FLUX CORED ARC WELDING (FCAW) WIRES 139 : 2 te 2 C ° Flat HV Fillet up Vertical Overhead Using Argon + 20-25% CO Using shielding gas 2 or equivalent ISO14175:or equivalent M21 2 1.21.6 Spool Spool 15kg 15kg 720390 720391 Wire Pack Pack + DC Diameter (mm) Type Weight No. Part Argon + 20-25% CO Packaging Data: Packaging Yield StressYield StrengthTensile ElongationValuesCVN Impact 600 MPa @ -40 65J av 520 MPa 26% RECOMMENDED SHIELDING GAS: ● TYPICAL ALL WELD METAL ANALYSIS*: ALL WELD TYPICAL METAL C: 0.06%Ni: 0.90% CO Argon + 20-25% *Using Mn: 1.35%TO Ti: HYDROGEN LEVELS TYPICAL DIFFUSIBLE 0.035%AS3752: / 100gms of deposited weld metal*. 5.0–6.0 mls of hydrogen Si: 0.35% B: 0.007%. “as manufactured”*for Argon + 20-25% CO product using shielding gas. TYPICAL ALL WELD MECHANICAL METAL PROPERTIES: shielding gas with a flow rate of 15–20 litres/min. or equivalent. 2 2 1.6 190-240 24-28 15-20 1.61.21.6 350-4001.2 230-2801.6 27-31 310-3601.2 26-30 170-220 26-30 200-250 24-28 160-210 25-30 20-25 24-28 24-28 25–30 15-20 15-20 15-20 1.2 250-300 27-31 20-25 Wire Voltage Current Welding Higher Strength Low Alloy, Low Strength Higher Rutile Wire Cored Flux Type + Argon for Use with Formulated 20-25% CO Versatile, Capabilities. All Positional Appeal. Excellent Operator performance. vertical Improved Diameter (mm) Range (amps) Range (volts) CTWD Positions Operating Data: Operating Classifications: Applications: Description and VERTI-COR 81 Ni1 81 VERTI-COR These machine settings are a guide only.These Actual voltage, welding current and CTWD used will depend on machine characteristics, pla thickness, run size, shielding gas and operator technique etc. All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argon + 20-25% CO AS 2203.1:A5.29: AWS/ASME-SFA E81T1-Ni1MH8 81 Ni1 is a microalloyed,Verti-Cor rutile type flux cored wire suitable for the all positional welding ( flat, horizontal-vertical, vertical-up and overhead etc) of medium to high strength steels. for use Formulated Argon + 20-25% CO2 shielding gas,with a 81 Ni1 produces Verti-Cor ) steel weld deposit of the 550 MPa low alloy ( nominally 1.0% Nickel ETP-GMp-W554A. Ni1 H10. tensile class. 81 Ni1 is easy-to-use in all positions and Verti-Cor produces smooth arc transfer characteristics, low spatter levels, mitre slag,fillet welds and a full covering easy releasing Verti-Cor similar to 3XP. 81 Ni1 is suitable for the fillet and butt welding of a broad Verti-Cor positions,range of higher strength steels in all welding except vertical- down. strength fillet applications include the under matching Typical welding of Bisalloy 60, steels. Tempered 70 and 80 Quenched and Properties: Metal Mechanical Weld Typical 81 Ni1 Verti-Cor with Actual weld metal mechanical properties achieved are influenced by many factors including, base metal analysis, welding parameters / heat input used, shielding gas selection,passes and run placement etc. number of weld your nearest CIGWELD branch for welding procedure recommendations. Please consult ▲ ▲ ▲ ▲ ▲ www.cigweld.com.au 140 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au ea nlss edn aaeesha nu sd hedn a eeto,nme fwl assadrnpaeet etc. Please consultyournearestCIGWELDdistributorforweldingprocedurerecommendations. numberofweldpassesandrun placement, shieldinggasselection, weldingparameters/heatinputused, metal analysis, base Actual weldmetalmechanicalpropertiesachievedwith Verti-Cor 81Ni1H4areinfluencedbymany factors including, Typical Weld MetalMechanicalProperties: Ni1H5 ETP-GC/Mp-W554A. strength steelsusing Argon +20-25%CO wire suitablefortheallpositionalweldingofmediumtohigh Verti-Cor 81Ni1H4isahigherstrengthrutiletypefluxcored E81T1-Ni1H4 E81T1-Ni1MH4; AWS/ASME-SFA A5.29: AS 2203.1: ▲ ▲ ▲ “eylwAS 4adA:H5diffusiblehydrogenstatus H4and AS: “Very low AWS: – Improvedcurrenttransferattheweldingtorchforsmooth, – Improvedwirefeedingwhicheliminates “bird nests” – rise toseveraluniquefeaturesandbenefitsincluding: The advanced seamlesscoppercoatedtubetechnologygives the undermatchingstrengthweldingofBisalloy60,70&80. Typical applicationsinclude positions exceptverticaldown. of abroadrangehigherstrengthsteelsinallwelding Verti-Cor 81Ni1H4issuitableforthefilletandbuttwelding similarto Verti-Cor 3XP. easilyreleasingslag, full covering, mitrefilletweldsanda lowspatterlevels, characteristics, use inallpositionsandproducessmootharctransfer Itiseasyto steel welddepositofthe550Mpatensileclass. Verti-Cor 81Ni1H4producesalowalloy(nominally1%Nickel) gases. ▲ ▲ ▲ ▲ Description and Applications: Classifications: VERTI-COR 81Ni1H4 of thewelddeposit. for improvedresistancetohydrogeninducedcoldcracking consistent arcstarting at thewirefeeder Argon +20-25%CO Formulated forusewitheither Type FluxCored Wire. Rutile Higher Strength Low Alloy, Precision Layer Wound. Low FumeLevels. Outstanding Operator Appeal. All Positional Capabilities. Versatile, feedability andcurrent pickup. Copper coatedforsmoothconsistent 2 or CO 2 2 shielding gases. or CO 2 shielding :00%M:11 i .8 N:1.16% 0.38% Ni: Si: 1.1% Mn: 0.05% C: ● ● RECOMMENDED SHIELDINGGAS: Argon+20-25%CO Using PROPERTIES: METALMECHANICAL TYPICAL ALLWELD manufactured productusing Argon +20-25%CO <3 mlsofhydrogen/100gmsdepositedweldmetalforas AS3752: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO IV YMS H10. Using Argon +20-25%CO METALTYPICAL ALLWELD ANALYSIS*: 4YS H10. Grade4Y, Grade4YSA H5. *with Argon +20-25%CO Det Norske Veritas American BureauofShipping Lloyds RegisterofShipping APPROVALS*: :00%M:14%S:05 N:1.0% 0.5%Ni: Si: 1.40% Mn: Using CO 0.06% C: lnain2%23% 500MPa 560MPa 22% 540MPa 85Jav@-40 CVN Impact Values 600MPa Elongation Tensile Strength Yield Stress Packaging Data: imtr(m yeWih Part No. Weight Type Diameter (mm) Welding GradeCO Ar +20-25%CO DC + iePc Pack Pack Wire . po 5g720551 720550 15kg 15kg Spool Spool 1.6 1.2 . ol2k 720592 720591 25kg 15kg Coil Spool 2.0 2.0 2 : 2 2 reuvln S115 2,M24 M21, or equivalent ISO14175: 2 or CO 2 : 2 ° shielding gases C S115 C1 ISO14175: 2 :CO 75J av@-50˚C 2 2: or CO 2 . DC (FCAW) WIRES CORED ARC WELDING FLUX VERTI-COR 81 Ni1 H4 CONT. + . Operating Data: All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argon + 20- 25% CO2 shielding gas with a flow rate of 15-20 litres/min. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions 1.2 250-300 27-31 20-25 Flat 1.6 350-400 27-31 25-30 2.0 380-460 28-32 25-30 1.2 230-280 26-30 20-25 HV Fillet 1.6 310-360 26-30 25–30 2.0 340-420 27-31 25-30 1.2 170-220 24-28 15-20 Vertical up 1.6 200-250 24-28 15-20 2.0 220-280 24-28 20-25 1.2 160-210 24-28 15-20 Overhead 1.6 190-240 24-28 15-20 2.0 210-270 23-27 20-25 These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.

www.cigweld.com.au 141 142 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au procedure recommendations. Please consultyournearestCIGWELDdistributorforwelding etc. numberofweldpassesandrunplacement, gas selection, shielding weldingparameters/heatinputused, metal analysis, base Cor 81Ni1H4areinfluencedbymanyfactorsincluding, Actual weldmetalmechanicalpropertiesachievedwith Verti- Typical Weld MetalMechanicalProperties: ETP-G/Mp-W559A.Ni2H10 strength steelsusing Argon +20-25%CO wire suitablefortheallpositionalweldingofmediumtohigh Verti-Cor 81Ni2isahigherstrengthrutiletypefluxcored E81T1-Ni2MH8 AWS/ASME-SFA A5.29: AS 2203.1: ▲ ▲ ▲ ▲ ▲ off shoreplatforms. and aluminiumkilledsteelsforlowtemperatureservicesuchas the undermatchingstrengthweldingofBisalloy60,70&80 Typical applicationsinclude positions exceptverticaldown. of abroadrangehigherstrengthsteelsinallwelding Verti-Cor 81Ni2issuitableforthefilletandbuttwelding similarto Verti-Cor 81Ni1. easilyreleasingslag, full covering, mitrefilletweldsanda lowspatterlevels, characteristics, use inallpositionsandproducessmootharctransfer Itiseasyto steel welddepositofthe550Mpatensileclass. Verti-Cor 81Ni2producesalowalloy(nominally2%Nickel) Description and Applications: Classifications: VERTI-COR 81Ni2 Low FumeLevels. Outstanding Operator Appeal. All Positional Capabilities. Versatile, Argon +20-25%CO Formulated forusewitheither Type FluxCored Wire. Rutile Higher Strength Low Alloy, 2 or CO 2 2 shielding gases. or equivalent. :00%M:11%S:05% i 2.0% 0.51%Ni: Si: 1.16% Mn: 0.02% C: lnain27% 590MPa 660MPa Argon+25%CO ● RECOMMENDED SHIELDINGGAS: CVN Impact Values Elongation Tensile Strength Yield Stress Using PROPERTIES: METALMECHANICAL TYPICAL ALLWELD manufactured productusing Argon +25%CO <8 mlsofhydrogen/100gmsdepositedweldmetalforas AS3752: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO Using Argon +25%CO METALTYPICAL ALLWELD ANALYSIS: *with Argon +25%CO Det Norske Veritas American BureauofShipping Lloyds RegisterofShipping APPROVALS*: Packaging Data: imtr(m yeWih Part No. Weight Type Diameter (mm) Ar +20-25%CO DC + iePc Pack Pack Wire . po 5g722391 722390 15kg 15kg Spool Spool 1.6 1.2 2 or equivalent ISO14175: 2 shielding gases 2 : 2,M24 M21, 2 70J av@-40˚C . 2: DC (FCAW) WIRES CORED ARC WELDING FLUX VERTI-COR 81 Ni2 CONT. + . Operating Data: All welding conditions recommended below are for use with semi-automatic operation, DC electrode positive and Argon + 25% CO2 shielding gas with a flow rate of 15-20 litres/min. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions 1.2 250-300 27-31 20-25 Flat

1.6 350-400 27-31 25-30 1.2 230-280 26-30 20-25 HV Fillet

1.6 310-360 26-30 25–30 1.2 170-220 24-28 15-20 Vertical up

1.6 200-250 24-28 15-20 1.2 160-210 24-28 15-20 Overhead

1.6 190-240 24-28 15-20 These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.

www.cigweld.com.au 143 144 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au ▲ ▲ hcns,rnsz,shieldinggasand operatortechniqueetc. runsize, thickness, pla weldingcurrentandCTWD usedwilldependonmachinecharacteristics, Actualvoltage, These machinesettingsareaguideonly. 20-25% CO DCelectrodepositiveand Argon + All weldingconditionsrecommendedbelowareforusewithsemi-automaticoperation, branch forweldingprocedurerecommendations. PleaseconsultyournearestCI numberofweldpassesandrunplacementetc. shieldinggasselection, parameters /heatinputused, basemetalan Actual weldmetalmechanicalpropertiesachievedwith Verti-Cor 91K2H4areinfluencedbymanyfactorsincluding, Typical Weld MetalMechanicalProperties: H5diffusiblehydrogenstatusforimprovedresistancetoinducedcoldcrackingofthe H4and AS: “Very low AWS: consistentarcstarting Improvedcurrenttransferattheweldingtorchforsmooth, – atthewirefeeder Improvedwirefeedingwhicheliminates “bird nests” – – rise toseveraluniquefeaturesandbenefitsincluding: The advanced seamlesscoppercoatedtubetechnologygives under matchingstrengthfilletweldingofBisalloy70and80steels. applications includethefullstrengthbuttweldingofBisalloy60or Typical exceptvertical-down. of higherstrengthsteelsinallweldingpositions, Verti-cor 91K2H4issuitableforthefilletandbuttweldingofabroadrange K2H5. ETP-GMp-W629A. using Argon +20-25%CO suitable fortheallpositionalweldingofmediumtohighstrengthsteels Verti-Cor 91K2H4isahigherstrengthrutiletypefluxcoredwire E91T1-K2MH4 AWS/ASME-SFA A5.29: AS 2203.1: ▲ ▲ ▲ oeig aiyrlaigsa,similarto Verti-Cor 3XPH4. easilyreleasingslag, covering, mitrefilletweldsandafull lowspatterlevels, transfer characteristics, Itiseasytouseinallpositionsandproducessmootharc tensile class. a lowalloy(nominally1.5%Nickel) steelwelddepositofthe550Mpa Description and Applications: Classifications: VERTI-COR 91K2H4 Operating Data: imtr(m ag ap)Rne(ot)CW Positions CTWD Range(volts) Range(amps) Diameter (mm) weld deposit. Low fumelevels. Very lowhydrogen status. 20-25% CO Formulated forUsewith Argon + Type FluxCored Wire Rutile Higher Strength Low Alloy, very lowH4classhydrogen levels. Copper coatedseamlesswire delivering ieCretVlaeWelding Current Voltage Wire . 6-1 42 15-20 15-20 15-20 25–30 20-25 24-28 25-30 20-25 24-28 24-28 26-30 160-210 200-250 26-30 27-31 170-220 27-31 310-360 230-280 1.2 350-400 1.6 250-300 1.2 1.6 1.2 1.6 1.2 . 9-4 42 15-20 24-28 190-240 1.6 2 shielding gaswithaflowrateof15–20litres/min. 2 . 2 hedn a.Verti-Cor 91K2H4produces shielding gas. ● RECOMMENDED SHIELDINGGAS: PROPERTIES: METALMECHANICAL TYPICAL ALLWELD 1.2% shielding gas. 0.3%Ni: Si: productusing Argon +20-25%CO * for “as manufactured” <3.5 mlsofhydrogen/100gmsdepositedweldmetal*. 1.3% AS3752: Mn: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO *Using Argon +20-25%CO 0.05% C: METALTYPICAL ALLWELD ANALYSIS*: lnain22% 560MPa >40Jav@-40 670MPa CVN Impact Values Elongation Tensile Strength Yield Stress Packaging Data: Argon +20-25%CO imtr(m yeWih Part No. Weight Type Diameter (mm) DC + iePc Pack Pack Wire . po 5g720555 720554 15kg 15kg Spool Spool 1.6 1.2 2 reuvln IO47:M1 M24 M21, or equivalent ISO14175: 2 shielding gas Using Argon +20-25%CO Overhead Vertical up HV Fillet Flat ° C lss welding alysis, GWELD te 2 2 : FLUX CORED ARC WELDING (FCAW) WIRES 145 ate arest C ° nalysis, Flat Flat HV Fillet up Vertical Overhead Using Argoshield 52: or equivalent ISO14175:or equivalent M21 M24. 2 + DC 1.21.6 Spool Spool 15kg 15kg 721381 721382 Wire Pack Pack Diameter (mm) Type Weight No. Part Packaging Data: Packaging Argon + 20-25%CO RECOMMENDED SHIELDING GAS: ● TYPICAL ALL WELD METAL (AWM) ANALYSIS* (Wt%): WELD TYPICAL ALL ANALYSIS* (AWM) METAL C: 0.06%Ni: 2.05% gas Argoshield 52 shielding * - Using Mn: 1.65%AS3752: Mo:TO HYDROGEN LEVELS TYPICAL DIFFUSIBLE 0.46% B: 0.004%. / 100gms of deposited weld metal *. 3.0 mls of hydrogen manufactured”“as * - for (ESO) using and Electrode Stickout product Si: 0.36% and 25mm with 1.6mm wire and mid- of 20mm with 1.2mm wire settings. range current and voltage MECHANICAL PROPERTIES: WELD METAL ALL TYPICAL 0.2% Proof Stress StrengthTensile ElongationValuesCVN Impact 775 MPa 835 MPa 55J av @ -20 18% or 2 or equivalent gases. 2 1.6 190-240 24-28 15-20 1.21.61.21.61.2 250-300 350-4001.6 230-2801.2 310-360 27-31 27-31 170-220 26-30 200-250 26-30 160-210 24-28 20-25 24-28 25-30 24-28 20-25 25–30 15-20 15-20 15-20 Wire Voltage Current CTWD Welding Very low hydrogen status. low hydrogen Very Rutile Type,Wire. Rutile Flux Cored Alloy Steel Low Versatile, Capabilities. Positional All Steels. of High Strength Welding Structural + Argon for Use with Formulated 20-25% CO on 15kg Wound Layer Precision Steel Spools. Diameter (mm) Range (amps) Range (volts) Positions Operating Data: Operating Classifications: Applications: Description and VERTI-COR 111 K3 H4 111 VERTI-COR electrodes or Tensi-cor 110TXP H4 flux cored wire are recommended for this application. 110TXP H4 flux cored wire are Tensi-cor electrodes or These machine settings are a guide only.These Actual voltage, welding current and E.S.O. used will depend on machine characteristics, pl thickness, run size, shielding gas and operator technique etc. All welding conditions recommended below are for use with semi-automatic operation,Argoshield DC electrode positive and 52 shielding gas with a flow rate of 15–20 litres/min. ▲ AS 2203.1:A5.29: AWS/ASME-SFA E111T1-K3M H4. 111 K3 H4 is a rutile based,Verti-cor low alloy flux cored wire down) welding of high suitable for the all positional (except vertical strength steels.CO Argon + 20 - 25% for use with Formulated ETP-GMp-W768A. K3 H5. ▲ ▲ ▲ ▲ ▲ equivalent shielding gases,equivalent alloy 111 K3 H4 produces a low Verti-cor steel (nominally 2.0% Nickel, 1.7% Manganese and 0.5% tensile class. Molybdenum) weld deposit of the 760MPa 111 K3 H4 is easy to use in all positions and produces Verti-cor smooth and stable arc transfer characteristics, low spatter levels, mitre slag.fillet welds and a full covering self-releasing high strength The 111 K3 H4 Verti-cor weld deposits and all positional capabilities make fillet welding of Bisalloy the ideal choice for the full strength butt and steels. Tempered 80 and similar Quenched and Note: is not recommended for the crack repair of high 111 K3 H4 Verti-Cor strength steel castings.Alloycraft 110 Fully basic consumables such as Properties: Metal Mechanical (AWM) Weld All Typical 111 K3 H4 are influenced by many factors including,Verti-cor Actual weld metal mechanical properties achieved with base metal a welding parameters / heat input used, shielding gas selection, number of weld passes and run placement etc. Please consult your ne CIGWELD branch for welding procedure recommendations. www.cigweld.com.au 146 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au properties usingCO wire producingoutstandinglowtemperatureimpact fullybasicfluxcored Supre-Cor 5isasecondgeneration, CM1H5. ETP-GCn/p-W505A. E71T-5MJ H4. E71T-5 H4, AWS/ASME-SFA A5.20: AS 2203.1: ▲ ▲ ▲ ▲ relieved’ conditions. properties areachievedinboththe ‘as welded’and ‘stress Excellentwelddeposit and heavyearthmovingequipment. offshoreoilandgasplatformstructures of pressurevessels, critical applicationsincludingthefilletandbuttwelding class ofSupre-Cor5make itsuitableforawiderangeof The premiumqualityweldmetaland ‘very low’hydrogen negative isthepreferredpolarity. For allweldingapplicationswithSupre-Cor5electrode Description and Applications: Description Classifications: SUPRE-COR 5 Toughness to-50 Improved Low Temperature Impact Cored Wire. FullyBasicFlux Second Generation, Precision Layer Wound. 1.2mm and1.6mmsizes. Improved Positional Capabilitiesof 2 Argonorequivalent shieldinggases. , ° T-M/-55.CM1 H5. ETP-GMn/p-W505A. C. Values lnain2%32% 470MPa 530MPa 90Jav@-51 28% 490MPa CVN Impact 550MPa Elongation Tensile Strength Yield Stress :00%M:12%S:0.56% Si: 1.23% Mn: 0.07% C: :00%M:13% i 0.74% Si: 1.38% Mn: Using CO 0.07% C: ● ● RECOMMENDED SHIELDINGGASES: Argon+20-25%CO Using PROPERTIES: TYPICAL ALL WELD METAL MECHANICAL <2.5 mlsofhydrogen/100gmsdepositedweldmetal. AS3752: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO H10 IIIYMS Using Argon +20-25%CO 3YS H10 Grade3SA,3YSA Grade 3S, H10 METALTYPICAL ALLWELD ANALYSIS: *with Argon+20-25%CO Norske Veritas Det American BureauofShipping Lloyds RegisterofShipping APPROVALS*: Packaging Data: Welding GradeCO Argon +20-25%CO imtr(m yeWih Part No. Weight Type Diameter (mm) iePc Pack Pack Wire . po 5g720982 15kg Spool 1.2 . po 5g720983 15kg Spool 1.6 2 : +/– DC 2 2 reuvln S115 2,M24 M21, ISO14175: or equivalent 2 2 : shielding gas. ° 80Jav@-51 C 2 S115 C1 ISO14175: UsingCO : 2 : ° C DC (FCAW) WIRES CORED ARC WELDING FLUX SUPRE-COR 5 CONT. +/– Operating Data: All welding conditions recommended below are for use with semi-automatic operation and DC electrode negative using Argon + 20-25% CO2 shielding gas with a flow rate of 15–20 litres/min. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions 1.2 250-300 26-30 20-25

1.6 330-380 26-30 25-30 Flat

1.2 230-280 25-29 20-25 HV Fillet 1.6 310-360 25-29 25-30

1.2 160-210 23-27 15-20 Vertical up 1.6 180-230 23-27 15-20 1.2 160-210 23-27 15-20

1.6 180-230 23-27 15-20 Overhead These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.

www.cigweld.com.au 147 DC SUPRE-COR XP H4 +/–

▲ Next generation, fully basic copper coated APPROVALS*: tubular flux cored wire. Lloyds Register of Shipping Grade 3S, 4YS H5 ▲ Very Low H4 Hydrogen Status. American Bureau of Shipping Grade 4SA, 4YSA H5 ▲ Copper coating improves feedability, Det Norske Veritas IV YMS H5 electrical conductivity and consumable *with Argon + 20-25% CO2 shielding gas combinations. parts life. TYPICAL ALL WELD METAL ANALYSIS: Using Argon + 20-25% CO : ▲ Reliable Low Temperature Impact 2 C: 0.06% Mn: 1.5% Si: 0.5% P: 0.25% S: 0.025%. Toughness to -40°C. Using CO2: C: 0.06% Mn: 1.2% Si: 0.5% P: 0.012% S: 0.012%. Classifications: TYPICAL DIFFUSIBLE HYDROGEN LEVELS TO AS 2203.1: ETD-GCnp-W504A. CM1 H5. AS3752: ETD-GMnp-W504A. CM1 H5. <3 mls of hydrogen / 100gms of deposited weld metal for AWS/ASME-SFA A5.20: E70T-5 H4 , E70T-5M H4. as manufactured product using Argon + 20-25% CO2. TYPICAL ALL WELD METAL MECHANICAL Description and Applications: PROPERTIES: Supre-Cor XP H4 is a tubular, copper coated basic flux cored Using Argon + 20-25% CO2:CO2: wire recommended for use with Argon + 20 - 25%C02 and CO2 Yield Stress 440 MPa 430 MPa (or equivalent) shielding gases. Supre-Cor XP H4 is available in 2.4mm size only and is suitable for the downhand fillet Tensile Strength 550 MPa 540 MPa and butt welding of heavy earthmoving and mining equipment. Elongation 24% 25% Supre-Cor XP H4 has an easily removable slag covering an CVN Impact 100J av @ -40°C 90J av @ -40°C excellent bead shape and low spatter level for a fully basic wire. Values FLUX CORED ARC WELDING WIRES (FCAW) The advanced seamless copper coated tube technology gives rise to several unique features and benefits including: RECOMMENDED SHIELDING GASES: – improved wire feeding which eliminates ‘bird nests’ at the ● Argon + 20-25% CO2 or equivalent ISO14175: M21, M24 wire feeder ● Welding Grade CO2 ISO14175: C1 – Improved current transfer at the welding torch for smooth, consistent arc starting Packaging Data: – Very low AWS: H4 and AS: H5 diffusible hydrogen status for improved resistance to hydrogen induced cold cracking Wire Pack Pack of the weld deposit. Diameter (mm) Type Weight Part No. 2.4 Coil 25kg 720911 Typical Weld Metal Mechanical Properties: Actual weld metal mechanical properties achieved with Supre-Cor XP are influenced by many factors including, base metal analysis, welding parameters / heat input used, shielding gas selection, number of weld passes and run placement etc.

Operating Data: All welding conditions recommended below are for use with semi-automatic operation and DC electrode positive using Argon + 20-25% CO2 shielding gas with a flow rate of 15–20 litres/min. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions

2.4 350-500 27-33 25-30 Flat

HV Fillet 2.4 350-500 27-33 25-30 These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc

148 www.cigweld.com.au DC (FCAW) WIRES CORED ARC WELDING FLUX METAL-COR XP +/– ▲ Grade 3 Shipping Society Approvals. APPROVALS*: ▲ Low Slag, Metal Cored Wire. Lloyds Register of Shipping Grade 3S, 3YS American Bureau of Shipping Grade 3SA, 3YSA ▲ High Deposition Efficiency ≈95%. Det Norske Veritas III YMS ▲ High Deposition Rates. *with Argon + 20-25% CO2 shielding gas or equivalent. ▲ Precision Layer Wound. TYPICAL ALL WELD METAL ANALYSIS*: Classifications: Using Argon + 20-25% CO2: C: 0.03% Mn: 1.45% Si: 0.6% AS 2203.1: ETD-GMn/p-W503A. CM1 H5. ETP*-GMn/p-W503A. CM1 H5. TYPICAL ALL WELD METAL MECHANICAL ( *1.2mm only ) PROPERTIES: AWS/ASME-SFA A5.18: E70C-6M H4 Using Argon + 20-25% CO2: Yield Stress. 530 MPa. Tensile Strength 590 MPa. Description and Applications: Elongation 28% Now with Grade 3 Shipping Society approvals, Metal-Cor XP CVN Impact Values 55J av @ -30°C. is a full iron powder cored wire recommended for a wide range of high speed fillet and butt welding applications in RECOMMENDED SHIELDING GASES: all downhand positions. ● Argon + 20-25% CO2 or equivalent ISO14175: M21, M24

1.2mm Metal-Cor XP can also be used in “short arc” or pulsed transfer mode to facilitate welding in all positions. Packaging Data: Combining the high deposition rates of a flux cored wire and the high efficiency of a solid wire, Metal-Cor XP is ideal Wire Pack Pack for the high productivity fillet and butt welding of mild and Diameter (mm) Type Weight Part No. medium strength carbon steels. Metal-Cor XP produces low 1.0 Spool 15kg 720960 fume levels. The smooth “spray arc transfer” gives very low spatter levels and excellent weld metal edge wetting for 1.2 Spool 15kg 720912 exceptional operator appeal. 1.6 Spool 15kg 720913 For optimum impact properties, Metal-Cor XP is recommended for use with DC electrode negative polarity. 1.6 Autopak 200kg 720913A

Metal-Cor XP is formulated for use with Argon + 20-25% CO2 or equivalent shielding gas.

www.cigweld.com.au 149 DC METAL-COR XP CONT. +/– Operating Data: All welding conditions recommended below are for use with semi-automatic operation, DC electrode negative using Argon + 20-25% CO2 shielding gas with a flow rate of 15–20 litres/min. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions 1.0 200-260 27-30 20-25 1.2 280-350 28-33 20-25 Flat 1.6 350-450 29-33 25-30

1.0 170-220 26-28 20-25 1.2 250-300 27-31 20-25 HV Fillet 1.6 300-380 27-31 25-30

1.0 170-220 26-28 20-25 1.2 250-300 27-31 20-25 Horizontal 1.6 300-380 27-31 25-30

These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc. FLUX CORED ARC WELDING WIRES (FCAW)

150 www.cigweld.com.au FLUX CORED ARC WELDING (FCAW) WIRES 151 te C. C C. ° ° ° Flat HV Fillet Horizontal 135J av @ -40 80J av @ -60 shielding gas or equivalent. : : 2 2 2 or equivalent ISO14175:or equivalent M21, M24 DC +/– 2 1.21.6 Autopak Autopak 230kg 230kg 720552A 720553A 1.21.6 Spool Spool 15kg 15kg 720552 720553 Wire Pack Pack Diameter (mm) Type Weight No. Part Argon + 20-25% CO Packaging Data: Packaging Yield Stress.Yield StrengthTensile ElongationValuesCVN Impact 530 MPa. 135J av @ -20 460 MPa. 32% C: 0.07%P: 0.013% Mn: 0.9% Si: Ni: 0.56% 0.04% S: 0.014% Cr: 0.03% PROPERTIES: Argon + 20-25% CO Using RECOMMENDED SHIELDING GASES: ● APPROVALS*: of ShippingLloyds Register of ShippingAmerican Bureau Det VeritasNorske Grade 3S, Grade 4SA, H5 4YS H5 4YSA Argon + 20-25% CO *with ANALYSIS*: TYPICAL ALL WELD METAL CO Argon + 20-25% Using IV YMS H5 TO HYDROGEN LEVELS TYPICAL DIFFUSIBLE AS3752: weld metal. <3.5 mls of hydrogen / 100gms of deposited TYPICAL ALL WELD MECHANICAL METAL 2 ETP*-GMp-W505A. CM1 H5. ( *1.2mm only ) shielding gas with a flow rate of 15–20 litres/min. 2 1.6 300-380 27-31 25-30 1.21.61.21.6 280-3501.2 350-450 250-300 28-33 300-380 29-33 250-300 27-31 27-31 27-31 20-25 25-30 20-25 25-30 20-25 Wire Voltage Current Welding High Deposition Rates. High Deposition Wound. Layer Precision High Efficiency Metal Cored Wire with Wire Cored Metal High Efficiency Appeal. Operator Excellent Approvals. 4 Shipping Society Grade Low Slag Formation. Very Temperature Outstanding Low Impact Properties. Efficiency. High Deposition Diameter (mm) Range (amps) Range (volts) CTWD Positions Operating Data: Operating Description and Applications: Description and Classifications: METAL-COR 5 METAL-COR thickness, run size, shielding gas and operator technique etc. These machine settings are a guide only.These Actual voltage, welding current and CTWD used will depend on machine characteristics, pla All welding conditions recommended below are for use with semi-automatic operation,Argon + DC electrode positive using 20-25% CO or equivalent shielding gas or equivalent *1.2mm Metal-Cor 5 can be used in short arc or pulsed transfer to facilitate welding in all positions. Metal-Cor 5 is a next generation metal cored wire offering Metal-Cor 5 is a next generation metal with deposition the operator appeal of a metal cored wire impressive rates similar to that of solid wire and combining to those of a comparable low temperature impact values Grade 5 wire. Metal-Cor 5 offers a wide range of operating welding of parameters and is ideal for high productivity mild and medium strength carbon steels. Metal-Cor 5 produces low fume levels, low spatter and excellent appeal. edge wetting for outstanding operator optimum performance Metal-Cor 5 is recommended for For use on DC electrode positive polarity (DC EP). Argon + 20-25% CO Metal-Cor 5 is formulated for use with ▲ ▲ AS 2203.1:A5.18: AWS/ASME-SFA E70C-6M H4 ETD-GMp-W505A. CM1 H5. ▲ ▲ ▲ ▲ ▲ www.cigweld.com.au 152 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au Argon +20-25%CO Formulated forusewith hydrogen inducedcracking. The H4hydrogenstatusgreatlyimprovesresistanceto H5diffusiblehydrogenstatus. H4and AS: very low AWS: feedability andconductivitywhilehelpingtoachievethe copper coatedtubeof Tensi-Cor 110TXPH4offersoptimum The seamless vertical-up weldingofhighstrengthsteels. horizontal-verticaland cored wiresuitablefortheflat, Tensi-Cor 110TXPH4isafullybasiclowalloysteelflux K4H5. ETD-GCn/p-W769A. E110T5K4H4. E110T5K4MH4: AWS/ASME-SFA A5.29: AS 2203.1: ▲ ▲ ▲ nlss edn aaeesha nu sd hedn a eeto,numberofweldpassesandrunplacement. shieldinggasselection, weldingparameters/heatinputused, analysis, Actual weldmetalmechanicalpropertiesachievedwith Tensi-Cor 110TXPareinfluencedbymanyfactorsincludingbasemetal Typical Weld MetalMechanicalProperties: H5diffusiblehydrogenstatusforimprovedresistancetoinducedcoldcrackingof H4and AS: “Very low AWS: feeder consistentarcstarting Improvedcurrenttransferattheweldingtorchforsmooth, – atthewire Improvedwirefeedingwhicheliminates “bird nests” – – The advanced seamlesscoppercoatedtubetechnologygivesrisetoseveraluniquefeaturesandbenefitsincluding: welding ofBisalloy80andsimilarquenchedtemperedsteels. make ittheidealchoiceforcrackfreefullstrengthbutt H5hydrogenstatus Tensi-Cor 110TXPH4 H4and AS: AWS: The premiumqualityweldmetalandverylow 0.4% chromium)steelwelddepositofthe690MPa class. 2%nickel and (nominally 0.4%molybdenum, Tensi-Cor 110TXPH4producesalowalloy gases, ▲ ▲ Description and Applications: Classifications: TENSI-COR 110TXPH4 the welddeposit. 20-25% CO Formulated forUsewith Argon + and conductivity. Copper coatingoffers optimumfeedability basic highstrength wire. Seamless coppercoatedtubularfully properties to-51˚C. Excellent Low Temperature mechanical Removal. Excellent BeadShapeandEasySlag 2 2 or CO and weldinggradeCO T-M/-79.K4H5. ETD-GMn/p-W769A. 2 Shielding Gases. 2 shielding lnain2%20% 700MPa 800MPa 20% 720MPa >65Jav@-51 CVN Impact Values 800MPa Elongation Tensile Strength Yield Stress ● ● RECOMMENDED SHIELDINGGASES: Using PROPERTIES: METALMECHANICAL TYPICAL ALLWELD 0.014% 0.022%S: P: 3.16% 0.31% Ni: as manufacturedproductusing Si: Argon +20-25%CO <3.5 mlsofhydrogen/100gmsdepositedweldmetalfor 0.39% 0.3% Mo: 2.72%Mo: AS3752: Ni: 1.22% Mn: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO 0.025% 0.4% P: Si: 0.52% Cr: 0.54% Cr: 0.06% C: 1.34% Mn: Using CO 0.025% S: 0.06% C: Using Argon +20-25%CO METAL:TYPICAL ALLWELD Packaging Data: Welding GradeCO Argon +20-25%CO imtr(m yeWih Part No. Weight Type Diameter (mm) iePc Pack Pack Wire . ol2k 720389 720387 25kg 15kg Coil Spool 2.4 1.6 2 : +/– DC Argon +20-25%CO 2 2 reuvIO47:M1 M24 M21, ISO14175: or equiv 2 : ° >55Jav@-51˚C C S115 C1 ISO14175: 2 : CO 2 : * 2 . FLUX CORED ARC WELDING (FCAW) WIRES 153 te Flat Flat HV Fillet up Vertical Horizontal DC +/– shielding gas with a flow rate of 15–20 litres/min with a flow rate shielding gas 2 2.41.6 380-4301.6 220-2702.4 27-31 260-310 25-30 360-410 27-31 25-30 27-31 25-30 25-30 25-30 1.62.41.6 300-350 400-450 280-330 28-32 28-32 27-31 25-30 25-35 25-30 Wire Voltage Current Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions Operating Data: Operating TENSI-COR 110TXP H4 CONT. 110TXP TENSI-COR All welding conditions recommended below are for use with semi-automatic operation,for use with semi-automatic below are conditions recommended All welding + Argon using DC electrode positive 20-25% CO These machine settings are a guide only.These Actual voltage, depend on machine characteristics, welding current and CTWD used will pla thickness, run size, etc. shielding gas and operator technique www.cigweld.com.au 154 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au IOE5 sargsee rdmr fTeEa ru,Ic aoe,P 73,USA. PA 17331, Hanover, Inc. NICORE 55isaregisteredtrademarkof The EsabGroup, shieldinggasandoperatortechniqueetc. runsize, thickness, pl usedwilldependonmachinecharacteristics, weldingcurrentandE.S.O. Actualvoltage, These machinesettingsareaguideonly. repair ofcracked ordamagedcastingsandthefillingoffoundrydefects. Typical applicationsincludethe Nicore 55isidealforusewhereanENiFe-CI typemanualarcelectrodeisrecommended. minimal spatter. with Nicore55requiresonlywirebrushingforcompleteremoval torevealawelddepositwithexcellentappearanceand The thinslagproduced malleableandSGironstomildsteel. Nicore 55isalsosuitableforthefilletandbuttweldingofgrey, welding ofcastirons. depositing anIron/Nickel weldmetalforthe Nicore 55isacompositefluxcoredwire ENiFe-CI (equivalent electrodeclassification). Meets AWS/ASME-SFA A5.15: ▲ ▲ Packaging andOperating Data: Description and Applications: Classifications: NICORE imtr(m ag ap)Rne(ot)Tp Weight Type Range(volts) Range (amps) Diameter (mm) Steels. Dissimilar Joining ofCastIron to Also Recommendedforthe Joining andRepairofCastIrons. Composite FluxCored Wire forthe ieCretVlaeCW akPc Part Pack Pack CTWD Current Voltage Wire . 2–5 72 3mHnipo .k 724046 6.8kg Handispool 13mm 27–29 220–250 1.2 ® 55 ades200HV. 12%. ● ● RECOMMENDED SHIELDINGGASES: ENiFe-CI AWS A5.15: Castcraft 55— COMPARABLE CIGWELDPRODUCTS: Hardness 0.45% Si: Elongation 500MPa. Tensile Strength PROPERTIES -USINGSTAINSHIELD: BalanceNi 0.40% Mn: METALMECHANICAL TYPICAL ALLWELD 50.0% Fe: 1.10% C: +1.5%O2: Argon METALTYPICAL ALLWELD ANALYSISUSING - Argon +>0-3%O Argon +>0-3%O +/– DC 2 2 + 1%H reuv S115 M13 ISO14175: or equiv. 2 ate No DC (FCAW) WIRES CORED ARC WELDING FLUX SHIELD-COR 4XP + ▲ Self Shielded Flux Cored Wire TYPICAL ALL WELD METAL ANALYSIS: Formulated for Fast Downhand Fillet C: 0.30% Mn: 0.55% Si: 0.10% & Butt Welding Jobs. Al: 1.50% S: 0.008% P: 0.013%. ▲ Excellent Operator Appeal. TYPICAL DIFFUSIBLE HYDROGEN LEVELS TO ▲ Excellent Tolerance to Joint AS3752: Misalignment or Poor Joint Fit-up. 10.0 - 12.0 mls of hydrogen / 100gms of deposited weld ▲ metal *. Low Spatter Levels / Easily Removed Slag. * - for “as manufactured” product using the recommended E.S.O lengths. Classifications: TYPICAL ALL WELD METAL MECHANICAL AS 2203.1: ETD-GNp-W500A. CM2 H15. PROPERTIES: AWS/ASME-SFA A5.20: E70T-4. Yield Stress 430 MPa Tensile Strength 590 MPa Description and Applications: Elongation 25% CVN Impact Values 50 J av @ +20°C. Shield-Cor 4XP is a self shielded flux cored welding wire designed for the high deposition rate fillet and butt welding of 30 J av @ 0°C mild and medium strength steels in all downhand ( primarily Actual weld metal mechanical properties achieved with Shield- flat and horizontal-vertical ) welding positions. Cor 4XP are influenced by many factors including, base metal analysis, welding parameters / heat input used, number of weld It has excellent operator appeal and produces a soft, spray arc passes and run placement etc. Please consult your nearest transfer with a full covering easily removed slag. The soft arc CIGWELD branch for welding procedure recommendations. characteristics of Shield-Cor 4XP give it improved tolerance to joint misalignment or joints with poor fit-up. RECOMMENDED SHIELDING GASES: Shield-Cor 4XP desulphurises the weld deposit thereby giving Not Required. improved resistance to weld metal cracking. Shield-Cor 4XP is designed to produce very high deposition Packaging Data: rates when used with a long electrode stickout and DC electrode positive polarity only. It produces its own protective shielding Wire Pack Pack gas and is therefore recommended for ‘on-site’ fabrication, Diameter (mm) Type Weight Part No. structural or repair welding applications. 2.4 Coil 27kg 720907 Typical applications include general fabrication and structural 2.8 Coil 27kg 720908 welding, field erection work and the outdoor repair of heavy machines and equipment.

Operating Data: All welding conditions recommended below are for use with semi-automatic operation, and DC electrode positive polarity. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions 2.4 300-400 27-30 60-70 Flat 2.8 330-430 28-32 60-70 2.4 280-380 27-30 60-70 HV Fillet 2.8 320-420 28-32 60-70 2.4 270-370 27-29 60-70 Horizontal 2.8 300-400 28-30 60-70

These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size and operator technique etc. www.cigweld.com.au 155 DC SHIELD-COR 8XP – ▲ Superior, all-positional performance. TYPICAL ALL WELD METAL ANALYSIS: ▲ Outstanding operator appeal. C: 0.17% Mn: 0.45% Si: 0.12% P: 0.01% ▲ Vacuum packaged. S: 0.003% V: 0.01%. Cu: 0.01% Al: 0.5% ▲ Excellent slag lift. TYPICAL ALL WELD METAL MECHANICAL PROPERTIES: Yield Stress 460 MPa Classifications: Tensile Strength 560 MPa AS 2203.1: ETP-GNn-W503A. CM1. Elongation 24% AWS/ASME-SFA A5.20: E71T-8. CVN Impact Values 55J av@-30˚C TYPICAL DIFFUSIBLE HYDROGEN LEVELS TO Description and Applications: AS3752: Shield-Cor 8XP is a self-shielding rutile type flux cored welding 7-8 mls per 100g wire for the joining of mild and medium strength plate and RECOMMENDED SHIELDING GAS: pipes in all positions. Not Required. The superior all positional performance of Shield-Cor 8XP make it the prime choice for structural steel work and tank building Packaging Data: where wires requiring shielding gas cannot be used. Stringer bead or weave techniques are equally suitable for use with this Wire Pack Pack Diameter (mm) Type Weight Part No. wire. The outstanding operator appeal of Shield-Cor 8XP make it the optimum choice for operators of all skill levels and 1.6 Spool 12kg 721304 FLUX CORED ARC WELDING WIRES (FCAW) experience. 2.0 Spool 12kg 721305

The user friendly nature of Shield-Cor 8XP is backed up by impressive all weld metal mechanical properties and superior deposition rates to that of comparable wires in this class.

Operating Data: All welding conditions recommended below are for use with semi-automatic operation, and DC electrode positive polarity. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions

1.6 170-250 20-24 15-25 Flat 2.0 220-290 22-26 20-30

1.6 170-260 20-24 15-25 HV Fillet 2.0 200-280 22-26 20-30 1.6 150-220 20-24 15-25 Vertical Up 2.0 180-200 22-26 20-30 1.6 150-220 21-25 12-20 Overhead 2.0 200-240 22-26 15-25

These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine characteristics, plate thickness, run size and operator technique etc.

156 www.cigweld.com.au FLUX CORED ARC WELDING (FCAW) WIRES 157 te Flat Flat HV Fillet Up Vertical Overhead – DC 1.62.0 Spool Spool 12kg 721306 12kg 721307 Wire Pack Pack Packaging Data: Packaging Diameter (mm) Type Weight No. Part RECOMMENDED SHIELDING GAS: Not Required. TYPICAL ALL WELD METAL ANALYSIS: ALL WELD TYPICAL METAL C: 0.06% S: 0.003% Mn: 0.93% TYPICAL ALL WELD MECHANICAL METAL Ni: 0.01%.PROPERTIES: StressYield Si: 0.31% P: Strength 0.08% Tensile Al: 0.5% ElongationValuesCVN Impact TO LEVELS TYPICAL DIFFUSIBLE HYDROGEN AS3752: 7-8 mls per 100g 560 MPa 75J av@-30˚C 480 MPa 26% 2.01.62.0 200-2801.6 150-2202.0 22-26 180-200 20-24 150-220 22-26 200-240 21-25 20-30 15-25 22-26 20-30 12-20 15-25 1.62.01.6 170250 220-290 170-260 20-24 22-26 20-24 15-25 20-30 15-25 Wire Voltage Current Welding Superior, performance. all-positional impact good low temperature Very toughness. packaged. Vacuum poor fit up. to Excellent tolerance Diameter (mm) Range (amps) Range (volts) CTWD Positions Description and Applications: Description and Classifications: SHIELD-COR 8Ni SHIELD-COR Operating Data: Operating AS 2203.1:A5.20: AWS/ASME-SFA E71T-8Ni1. type flux cored Shield-Cor 8XP is a self-shielding rutile/basic ETP-GNn-W503A. medium strength plate welding wire for the joining of mild and Ni1. toughness is and pipes in all positions where low temperature important. excellent all positional prformance of Shield-Cor The it the prime choice for structural steel work and tank 8Ni make gas cannot be used, building where wires requiring shielding and tanks. such as the construction of off-shore structures outstanding low temperature impact properties of The productivity it the best choice for high Shield-Cor 8Ni make cannot beused. welding in areas where gas shielded wires broad operating range of Shield-Cor 8Ni is supported by The impressive all weld, properties. metal mechanical ▲ ▲ ▲ ▲ thickness, run size and operator technique etc. These machine settings are a guide only.These Actual voltage, welding current and CTWD used will depend on machine characteristics, pla All welding conditions recommended below are for use with semi-automatic operation, and DC electrode positive polarity. www.cigweld.com.au 158 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au ae,fne,selfae,galvanised tanksandornamentalironworketc. steelframes, fences, gates, Applications includethegeneralpurposefabricationorrepairofmildandgalvanised steelfixturesandstructuresincluding overhead. current andvoltagesettings1.2mmShield-Cor11canbeeasilyusedinallweldingpositionsincludingvertical-up/down and When ‘tuned in’totheoptimum excellent filletshapeandedgewettingareachievedwhenweldinggalvanised steelfixtures. Smoothstablearcingand The softarctransfergivesShield-Cor11improvedtolerancetojointmisalignmentorpoorfit-up. covering slag. spatter lossesandaneasy-to-removefull produces smootharccharacteristicswithlow used withDCelectrodenegativepolarity E71T-11 andwhen requirements of AWS A5.20: Shield-Cor 11meetstheperformance mild andgalvanised steels. filletandbuttweldingof single ormulti-passlap, cored wirerecommendedforthegeneralpurpose Shield-Cor 11isanallpositionalself-shieldedflux CM2. ETP-GNn-W500A. E71T-11. AWS/ASME-SFA A5.20: AS 2203.1: ▲ ▲ ▲ ▲ ▲ ▲ Description and Applications: Classifications: SHIELD-COR 11 and GalvanisedSteels. Ideal for Welding Thin SectionMild Edge Wetting. Smooth RippledFilletswithGood Misalignment orPoor Joint Fit-up. Excellent Tolerance toJoint Excellent Operator Appeal. All Positional Capabilities. Versatile, Self-shielded FluxCored wire. lnain22% CIGWELD branchforweldingprocedurerecommendations. Pleaseconsultyournearest passes andrunplacementetc. numberofweld weldingparameters/heatinputused, analysis, 445MPa basemetal Cor 11areinfluencedbymanyfactorsincluding, 620MPa Actual weldmetalmechanicalpropertiesachievedwithShield- Not Required. RECOMMENDED SHIELDINGGAS: Elongation Tensile Strength Yield Stress PROPERTIES: METALMECHANICAL TYPICAL ALLWELD lengths. 0.007%. P: productusingtherecommended E.S.O. * -for “as manufactured” 0.40% Si: metal *. 15.0 -20.0mlsofhydrogen/100gmsdepositedweld 0.004% S: AS3752: 0.70% Mn: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO 1.65% Al: 0.25% C: METALTYPICAL ALLWELD ANALYSIS: imtr(m yeWih Part No. Weight Type Diameter (mm) Packaging Data: iePc Pack Pack Wire . po 5g720925 15kg 720923 15kg Spool Spool 1.6 1.2 DC – FLUX CORED ARC WELDING (FCAW) WIRES 159 te Flat Flat HV Fillet up Vertical Overhead – DC 1.61.21.6 180-2401.2 130-1801.6 18-21 160-210 16-18 130-180 18-21 160-200 16-18 20-25 15-20 18-21 20-25 15-20 20-25 1.21.61.2 180-230 180-250 150-200 16-18 18-21 16-18 15-20 20-25 15-20 Wire Voltage Current Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions Operating Data: Operating SHIELD-COR 11 CONT. 11 SHIELD-COR These machine settings are a guide only.These Actual voltage, depend on machine characteristics, welding current and CTWD used will pla All welding conditions recommended below are for use with semi-automatic operation and DC electrode negative only. and DC electrode negative operation for use with semi-automatic below are conditions recommended All welding thickness, run size, and operator technique etc. shielding gas www.cigweld.com.au 160 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au nldn ae,fne,selfae,galvanised tanksandornamentalironworketc. steelframes, fences, including gates, Applicationsincludethegeneralpurposefabricationorrepairofmildandgalvanised steelfixturesandstructures as 1.0mm. onmaterialsasthin includingvertical-up/downandoverhead, (0.8mm and0.9mm)caneasilybeusedinallweldingpositions, When ‘tuned in’totheoptimumcurrentandvoltagesettingswiderangeofwiresizes galvanised steelfixtures. and edgewettingareachievedwhenwelding Smooth stablearcingandexcellentfilletshape tolerance tojointmisalignmentorpoorfit-up. smooth arctransfergivesShield-Cor15improved The easy-to-remove fullcoveringlightslag. andan lowspatterlosses, arc action, Welding characteristicsaresuperbwithasmooth general purposerutiletypeelectrodes. deposition efficienciesarehigherthanthatof Travel speedsarehighand on thinplate. polarity whichminimisestheriskofburnthrough Shield-Cor 15isusedwithDCelectrodenegative galvanised andmildsteels. filletandbuttweldingofthingauged lap, Itisexcellentforsingle-pass applications only. CM2. ETPS-GNn-W500A. cored wirerecommendedforsinglepasswelding Shield-Cor 15isanallpositionalself-shieldedflux E71T-GS. AWS/ASME-SFA A5.20: AS 2203.1: ▲ ▲ ▲ ▲ ▲ ▲ Description and Applications: Classifications: SHIELD-COR 15 and GalvanisedSteels. Ideal for Welding Thin SectionMild Edge Wetting. Smooth RippledFilletswithGood Misalignment orPoor Joint Fit-up. Excellent Tolerance toJoint AllPositional Capabilities. Versatile, For SinglePass applicationsOnly. Self-shielded FluxCored wire. lnain21% CIGWELD branchforweldingprocedurerecommendations. 430MPa Pleaseconsultyournearest passes andrunplacementetc. 600MPa numberofweld weldingparameters/heatinputused, analysis, basemetal Cor 15areinfluencedbymanyfactorsincluding, Actual weldmetalmechanicalpropertiesachievedwithShield- Not Required. RECOMMENDED SHIELDINGGAS: Elongation Tensile Strength Yield Stress PROPERTIES: METALMECHANICAL TYPICAL ALLWELD 0.40% Si: lengths. productusingtherecommended E.S.O. * -for “as manufactured” 0.007%. 0.004%P: 15.0 -20.0mlsofhydrogen/100gmsdepositedweldmetal*. S: 0.70% Mn: AS3752: TYPICAL DIFFUSIBLEHYDROGENLEVELS TO 2.10% Al: 0.25% C: METALTYPICAL ALLWELD ANALYSIS: m)Tp egtPart No. Weight Type (mm) im akPack Pack Diam. Wire Wire Packaging Data: . 0m adsol45g721924 721923 4.5kg 721976 721956 0.45kgx(4/ctn) 4.5kg 0.45kgx(4/ctn) 200mmHandispool 100mmMinispool 0.9 200mmHandispool 100mmspool 0.9 0.8 0.8 . 0m adsol45g720302 4.5kg 200mmHandispool 1.2 DC – FLUX CORED ARC WELDING (FCAW) WIRES 161 te Flat Flat HV Fillet up Vertical Overhead – DC 0.80.91.2 60-120 80-150 130-180 14-16 15-17 16-18 10-12 12-15 15-20 0.80.91.2 80-1400.8 100-175 150-2000.91.2 14-16 15-17 60-120 16-18 80-150 130-180 10-12 14-16 12-15 15-17 15-20 16-18 10-12 12-15 15-20 0.80.91.2 90-150 110-180 180-230 14-16 15-17 16-18 10-12 12-15 15-20 Wire Voltage Current Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions Operating Data: Operating SHIELD-COR 15 CONT. 15 SHIELD-COR These machine settings are a guide only.These Actual voltage, welding current and CTWD used will depend on machine characteristics, pla thickness, run size, shielding gas and operator technique etc. All welding conditions recommended below are for use with semi-automatic operation and DC electrode negative only. and DC electrode negative operation for use with semi-automatic below are conditions recommended All welding www.cigweld.com.au 162 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au ▲ E308LT1-1 (CO AWS/ASME-SFA A5.22: ▲ low spatterlevelswithbothCO gives smootharctransfercharacteristicsandvery The rutiletypefluxcore welding applications. flux coredwirerecommendedforallpositional Verti-Cor 308LT 304and304Letc. 302, including AISI types301, applications on19Cr/9Nistainlesssteelgrades flux coredwiredevelopedforpositionalwelding Verti-Cor 308LT isagasshieldedstainlesssteel welding positions. vertical-upandoverhead horizontal-vertical, flat, smooth mitretoslightlyconvexfilletweldsinthe slag givesexcellentweldpoolcontrolresultingin Argon +20-25%CO2shieldinggases The fastfreezing ▲ ▲ Description and Applications: Classifications: VERTI-COR 308LT Argon +20-25%CO2Shieldinggases. Stainless Steels. High DepositionRate Welding of ● Formulated forCO Plastic Packs. Vacuum Sealedin Aluminised Cored Wires; Verti-Cor StainlessSteelFlux 308LT-Capabilities Positional All 2 ) /E308LT1-4 (Ar+20-25%CO savraie stainlesssteel is aversatile, 2 or 2 and 2 ). recommendations. consult yournearestCIGWELDbranchforweldingprocedure Please numberofweldpassesandrunplacementetc. selection, shieldinggas weldingparameters/heatinputused, analysis, basemetal wires areinfluencedbymanyfactorsincluding, Actual weldmetalmechanicalpropertiesachievedwith Verti-Cor ● ● RECOMMENDED SHIELDINGGASES: E308L-17 AWS A5.4: Satincrome 308L-17Electrode ER308L AWS A5.9: Comweld 308LGAS/TIGrod ER308LSi AWS A5.9: Autocraft 308LSiGMAW Wire COMPARABLE CIGWELDPRODUCTS: 0.020% P: PROPERTIES: 9.9% METALMECHANICAL TYPICAL ALLWELD Ni: 0.003% S: 19.5% Cr: 1.30% 0.03%Mn: 0.70% C: Si: Using Welding GradeCO METALTYPICAL ALLWELD ANALYSIS: lnain4%40% 580MPa 43% 400MPa 550MPa 390MPa Elongation Tensile Strength 0.2% ProofStress imtr(m yeWih Part No. Weight Type Diameter (mm) Packaging Data: Welding GradeCO Argon +20-25%CO iePc Pack Pack Wire . po 5g722889 15kg Spool 1.2 DC + 2 Using CO 2 reuvln IO47:M21 or equivalent ISO14175: 2 2 Argon+20-25%CO2: : S115 C1 ISO14175: FLUX CORED ARC WELDING (FCAW) WIRES 163 te Flat Flat HV Fillet up Vertical Overhead + DC shielding gas with a flow rate of 15–20 litres/min. with a flow rate shielding gas 1.21.2 150-2001.2 23-28 120-180 22-27 140-180 15-20 22-27 15-20 15-20 1.2 150-250 23-28 15-20 2 Wire Voltage Current Welding Diameter (mm) (amps) Range Range (volts) CTWD Positions Operating Data: Operating VERTI-COR 308LT CONT. 308LT VERTI-COR These machine settings are a guide only.These Actual voltage, depend on machine characteristics, welding current and CTWD used will pla All welding conditions recommended below are for use with semi-automatic operation and DC electrode positive and welding and DC electrode positive operation for use with semi-automatic below are conditions recommended All welding grade CO thickness, run size, etc. shielding gas and operator technique www.cigweld.com.au 164 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au ▲ E309LT1-1 (CO characteristics andverylowspatterlevelswithbothCO The rutiletypefluxcoregivessmootharctransfer suchas3Cr12. ferriticstainlesssteels, “400 series” low alloysteelsandfortheweldingofselected austeniticstainlesssteelstomildor “300 series” Verti-Cor 309LT issuitableforthedissimilarweldingofother applications onmatching309and309Lstainlesssteels. developed forawiderangeofpositionalanddownhandwelding Verti-Cor 309LT isagasshieldedstainlesssteelfluxcoredwire ▲ ▲ ▲ recommendation. Thermadyne Area Managerforweldingprocedure of weldpassesandrunplacementetc.Pleaseconsultyour number shieldinggasselection, metal analysis/heatinputused, Verti-Cor wiresareinfluencedbymanyfactorsincludingbase Actual weldmetalmechanicalpropertiesachievedwith vertical-upandoverheadweldingpositions. horizontal-vertical, smooth mitretoslightlyconvexfilletweldsintheflat, slag givesexcellentweldpoolcontrolresultingin Argon +20-25%CO2shieldinggases The fastfreezing AWS/ASME-SFA A5.22: Description and Applications: Classifications: VERTI-COR 309LT Argon +20-25%CO2Shieldinggases. Stainless Steels. High DepositionRate Welding of ● Formulated forCO Plastic Packs. Vacuum Sealedin Aluminised Cored Wires; Verti-Cor StainlessSteelFlux 309LT-Capabilities Positional All 2 ) /E309LT1-4 (Ar+20-25%CO 2 or 2 ). 2 and recommendations consult yournearestCIGWELDbranchforweldingprocedure Please numberofweldpassesandrunplacementetc. selection, shieldinggas weldingparameters/heatinputused, analysis, basemetal wires areinfluencedbymanyfactorsincluding, Actual weldmetalmechanicalpropertiesachievedwith Verti-Cor ● ● RECOMMENDED SHIELDINGGASES: E309Mo-17 AWS A5.4: Satincrome 309Mo-17Electrode ER309L AWS A5.9: Comweld 309LGAS/TIGrod ER309LSi AWS A5.9: Autocraft 309LSiGMAW Wire COMPARABLE CIGWELDPRODUCTS: . PROPERTIES: METALMECHANICAL TYPICAL ALLWELD Using Welding GradeCO METALTYPICAL ALLWELD ANALYSIS: lnain4 38% 40% 580MPa 430MPa 550MPa 410MPa Elongation Tensile Strength 0.2% ProofStress r 36 i 30 :0.023% P: 0.60% Si: 13.0% Ni: 1.12% Mn: 0.003% S: 23.6% Cr: 0.03% C: Packaging Data: Welding GradeCO Argon +20-25%CO imtr(m yeWih Part No. Weight Type Diameter (mm) iePc Pack Pack Wire . po 5g722882 722881 15kg 15kg Spool Spool 1.6 1.2 DC + 2 2 Using CO reuvln S115 M21 or equivalent ISO14175: 2 S115 C1 ISO14175: : 2 Argon+20-25%CO2: : FLUX CORED ARC WELDING (FCAW) WIRES 165 te Flat HV Fillet up Vertical Overhead + DC shielding gas with a flow rate of 15-20 litres/min. with a flow rate shielding gas 1.61.21.6 250-3501.2 120-1801.6 28-35 200-250 22-27 140-180 23-27 190-250 22-27 25-30 15-20 23-27 20-25 15-20 20-25 1.21.61.2 150-250 300-400 150-200 23-28 28-35 23-28 15-20 25-30 15-20 2 Wire Voltage Current Welding Diameter (mm) (amps) Range Range (volts) CTWD Positions Operating Data: Operating VERTI-COR 309LT CONT. 309LT VERTI-COR These machine settings are a guide only.These Actual voltage, depend on machine characteristics, welding current and CTWD used will pla All welding conditions recommended below are for use with semi-automatic operation,for use with semi-automatic below are conditions recommended All welding and welding DC electrode positive grade CO thickness, run size, etc. shielding gas and operator technique www.cigweld.com.au 166 FLUX CORED ARC WELDING (FCAW) WIRES www.cigweld.com.au E316LT1-1 (CO AWS/ASME-SFA A5.22: ▲ ▲ Thermadyne Area Managerforweldingprocedurerecommendation. of weldpassesandrunplacementetc.Pleaseconsultyour number shieldinggasselection, metal analysis/heatinputused, Verti-Cor wiresareinfluencedbymanyfactorsincludingbase Actual weldmetalmechanicalpropertiesachievedwith welding positions. vertical-upandoverhead horizontal-vertical, flat, smooth mitretoslightlyconvexfilletweldsinthe slag givesexcellentweldpoolcontrolresultingin and Argon +20-25% CO2shieldinggases The fastfreezing characteristics andverylowspatterlevelswithbothCO The rutiletypefluxcoregivessmootharctransfer 304and304Ltypes. 302, including 301, austeniticstainlesssteels of other “300 series” is alsosuitableforthegeneralpurposewelding Verti-Cor 316LT 316 and316Lstainlesssteels. applications onmatchingMolybdenumbearing flux coredwiredevelopedforpositionalwelding Verti-Cor 316LT isagasshieldedstainlesssteel ▲ ▲ Description and Applications: Classifications: VERTI-COR 316LT Cored Wires; Verti-Cor StainlessSteelFlux Argon +20-25%CO2Shieldinggases. Stainless Steels. High DepositionRate Welding of Formulated forCO Plastic Packs. Vacuum Sealedin Aluminised ● 316LT-Capabilities Positional All 2 ) /E316LT1-4 (Ar+20-25%CO 2 or 2 ). 2 r 88 i 20 o 2.5% Mo: 0.60% Si: 0.002% S: 12.0% Ni: 1.10% Mn: 0.024% P: 18.8% Cr: 0.03% C: lnain4 39% 42% 580MPa 410MPa 555MPa Elongation 400MPa Tensile Strength 0.2% ProofStress recommendations. consult yournearestCIGWELDbranchforweldingprocedure Please numberofweldpassesandrunplacementetc. selection, shieldinggas weldingparameters/heatinputused, analysis, basemetal wires areinfluencedbymanyfactorsincluding, Actual weldmetalmechanicalpropertiesachievedwith Verti-Cor ● ● RECOMMENDED SHIELDINGGASES: -17 E316L AWS A5.4: Satincrome 316L-17Electrode ER316L AWS A5.9: Comweld 316LGAS/TIGrod ER316LSi AWS A5.9: Autocraft 316LSiGMAW Wire COMPARABLE CIGWELDPRODUCTS: PROPERTIES: METALMECHANICAL TYPICAL ALLWELD Using Welding GradeCO METALTYPICAL ALLWELD ANALYSIS: Packaging Data: Welding GradeCO Argon +20-25%CO imtr(m yeWih Part No. Weight Type Diameter (mm) iePc Pack Pack Wire . po 5g722885 15kg Spool 1.2 DC + Using CO 2 2 reuvln IO47:M21 or equivalent ISO14175: S115 C1 ISO14175: 2 : 2 : Using Argon +20-25%CO UsingArgon : 2 : FLUX CORED ARC WELDING (FCAW) WIRES 167 te Flat HV Fillet up Vertical Overhead + DC shielding gas with a flow rate of 15-20 litres/min. with a flow rate shielding gas 1.21.2 150-2001.2 23-28 120-180 22-27 140-180 15-20 22-27 15-20 15-20 1.2 150-250 23-28 15-20 2 Wire Voltage Current Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions

Operating Data: Operating VERTI-COR 316LT CONT. 316LT VERTI-COR These machine settings are a guide only.These Actual voltage, depend on machine characteristics, welding current and CTWD used will pla All welding conditions recommended below are for use with semi-automatic operation,for use with semi-automatic below are conditions recommended All welding and welding DC electrode positive grade CO thickness, run size, and operator technique etc. shielding gas www.cigweld.com.au FLUX CORED ARC WELDING (FCAW) WIRES (FCAW) WELDING ARC CORED FLUX DC STOODY SOS 308L + S (Replaces Shieldcrome 308LT-O) TYPICAL ALL WELD METAL ANALYSIS: C: 0.02% Mn: 1.20% Si: 0.50% ▲ SHIELDCROME Stainless Steel Flux Cored Cr: 20.80% Ni: 10.2% Wires. TYPICAL ALL WELD METAL MECHANICAL ▲ Convenient Self Shielded (Open Arc) PROPERTIES: Operation For “In situ or Outdoor Tensile Strength 600 MPa Applications. Elongation 43% ▲ High Deposition Rate Downhand Welding. COMPARABLE CIGWELD PRODUCTS: ▲ For downhand welding application on Shieldcrome 308LT all positional gas shielded 19Cr/10Ni type stainless steels including FCAW wire type 301, 302, 304 and 304L. AWS A5.22: E308LT1-1 / E308LT1-4. Shieldcrome 308LTD downhand gas shielded FCAW wire Classifications: AWS A5.22: E308LT0-1 / E308LT0-4. AWS/ASME-SFA A5.22: E308LTO-3. Autocraft 308LSi GMAW wire WTIA Tech Note 4/AS 2576: 1315-B7. AWS A5.9: ER308LSi. Ferrite Number: 8.0 Comweld 308L Gas / TIG rod AWS A5.9: ER308L. Description and Applications: Satincrome 308L-17 electrode Shieldcrome 308LT-O is a self shielded (or open AWS A5.4: E308L-17. arc) stainless steel flux cored wire developed for a RECOMMENDED SHIELDING GAS: wide range of “in situ” downhand welding Not required. applications on 19Cr/10Ni type stainless steels including type 201, 202, 301, 302, 304 and 304L. FLUX CORED ARC WELDING WIRES (FCAW) Shieldcrome 308LT-O is ideal for fast fillet and butt Packaging Data: welding applications in the flat and horizontal-vertical positions. Wire Wire Pack Pack Pack Diameter (mm) Type Type Weight Part No. Typical All Weld Metal Mechanical Properties: 2.4 308LT-O Coil 22kg 11175400 Actual weld metal mechanical properties achieved with Shieldcrome wires are influenced by many factors including, base metal analysis, welding parameters / heat input used, number of weld passes and run placement etc. Please consult your nearest CIGWELD branch for welding procedure recommendations. Operating Data: All welding conditions recommended below are for use with semi-automatic self shielded operation and DC electrode positive. Wire Current Voltage Welding Diameter (mm) Range (amps) Range (volts) CTWD Positions

2.4 300-350 28-30 20-25 Flat

2.4 300-350 28-30 20-25 HV Fillet

These machine settings are a guide only. Actual voltage, welding current and E.S.O. used will depend on machine characteristics, plate thickness, run size, shielding gas and operator technique etc.

168 www.cigweld.com.au FLUX CORED ARC WELDING (FCAW) WIRES 169 te Flat HV Fillet + DC 2.4 309LT-O Coil 22kg 11231200 Wire Wire Pack Pack Pack Packaging Data: Packaging Diameter (mm) Type Type Weight No. Part RECOMMENDED SHIELDING GAS: Not required. TYPICAL ALL WELD METAL ANALYSIS: ALL WELD TYPICAL METAL C: 0.02%Cr: 24.4% TYPICAL ALL WELD MECHANICAL METAL Mn: 1.20%PROPERTIES: Ni: 12.6% StrengthTensile Elongation Si: 0.5% CIGWELD PRODUCTS: COMPARABLE shielded FCAW wire all positional gas Shieldcrome 309LT AWS A5.22: / E309LT1-1 E309LT1-4. downhand gas shielded FCAW wire Shieldcrome 309LTD AWS A5.22: / E309LT0-1 E309LT0-4. 610 MPa Autocraft 309LSi GMAW wire AWS A5.9: ER309LSi. TIG rod Comweld 309L Gas / AWS A5.9: ER309L. 38% Satincrome 309Mo-17 electrode AWS A5.4: E309Mo-17. 2.4 300-3502.4 28-30 300-350 20-25 28-30 20-25 Wire Voltage Current Welding High Deposition Rate Downhand High Deposition Welding. SHIELDCROME Stainless Steel Flux Stainless SHIELDCROME Wires. Cored Shielded Convenient Self “In situ” For Operation Arc) (Open Applications. or Outdoor or as a Dissimilar Steels Joining For Surfacing. to Hard Buffer Layer Prior Diameter (mm) Range (amps) Range (volts) CTWD Positions Operating Data: Operating Description and Applications: Description and Classifications: STOODY SOS 309L SOS STOODY thickness, run size, shielding gas and operator technique etc. These machine settings are a guide only.These Actual voltage, welding current and CTWD used will depend on machine characteristics, pla All welding conditions recommended below are for use with semi-automatic self shielded operation and DC electrode All welding conditions recommended below are for use with semi-automatic self positive. Shieldcrome 309LT-O is a self shielded (or open Shieldcrome 309LT-O for a arc) stainless steel flux cored wire developed “in situ”wide range of downhand welding stainless applications on matching 309 and 309L steels. is also recommended 309LT-O Shieldcrome of other for the dissimilar fillet and butt welding mild or ‘300 series’ austenitic stainless steels to “buttering”low alloy steels and for the of steels prior to the application of hardfacing. Properties: Metal Mechanical Weld Typical influenced by many factors including,Actual weld metal mechanical properties achieved with Shieldcrome wires are base metal analysis, input used, welding parameters / heat number of weld passes and run placement etc. Please consult your nearest CIGWELD branch for welding procedure recommendations. ▲ A5.22: AWS/ASME-SFA Note 4/AS 2576:Tech WTIA 1315-B7. E309LTO-3. NumberFerrite 15.0 (Replaces Shieldcrome 309LT-O) Shieldcrome (Replaces ▲ ▲ ▲ www.cigweld.com.au 170 SUBMERGED ARC WIRES AND FLUXES 171 175 173 174 176 Page No Page SUBMERGED ARC WIRES AND AND ARC WIRES SUBMERGED FLUXES Description Autocraft SA1 Autocraft Autocraft SA2 Satinarc 4 Satinarc 15 www.cigweld.com.au 172 MILD STEEL AND IRON POWDER SUBMERGED ARC WIRES AND FLUXES www.cigweld.com.au on hr tetr h edn r,andthearclength. point whereitenterstheweldingarc, tothe CTWDincludesthewirelengthfromcontacttip, shown below. Aschematic diagramofCTWDis the contacttipandworkpiece. isdefinedasthedistancebetweenendof electrode stickout(ESO), Contact Tip to Work Distance(CTWD), CONTACTEXPLAINED TIPTODISTANCE(CTWD) WORK CTWD Flux also sometimesreferredtoas Zone (RHZ) Heating Resistive Ar c Length Conta c t Tip DC FLUXES SUBMERGED ARC WIRES AND AUTOCRAFT SA1 +/– ▲ Copper Coated, Low Carbon TYPICAL WIRE ANALYSIS: Low Manganese Steel Submerged Arc Wire. C: 0.08% Mn: 0.50% Si: 0.01% ▲ Cost Effective General Purpose S: 0.017% P: 0.010% Welding with a ‘Active’ Fluxes including Satinarc 15.

Classifications: AS 1858.1: EL12. AWS/ASME-SFA A5.17: EL12.

Description and Applications: Autocraft SA1 is a copper coated, low carbon steel wire for general purpose submerged arc welding applications. The very low deoxidant levels of Autocraft SA1 (nominally 0.5% Manganese, 0.01% Silicon) necessitates its use with ‘active’ or contributory fluxes such as Satinarc 15. Autocraft SA1 / Satinarc 15 is a versatile, submerged arc welding combination suitable for a multitude of fast fillet and butt welding applications on rusty or mill scaled plate up to 25mm thick.

Packaging and Operating Data*: Wire Diameter Current Voltage CTWD Pack Type Pack Weight Part No mm Range (amps) Range (volts) (mm) 2.0 200-550 24-32 20-25 Coil 30kg 720582 2.4 250-700 26-34 20-25 Coil 30kg 720583 3.2 300-900 28–34 25-30 Coil 30kg 720584 4.0 400-1000 30-38 20-25 Coil 30kg 720585 Parameters are for single wire automatic applications. Other packaging options are available on indent, please contact your CIGWELD representative.

www.cigweld.com.au 173 DC AUTOCRAFT SA2 +/– ▲ Copper Coated, Low Carbon Steel TYPICAL WIRE ANALYSIS: Submerged Arc Wire. C: 0.10% Mn: 1.0% Si: 0.22% ▲ Cost Effective General Purpose and S: 0.017% P: 0.010% Higher Quality Welding with a ‘Neutral’ Flux such as Satinarc.

Classifications: AS 1858.1: EM12K. AWS/ASME-SFA A5.17: EM12K.

Description and Applications: Autocraft SA2 is a copper coated - nominal 1.0% Manganese, 0.20% Silicon - steel submerged arc welding wire. The chemical analysis of Autocraft SA2 makes it suitable for a wide range of general purpose and critical submerged arc welding applications with a ‘neutral’ flux such as Satinarc 4. When used with this flux, Autocraft SA2 produces a high weld metal tensile strength.

Packaging and Operating Data*: SUBMERGED ARC WIRES AND FLUXES Wire Diameter Current Voltage CTWD Pack Type Pack Weight Part No mm Range (amps) Range (volts) (mm) 2.0 200-550 24-32 20-25 Coil 30kg 720662 2.4 250-700 26-34 20-25 Coil 30kg 720663 3.2 300-900 28–34 25-30 Coil 30kg 720664 4.0 400-1000 30-38 30-35 Coil 30kg 720665

174 www.cigweld.com.au DC FLUXES SUBMERGED ARC WIRES AND SATINARC 4 +/– ▲ Semi-Basic Submerged Autocraft SA1 / Satinarc 4 Arc Flux. ▲ For Multi Pass Butt Welding APPROVALS: Applications Requiring Low Lloyds Register of Shipping - Grade DBF 2T, 3M 2O Temperature Impact Properties. American Bureau of Shipping - Grade 2T, 3M ▲ Recommended for Use with TYPICAL ALL WELD METAL ANALYSIS: Autocraft SA2. C: 0.05% Mn: 0.85% Si: 0.30% ▲ Excellent Slag Lift in Deep S: 0.008% P: 0.022% ‘Vee’ Joints. TYPICAL ALL WELD METAL MECHANICAL PROPERTIES (AS WELDED): Yield Stress 380 MPa. Classifications: Tensile Stress 490 MPa Autocraft SA1 & Satinarc 4 Elongation 32% AWS A5.17: F6A2- EL12 CVN Impact Values 90 J av @ -20°C. AS 1858.1: EL12-FMM-W403A. Autocraft SA2 / Satinarc 4 Autocraft SA2 & Satinarc 4 AWS A5.17: F7A4-EM12K. APPROVALS: AWS A5.17: F6P4-EM12K. Lloyds Register of Shipping - Grade 3M 3YM AS 1858.1: EM12K-FMM-W503A. TYPICAL ALL WELD METAL ANALYSIS: C: 0.09% Mn: 1.2% Si: 0.4% Description and Applications: S: 0.020% P: 0.030% Satinarc 4 is a semi-basic, agglomerated flux TYPICAL ALL WELD METAL MECHANICAL suitable for a wide range of fillet and butt welding PROPERTIES (AS WELDED): applications. Yield Stress 425 MPa. It is recommended for heavier, multi-pass butt Tensile Stress 520 MPa welding applications and produces excellent slag Elongation 29% lift in narrow joint preparations. CVN Impact Values 100 J av @ -20°C. The Autocraft SA2 / Satinarc 4 combination 140 J av@ 0°C. provides consistent ‘as welded’ and ‘stress relieved’ mechanical properties. Despite its basic slag system, Satinarc 4 produces good weld profiles, Flux Constituents: edge wetting and slag lift in single and multi-pass welding applications. (Basicity Index* = 1.6 SiO2 + TiO2 CaO + MgO Al203 + MnO CaF2 Operating Capabilities: 20% 25% 35% 15% Satinarc 4 flux produces smooth arc characteristics * Basicity Index to Boniszewski. and excellent slag lift in deep ‘vee’ weld preparations. Weld beads will exhibit a fine rippled surface Packaging Data: appearance and smooth side wall wash. Satinarc 4 operates well with AC or DC power and Pack Type Pack Weight Part No is tolerant to lightly rusted or scaled plate. 4 Ply Paper Bag 25kg net 720412

www.cigweld.com.au 175 176 SUBMERGED ARC WIRES AND FLUXES www.cigweld.com.au build upofManganeseandSilicon. heavy multi-passbuttweldingapplicationsduetoexcessive resistance tosurfacecontaminationbutprohibitsitsusein The activeoracidicnatureofSatinarc15givesitgood AC ormulti-wiresystems. currents upto1200ampswithDC, It isahighlyversatilefluxandcanbeusedatwelding excellent filletshapesathigh(upto1.8m/min)travelspeeds. Satinarc 15fluxproducessmootharccharacteristicsand Operating Capabilities: of platethicknessesgreaterthan25mm. prohibits theuseofSatinarc15inmulti-passbuttwelding welds goodresistancetosurfacerustandMillscaleit active (oracidic)natureofSatinarc15willgivedeposited Whilstthe applications upto1200ampsonasinglewire. AC ormulti-wirewelding Satinarc 15isalsosuitableforDC, to pockmarkingcanbeusedadvantage. excellentblendingatweldtoesandresistance rust/mill scale, high speedfilletweldingapplicationswhereitstoleranceto Itisrecommendedfor applications onplateupto25mmthick. CIGWELD suitableforamultitudeoffilletandbuttwelding Satinarc 15isageneralpurposeagglomeratedfluxfrom Autocraft SA2/Satinarc15: Autocraft SA1/Satinarc15: ▲ ▲ ▲ ▲ ▲ Description and Applications: Classifications: SATINARC 15 High Current CarryingCapacity. Good Tolerance toRustandMillScale. and Autocraft SA2wires. SA1 with Autocraft Effective Welding Cost thick. Applications onplatelessthan25mm For FilletandMultiPass Butt Welding Arc Flux. General PurposeSubmerged Active, S881 EM12K-FGH-W403A AS1858.1: F7A2-EM12K AWS/ASME-SFA A5.17: EL12-FGH-W403A AS1858.1: F6A2-EL12 AWS/ASME-SFA A5.17: * BasicityIndextoBoniszewski. lnain28% 590MPa 480MPa. 60Jav@-20 (Basicity Index*=0.8 CVN Impact Values Elongation 0.85% Si: Tensile Stress Yield Stress 0.020% P: PROPERTIES (AS WELDED): 1.70% Mn: METALMECHANICAL TYPICAL ALLWELD 0.014% S: 0.07% C: METALTYPICAL ALLWELD ANALYSIS: 32% 3YM American BureauofShipping-Grade2YT, 500MPa 400MPa. 80Jav@-20 3YM2O Lloyds RegisterofShipping-GradeDBF2YT, APPROVALS: CVN Impact Values Elongation 0.55% Si: Tensile Stress Yield Stress 0.016% P: PROPERTIES (AS WELDED): 1.25% Mn: METALMECHANICAL TYPICAL ALLWELD 0.011% S: 0.05% C: METALTYPICAL ALLWELD ANALYSIS: 3M American BureauofShipping-Grade2T, 3M2O Lloyds RegisterofShipping-GradeDBF2T, APPROVALS: Flux Constituents: Autocraft SA2/Satinarc 15 Autocraft SA1/Satinarc 15 Packaging Data: l ae a 5gnt720415 25kgnet 4 PlyPaper Bag i2+TO a g l0 n CaF2 Al203+MnO CaO+MgO SiO2 + TiO2 34%2-8 52%4-6% 15-21% 22-28% 43-48% akTp akWih PartNo Pack Weight Pack Type +/– DC ° ° C. C. SUBMERGED ARC WIRES AND FLUXES 177 www.cigweld.com.au 178 GAS AND TIG WELDING CONSUMABLES 179 201 181 189 184 185 186 190 191 203 207 182 187 188 205 196 Page No Page GAS AND TIG WELDING WELDING TIG AND GAS CONSUMABLES Description How to Select the Best Comweld Rod Best Comweld Select the How to Flame Adjustment and Definitions Terms Steel Comweld Mild Comweld LW1-6 Comweld Super Steel Comweld CrMo1 180 Bronze RodComweld Nickel Comweld Comcoat N 206 Comweld High Test Comweld High Comweld LW1 Comweld LW1-3 Comweld CrMo2 SteelComweld 308L Stainless SteelComweld 309L Stainless SteelComweld 316L Stainless Stainless SteelComweld 2209 Duplex Comweld AL1100 (Pure) AL4043 (5% Silicon)Comweld AL4047 (10% Silicon)Comweld AL5356 (5% Magnesium)Comweld Comweld General Purpose, Cast Iron Rod Bar Comweld Galvanising Comweld Manganese Bronze RodComweld Comcoat C Bronze RodTobin Comweld 192 195 T Comweld Comcoat 193 194 Comweld Silicon Bronze Rod(801) 200 197 199 198 202 204 208 www.cigweld.com.au HOW TO SELECT THE BEST COMWELD ROD

To assist you in selecting the most suitable alloy and process for the particular application, we have recommended below the alloy and process that would be most suitable for your use. Once you have selected the best alloy, refer to contents for detailed information on its characteristics, technical specifications, applications and procedure.

Process Comweld Alloy Comweld Flux Joining copper, brass, bronze, etc. Braze Welding Phos Copper No flux “ Comcoat T or *Tobin Bronze *Copper & Brass “ Comcoat N or *Nickel Bronze *Copper & Brass GTA Welding (TIG) Comweld Aluminium Bronze No flux GTA Welding (TIG) Comweld Silicon Bronze No flux Soldering 965 Silver Solder 965 Soldering Flux

Joining Steel. Oxy Acetylene Fusion Welding Mild Steel, High Test No flux GTA Welding (TIG) Comweld LW1, Super Steel No flux Braze Welding Comcoat C No flux

GAS AND TIG WELDING CONSUMABLES Braze Welding Manganese Bronze Copper & Brass Soldering 965 Silver Solder 965 Soldering Flux

Repairing Cast Iron. Oxy Acetylene Fusion Welding GP Super Silicon Cast Iron No Flux GTA Welding (TIG) GP Super Silicon Cast Iron No flux Braze Welding Comcoat C No flux “ Manganese Bronze No Flux “ Comcoat N No flux “ Nickel Bronze No Flux

Joining Stainless Steel. Oxy Acetylene Fusion Welding Comweld 308L, 309L, 316L & 2209 No Flux GTA Welding (TIG) Comweld 308L, 309L, 316L & 2209 No flux Soldering 965 Silver Solder 965 Soldering Flux

Joining Aluminium. Oxy Acetylene Fusion Welding AL1100, AL4043, AL4047 & AL5356 Aluminium Welding Flux GTA Welding (TIG) AL1100, AL4043 & AL5356 No flux Braze Welding AL4047 No Flux Soldering Aluminium Solder No flux

180 www.cigweld.com.au GAS AND TIG WELDING CONSUMABLES GAS AND TIG WELDING FLAME ADJUSTMENT Correct flame adjustment is a most important factor in making a successful oxy-acetylene weld. Careful consideration should be given to this, so that CIGWELD welding rods and fluxes are used to their best possible advantages. There are basically three types of flame adjustments, ie. neutral, oxidising (excess oxygen) and reducing or carburising (excess acetylene). The neutral flame setting is used for the majority of welding and brazing requirements. So that you can easily identify each type, a sketch of the different flame settings is shown below.

Neutral Flame: For steel, stainless steel, cast iron, copper, aluminium, etc.

A neutral flame is where equal amounts of oxygen and acetylene are mixed at the same rate. The white inner cone is clearly defined and shows no haze.

Oxidising Flame: An oxidising flame is necessary for welding brass.

An oxidising flame is achieved by using excess oxygen (or reduced acetylene). The white inner cone is very pale and may cause the tip to “pop”.

Carburising or Reducing Flame: Excess acetylene is necessary for hard facing.

A carburising flame is achieved by using a small amount of excess acetylene. The white inner cone will show signs of a haze of “feather” at the end of the inner cone. www.cigweld.com.au 181 TERMS AND DEFINITIONS

Alloy: A mixture of two or more entirely different metals united by melting together.

Annealing: Process of gradually cooling a metal part after welding or reheating it to make it soft for mechanical working. Annealing will also relieve any stresses that originally existed or that may be set up by the welding operation.

Backhand Welding: (rightward, backward). Welding with the blowpipe flame pointing in the direction opposite to that in which the weld progresses, that is, toward the finished portion of the weld. The opposite of forehand welding.

Blowhole: A cavity in weld metal caused by a bubble of gas becoming entrapped in the solidifying metal.

Brazing: A joining process in which the molten filler metal is drawn by capillary action between two closely adjacent surfaces to be joined. The filler metal is a non-ferrous metal or alloy with a melting point above 450˚C, but lower than that of the metal being joined. It is a process more comparable to soldering than to welding.

Braze Welding: GAS AND TIG WELDING CONSUMABLES Unlike brazing does not depend on capillary attraction. The parent metal is not melted, but the joint design is similar to that which would be used if a fusion weld were made. The filler metal is generally a non-ferrous metal or alloy, with a melting point above 500˚C.

Bronze Welding: A term which has been used to describe a braze-welding process in which a copper-rich filler materials is used. Can be applied to the fusion welding of bronze.

Butt Weld: (groove weld). A weld in which the two edges of metal to be united are abutted together.

Cone: The part of a flame that is conical in shape and located at the end of the welding tip, heating tip or cutting nozzle.

Ductility: The property which permits metal to be drawn, formed or shaped.

Filler Rod: A metal rod or wire which is melted and deposited in the weld and used to supply additional material.

Fillet Weld: A weld made in a corner, as in a lap or T-joint.

Flame Brazing: A brazing process in which the necessary heat is supplied by means of an oxy-fuel gas flame.

182 www.cigweld.com.au GAS AND TIG WELDING CONSUMABLES GAS AND TIG WELDING TERMS AND DEFINITIONS CONT.

Flux Inclusion: A cavity in the weld metal containing flux caused by a quantity of flux becoming entrapped as the metal solidifies.

Forehand Welding: (Leftward, forward). Welding with the blowpipe flame pointing in the direction in which the weld progresses, that is, towards the unfinished seam. The opposite of Backhand Welding.

Fusion Welding: The type of welding in which the edges of the two pieces of metal being joined are melted and completely fused together without pressure and in which the filler rod, if used, is of similar composition to the parent metal.

Handigas: A liquefied petroleum fuel gas supplied by BOC Gases for cutting and heating.

Hardfacing: A process wherein metal harder than the parent metal is deposited on to a surface.

Neutral Flame: An oxy-fuel gas flame in which the inner cone, or that portion of the flame used, is neither oxidising nor carburising. It is characterised by an almost colourless outer envelope and a sharply defined inner cone without feather or secondary flame.

Outer Envelope: The secondary phase of combustion in any oxy-fuel gas flame which surrounds the innercone.

Penetration: The depth of fusion obtained in a welded joint.

Silver Brazing: (Silver Soldering) A low temperature brazing process in which a silver alloy is used as filler metal.

Tinning: The act of coating another metal with tin. The term is also applied in brazing and braze welding, where the spreading out of a thin layer of fluxed brazing metal ahead of the main deposit to form a “tinning” coat provides a strong bond between parent metal and deposit.

www.cigweld.com.au 183 COMWELD MILD STEEL

▲ Black Annealed, Low Carbon Steel JOINING PROCESS: Rod for Oxy-Acetylene Welding. Gas (Fusion) Welding only. ▲ Recommended for Gas Welding of TYPICAL WELD DEPOSIT PROPERTIES: Steels and Wrought Irons. All Weld Metal Tensile Strength 370 MPa. ▲ Not Suitable for Gas Tungsten Arc Elongation 30% Welding. Approximate Melting Point 1490°C. Weld Metal Density 7.85 gms / cm3 TYPICAL ROD ANALYSIS: C: 0.07% Mn: 0.50% Si: 0.008% Classifications: S: 0.008% P: 0.011% Fe: Balance AS 1167.2: RG. AWS/ASME-SFA A5.2: R45. Packaging Data: Description and Applications: Rod Size Pack Approximate Part No (mm) Weight/Type Rods/kg As the name implies, Comweld Mild Steel is an uncoated mild steel filler rod suitable for the 1.6 x 500 1kg Handipack 130 322045 oxy-acetylene (fusion) fillet and butt welding of 1.6 x 1,000 5kg Pack 64 321334 carbon steel and wrought iron. Comweld Mild Steel produces a free flowing weld 2.4 x 750 5kg Pack 29 321337 pool without the need for an externally applied 3.2 x 750 5kg Pack 16 321339 GAS AND TIG WELDING CONSUMABLES flux. A neutral to slightly reducing flame setting is recommended for use with Comweld Mild Steel. Resultant weld deposits are ductile and in the 350 - 400 MPa tensile class. The low deoxidant level of Comweld Mild Steel makes it unsuitable for Gas Tungsten Arc (TIG) welding applications.

184 www.cigweld.com.au GAS AND TIG WELDING CONSUMABLES GAS AND TIG WELDING COMWELD HIGH TEST \ ▲ Copper Coated, Steel Filler Rod for JOINING PROCESS: Gas and Gas Tungsten Arc (TIG) Gas (Fusion) and Gas Tungsten Arc (TIG) welding. Welding. ▲ TYPICAL WELD DEPOSIT PROPERTIES: Higher Strength (400-450MPa) All Weld Metal Tensile Strength 425 MPa. Oxy-Acetylene and TIG Welding of Elongation 28% Steels. Approximate Melting Point 1490°C. Weld Metal Density 7.85 gms / cm3 TYPICAL ROD ANALYSIS: Classifications: C: 0.12% Mn: 1.17% Si: 0.25% S: 0.009% P: 0.015% Fe: Balance AS 1167.2: R1. AWS/ASME-SFA A5.2: R60. Packaging Data: Description and Applications: Rod Size Pack Approximate Part No Comweld High Test is a copper coated steel filler (mm) Weight/Type Rods/kg rod suitable for the oxy-acetylene (fusion) welding 1.6 x 915 5kg Pack 84 321357 and Gas Tungsten Arc (TIG) welding of carbon steels. 2.4 x 915 5kg Pack 34 321360 Comweld High Test produces a free flowing weld 3.2 x 915 5kg Pack 21 321362 pool when gas welding, without the need for an externally applied flux. Resultant weld deposits are ductile and in the 400 - 450 MPa tensile class. A neutral to slightly reducing flame setting is recommended for use with Comweld High Test which is used extensively for the gas welding of pressure pipelines where higher joint strengths are required. The nominal 1.2% Manganese and 0.2% Silicon deoxidant levels of Comweld High Test make it suitable for Gas Tungsten Arc (TIG) welding applications.

Procedure for Gas (Oxy-acetylene) Welding: 1. Thoroughly clean all areas to be welded. 2. Adjust flame to a neutral setting. 3. Preheat thicker joint sections. 4. Heat a small area of the joint until molten and progressively add Comweld High Test filler rod to the weld pool. Ensure the rod is melted by the molten weld pool and not the flame. 5. Allow completed joint to cool and remove residual scale by grinding, or wire brushing.

Procedure for Gas Tungsten Arc (TIG) Welding: 1. Thoroughly clean all areas to be joined. 2. For the butt welding of thick plates, bevel edges to 60°-70° included angle. 3. Use a Thoriated or Ceriated tungsten electrode, ground to a sharp needle point making sure the grinding lines run with the length (longitudinally) of the electrode’s axis. The length of the needle point should be approximately 2-3 x the diameter of the tungsten electrode. 4. Use Direct Current Electrode Negative (DC-) and Welding Grade Argon. 5. Preheat thick sections prior to welding. Heat a spot on the base metal until it shows signs of melting and progressively add the filler rod to the weld pool.

www.cigweld.com.au 185 COMWELD LW1

▲ Copper Coated, Low Carbon Steel JOINING PROCESS: Rod for Gas Tungsten Arc Welding Gas (Fusion) and Gas Tungsten Arc (TIG) welding. Applications. TYPICAL ALL WELD METAL MECHANICAL ▲ End-Stamped ‘ER70S-4’ for Instant I.D. PROPERTIES: Yield Stress 400 MPa. Tensile Strength 500 MPa. Classifications: Elongation 29% AS 1167.2: R4. CVN Impact Values 100 J av @ -20°C AWS/ASME-SFA A5.18: ER70S-4. TYPICAL ROD ANALYSIS: C: 0.08% Mn: 1.16% Si: 0.75% Description and Applications: S: 0.010% P: 0.015% Fe: Balance Comweld LW1 is a copper coated, double COMPARABLE CIGWELD PRODUCTS: de-oxidised low carbon steel filler rod suitable for Autocraft LW1 GMAW wire the oxy-acetylene (fusion) welding and Gas AWS A5.18: ER70S-4 Tungsten Arc (TIG) welding of a wide range of mild and medium strength steels. Comweld LW1 is recommended for the TIG Packaging Data: welding of steel pipes, plates and castings with a tensile strength in the 500 MPa class. It is tolerant Rod Size Pack Approximate Part No to surface rust and mill scale and is ideal for root (mm) Weight/Type Rods/kg pass welding applications where tough and

GAS AND TIG WELDING CONSUMABLES 1.6 x 915 5kg Pack 84 321411 ductile welds are produced. When using Comweld LW1 for gas welding 2.4 x 915 5kg Pack 34 321412 applications a neutral to slightly reducing flame setting is recommended.

Procedure for Gas (Oxy-acetylene) Welding: 1. Thoroughly clean all areas to be welded. 2. Adjust flame to a neutral setting. 3. Preheat thicker joint sections. 4. Heat a small area of the joint until molten and progressively add Comweld LW1 filler rod to the weld pool. Ensure the rod is melted by the molten weld pool and not the flame. 5. Allow completed joint to cool and remove residual scale by grinding, or wire brushing.

Procedure for Gas Tungsten Arc (TIG) Welding: 1. Thoroughly clean all areas to be joined. 2. For the butt welding of thick plates, bevel edges to 60°-70° included angle. 3. Use a Thoriated or Ceriated tungsten electrode, ground to a sharp needle point making sure the grinding lines run with the length (longitudinally) of the electrode’s axis. The length of the needle point should be approximately 2-3 x the diameter of the tungsten electrode. 4. Use Direct Current Electrode Negative (DC-) and Welding Grade Argon. 5. Preheat thick sections prior to welding. Heat a spot on the base metal until it shows signs of melting and progressively add the filler rod to the weld pool.

186 www.cigweld.com.au GAS AND TIG WELDING CONSUMABLES 187 C ° (mm) Weight/Type Rods/kg Rod Size Pack Approximate No Part 1.6 x 10002.4 x 1000 5kg Pack 5kg Pack 64 29 321423 321424 Packaging Data: Packaging included angle. JOINING PROCESS: JOINING (TIG) welding. Arc Tungsten and Gas Gas (Fusion) TYPICAL ALL WELD MECHANICAL METAL PROPERTIES: StressYield StrengthTensile ElongationValuesCVN Impact ANALYSIS: TYPICAL ROD C: 0.07%S: 0.012% 500 MPa. -20 100 J av @ 400 MPa. Mn: 1.1% P: 0.015% 30% Si: 0.5% Fe: Balance ° -70 ° grinding lines run with the length (longitudinally) of the electrode’s axis.grinding lines run with the length (longitudinally) of the electrode’s needle length of the The point should be approximately 2-3 x the diameter of the tungsten electrode. melting and progressively add the filler rod to the weld pool. the weld pool. Ensure the rod is melted by the molten weld pool and not the flame. Copper Coated,Copper Carbon Steel Low Welding TIG & Oxy Gas Rod for Applications. “ER70S-3” End stamped with for easy I.D. tube. cardboard Resealable 5kg Classifications: Applications: Description and COMWELD LW1-3 COMWELD 4.5.Argon. Grade Welding Use Direct Current Electrode Negative (DC-) and Preheat thick sections prior to welding. Heat a spot on the base metal until it shows signs of 3. or Ceriated tungsten electrode,Thoriated Use a ground to a sharp needle point making sure the 5.Welding: (TIG) Arc Tungsten for Gas Procedure Allow completed joint to cool and remove residual scale by grinding, or wire brushing. 1.2. areas to be joined. clean all Thoroughly the butt welding of thick plates, For bevel edges to 60 AS 1167.2:A5.18: AWS/ASME-SFA ER70S-3. is a copper coated,Comweld LW1-3 low carbon steel filler rod suitable for the oxy-acetylene R3. Arc (TIG) Tungsten (fusion) welding and Gas welding of a wide range of mild and medium strength steels. TIG is recommended for the Comweld LW1-3 welding of steel pipes, plates and castings with a class.tensile strength in the 500 MPa It is tolerant for root to surface rust and mill scale and is ideal and ductile welds are produced. pass welding applications where tough reducing flame setting is recommended. for gas welding applications a neutral to slightly When using Comweld LW1-3 Welding: for Gas (Oxy-acetylene) Procedure 1.2.3. areas to be welded. clean all Thoroughly 4. Adjust flame to a neutral setting. joint sections. Preheat thicker to filler rod Test Comweld High Heat a small area of the joint until molten and progressively add ▲ ▲ ▲ www.cigweld.com.au 188 GAS AND TIG WELDING CONSUMABLES www.cigweld.com.au .Peettikscin ro owlig Heataspotonthebasemetaluntilitshowssignsof Preheatthicksectionspriortowelding. UseDirectCurrentElectrodeNegative(DC-)and Welding Grade Argon. 5. 4. groundtoasharpneedlepointmakingsurethe Usea Thoriated orCeriatedtungstenelectrode, 3. .Frtebt edn ftikpae,beveledgesto60 For the buttweldingofthickplates, Thoroughly cleanallareastobejoined. 2. 1. orwirebrushing. Allowcompletedjointtocoolandremoveresidualscalebygrinding, Procedure forGas Tungsten Arc (TIG) Welding: 5. HeatasmallareaofthejointuntilmoltenandprogressivelyaddComweldHigh Test fillerrodto Preheatthicker jointsections. Adjustflametoaneutralsetting. 4. Thoroughly cleanallareastobewelded. 3. 2. 1. Procedure forGas(Oxy-acetylene) Welding: When usingComweldLW1-6 forgasweldingapplicationsaneutraltoslightlyreducingflamesettingisrecommended. pass weldingapplicationswheretoughandductileweldsareproduced. to surfacerustandmillscaleisidealforroot Itistolerant tensile strengthinthe500MPa class. platesandcastingswitha welding ofsteelpipes, Comweld LW1-6 isrecommendedforthe TIG strength steels. welding ofawiderangemildandmedium (fusion) weldingandGas Tungsten Arc (TIG) R6. steel fillerrodsuitablefortheoxy-acetylene lowcarbon Comweld LW1-6 isacoppercoated, ER70S-6. AWS/ASME-SFA A5.18: AS 1167.2: ▲ ▲ ▲ Description and Applications: Classifications: COMWELD LW1-6 Resealable 5kgcardboard tube. easy I.D. for End stampedwith “ER70S-6” Applications. Rod forGas TIG &Oxy Welding LowCarbonSteel Copper Coated, melting andprogressivelyaddthefillerrodtoweldpool. point shouldbeapproximately2-3xthediameteroftungstenelectrode. The lengthoftheneedle grinding linesrunwiththelength(longitudinally)ofelectrode’s axis. h edpo.Ensuretherodismeltedbymoltenweldpoolandnotflame. the weldpool. ° -70 ° :002 :005 e Balance Fe: 0.88% Si: ER70S-6 AWS A5.18: 29% 0.015% Autocraft LW1-6 GMAWwire P: 1.55% Mn: COMPARABLE CIGWELDPRODUCTS: 400MPa. 100Jav@ -20 500MPa. 0.012% S: 0.07% C: TYPICAL ROD ANALYSIS: CVN Impact Values Elongation Tensile Strength Yield Stress PROPERTIES: METALMECHANICAL TYPICAL ALLWELD Gas (Fusion)and Tungsten Arc (TIG)welding. JOINING PROCESS: included angle. Packaging Data: . 005gPc 9321418 321417 29 64 5kgPack 5kgPack 2.4 x1000 1.6 x1000 o iePc prxmt Part No Approximate Pack Rod Size m)Wih/yeRods/kg Weight/Type (mm) ° C GAS AND TIG WELDING CONSUMABLES 189 C ° (mm) Weight/Type Rods/kg Packaging Data: Packaging Rod Size Pack Approx. No Part 1.6 x 9152.4 x 915Tube* 5kg Tube* 5kg 70 31 321370 321373 included angle. COMPARABLE CIGWELD PRODUCTS: COMPARABLE Autocraft Super Steel GMAW wire AWS A5.18: ER70S-2 * Resealable JOINING PROCESS: JOINING Arc (TIG) welding. Tungsten Gas TYPICAL ALL WELD DEPOSIT MECHANICAL PROPERTIES: StressYield StrengthTensile ElongationValuesCVN Impact ANALYSIS: TYPICAL ROD C: 0.06%Ti: 0.08%S: 0.007% 520 MPa. 150 J av @ -29 425 MPa. Mn: 1.08% Zr: 0.07% P: 0.008% 34% Si: 0.52% Al: 0.08% Fe: Balance ° -70 ° grinding lines run with the length (longitudinally) of the electrode’s axis.grinding lines run with the length (longitudinally) of the electrode’s needle length of the The point should be approximately 2-3 x the diameter of the tungsten electrode. melting and progressively add the filler rod to the weld pool. Ensure the rod is melted by the molten weld pool and not the flame. Low Carbon Steel Filler Rod for Gas Rod for Gas Steel Filler Low Carbon Arc (TIG) Welding. Tungsten Weld Superior Deoxidised for Triple and Resistance to Deposit Quality Porosity. Class AWS End Stamped with “ER70S-2”. Tube. Cardboard Resealable 5 kg Classifications: Applications: Description and COMWELD SUPER STEEL SUPER COMWELD 4.5.Argon. Grade Welding Use Direct Current Electrode Negative (DC-) and Preheat thick sections prior to welding. Heat a spot on the base metal until it shows signs of 3. or Ceriated tungsten electrode,Thoriated Use a ground to a sharp needle point making sure the AS 1167.2:A5.18: AWS/ASME-SFA ER70S-2. ‘triple Comweld Super Steel is a copper coated for deoxidised’ steel welding rod recommended R2. Arc (TIG) welding of Tungsten the high quality Gas carbon and carbon-Manganese steels. Titanium, Comweld Super Steel is deoxidised with Aluminium and Zirconium in addition to deposit Manganese and Silicon for improved weld quality.TIG welding rusty It is the ideal choice for root pass or mill scaled plates and pipes and the welding of pipes, joints tanks and heavy walled where good root toughness and radiographic soundness are achieved under high dilution. Welding: for Gas (Oxy-acetylene) Procedure 1.2.3. all areas to be welded. clean Thoroughly 4. Adjust flame to a neutral setting. joint sections. Preheat thicker add Comweld Super Steel filler rod to the weld pool. Heat a small area of the joint until molten and progressively 5.Welding: (TIG) Arc Tungsten for Gas Procedure grinding, Allow completed joint to cool and remove residual scale by or wire brushing. 1.2. all areas to be joined. clean Thoroughly the butt welding of thick plates, For bevel edges to 60 ▲ ▲ ▲ ▲ www.cigweld.com.au 190 GAS AND TIG WELDING CONSUMABLES www.cigweld.com.au .Tecnrlo rha,itrasadps edha ramn eprtrsi rtclt viig edcakn.Heat interpassandpostweldheattreatmenttemperaturesiscriticaltoavoidingcracking. The controlofpreheat, UseDirectCurrentElectrodeNegative(DC-)and Welding Grade Argon. 5. 4. groundtoasharpneedlepointmakingsurethe Usea Thoriated orCeriatedtungstenelectrode, 3. .Frtebt edn ftikrpae,beveledgesto60 For the buttweldingofthicker plates, Thoroughly cleanallareastobejoined. 2. 1. Procedure forGas Tungsten Arc (TIG) Welding: which canbesubsequentlyheattreated. the weldingofcasehardenablesteelsor TIG weldingofCr-Mo steeltocarbonandfor Comweld CrMo1isalsosuitableforthedissimilar petrochemical industriesetc. temperatures (upto550 platesandcastingsusedatelevated service pipes, 1Cr-1/2Mo and11/4Cr-1/2Mo steel 1/2Cr-1/2Mo, is recommendedforthe TIG weldingof It Chromium (Cr)and0.50%Molybdenum(Mo). RB2. welding rodalloyedwithnominally1.25% Comweld CrMo1isacoppercoatedsteel TIG ER80S-B2. AWS/ASME-SFA A5.28: AS 1167.2: ▲ ▲ ▲ Description and Applications: Classifications: COMWELD CrMo1 ER80S-B2 forEasyIdentification. End Stampedwith AWS Class Corrosive Service. Steels forElevated Temperature and Welding ofCr-MoCreep Resistant Gas Tungsten(TIG) the ArcFor Resealable 5kgCardboard Tube. a spotonthebasemetaluntilitshowssignsofmeltingandprogressivelyaddfillerrodtoweldpool. point shouldbeapproximately2-3xthediameteroftungstenelectrode. The lengthoftheneedle grinding linesrunwiththelength(longitudinally)ofelectrode’s axis. ° C) inthepowerand ° -70 V matVle 60Jav@+20 600MPa. 500MPa. 20% CVN Impact Values Elongation (in2inches) Tensile Strength 0.2% ProofStress * Resealable W 52:ER80S-B2 0.015% AWS A5.28: P: 0.60% Autocraft CrMo1GMAWwire Si: E8018-B2 AWS A5.5: Alloycraft 80-B2electrode Balance Fe: 0.50% COMPARABLE Mo: CIGWELDPRODUCTS: 0.60% Mn: 0.010% S: 1.30% Cr: 0.09% C: TYPICAL ROD ANALYSIS: PROPERTIES: METALMECHANICAL TYPICAL ALLWELD Post weldheattreatedat620 . 005gTb*2 321379 29 5kg Tube* 2.4 x1000 ° o iePc prx Part No Approx. Pack Rod Size Packaging Data: m)Wih/yeRods/kg Weight/Type (mm) included angle. Welding Grade Argon: ° C asrequiredby AWS A5.28. ° C GAS AND TIG WELDING CONSUMABLES 191 C ° C as required by AWS A5.28. AWS C as required by ° Welding Grade Argon: Grade Welding included angle. (mm) Weight/Type Rods/kg Packaging Data: Packaging Rod Size Pack Approx. No Part ° 2.4 x 1,000Tube* 5kg 29 321383 Post weld heat treated at 690 weld heat treated Post COMPARABLE CIGWELD PRODUCTS: COMPARABLE Alloycraft 90-B3 electrode AWS A5.5: E9018-B3 * Resealable TYPICAL ALL WELD METAL ALL WELD TYPICAL MECHANICAL METAL PROPERTIES: ANALYSIS: TYPICAL ROD C: 0.08%Cr: 2.50%S: 0.010% Mn: 0.70% Mo: 1.00% Fe: Balance Si: 0.60% P: 0.015% 0.2% Proof Stress StrengthTensile Elongation (in 2 inches)ValuesCVN Impact 18% 560 MPa. 670 MPa. +20 60 J av @ -70 ° C) in the power and petrochemical ° grinding lines run with the length (longitudinally) of the electrode’s axis.grinding lines run with the length (longitudinally) of the electrode’s needle length of the The point should be approximately 2-3 x the diameter of the tungsten electrode. a spot on the base metal until it shows signs of melting and progressively add the filler rod to the weld pool. Resealable 5kg Cardboard Tube. 5kg Cardboard Resealable For Arc the (TIG) Tungsten Gas and Cr-Mo-V Cr-Mo of Welding Resistant Steels for Elevated Creep Service. Corrosive and Temperature Class AWS End Stamped with Easy Identification. ‘ER90S-B3’ for Classifications: Applications: Description and COMWELD CrMo2 COMWELD AS 1167.2:A5.28: AWS/ASME-SFA ER90S-B3. TIG Comweld CrMo2 is a copper coated steel welding rod alloyed with nominally 2.5% RB3. (Mo).Chromium (Cr) and 1.0% Molybdenum It is TIG welding of 2recommended for the 1/4Cr - 1 steel pipes,Mo and Cr-Mo-V plates and castings service temperatures used at elevated (up to 600 ▲ ▲ ▲ 4.5.Argon. Grade Welding Use Direct Current Electrode Negative (DC-) and control of preheat, The and post weld heat treatment temperatures is critical to avoiding weld cracking. interpass Heat 3. or Ceriated tungsten electrode,Thoriated Use a ground to a sharp needle point making sure the industries etc. dissimilar Comweld CrMo2 is also suitable for the steels to carbon TIG welding of selected Cr-Mo TIG welding of heat treatable steel and for the up to 3% steels and case hardenable steels with Chromium content. Welding: (TIG) Arc Tungsten for Gas Procedure 1.2. all areas to be joined. clean Thoroughly plates, the butt welding of thicker For bevel edges to 60 www.cigweld.com.au 192 GAS AND TIG WELDING CONSUMABLES www.cigweld.com.au .Frtebt edn ftikpae,beveledgesto60 For thebuttweldingof thickplates, Thoroughly cleanallareastobejoined. 2. 1. Procedure forGas Tungsten Arc (TIG) Welding: For the Allowcompletedjointtocoolandremoveresidualfluxbygrindingwirebrushing. 6. Heatasmallareaofthejointuntilmolten Preheatthicker jointsections. 5. 4. ApplyaStainlessSteelfluxtofiller Adjustflametoaneutralsetting. Thoroughly cleanallareastobewelded. 3. 2. 1. Procedure forGas(Oxy-acetylene) Welding: cryogenic applications. 304L stainlesssteelsincorrosionresistantand recommended forthecriticalweldingof304and Itis stabilised 300seriesstainlesssteels. welding ofawiderangelowcarbonand R308L. carbon rodfortheGasor Tungsten Arc (TIG) Comweld 308Lstainlesssteelisahighqualitylow ER308L. AWS/ASME-SFA A5.9: AS 1167.2: ▲ ▲ ▲ ▲ .Frtebs laigadfnsigrslsueCGED“hoergt ikigpse(atN.321918). pickling paste(Part No. For thebestcleaningandfinishingresultsuseCIGWELD “ChromeBright” Heataspoton thebasemetaluntilitshowssignsofmeltingand 6. Preheatsurfacestobe welded. UseDirectCurrentElectrodeNegative(DC-)and Welding Grade Argon. 5. 4. groundtoasharpneedlepointmakingsurethe Usea Thoriated orCeriatedtungstenelectrode, 3. Description and Applications: Classifications: COMWELD 308L Label forInstantI.D. DARK BLUECOLOURCODEDPack Class ‘308L’. End Stampedwith AS / AWS Welding. Suitable forGasandGTA (TIG) Resealable 5kgPlastic Tube. etcenn n iihn eut s CGED“hoergt ikigpse(atN.321918). picklingpaste(Part No. best cleaningandfinishingresultsuseCIGWELD “ChromeBright” the flame. melted bythemoltenweldpoolandnot Ensuretherodis rod totheweldpool. and progressivelyaddComweld308Lfiller progressively addthefillerrodtoweldpool. point shouldbeapproximately2-3xthediameteroftungstenelectrode. The lengthoftheneedle grinding linesrunwiththelength(longitudinally)ofelectrode’s axis. rod andjointareas. ° -70 ° included angle. * Resealable E308LT-1-1/4 AWS A5.22: Shieldcrome 308LT FCAWwires ER308LSi AWS A5.9: Autocraft 308LSiGMAWwire E308L-18 AWS A5.4: Murex Speedex308L 0.020% P: E308L-17 AWS A5.4: 0.50% Si: Satincrome 308L-17electrode Balance Fe: COMPARABLE CIGWELDPRODUCTS: 9.75% Austenitewith Ni: 1.90% Mn: 0.005% S: 19.90% Cr: 0.015% C: 7.95gms/cm TYPICAL ROD ANALYSIS: 600MPa. 450MPa. Microstructure Metal All Weld 1400 Weld MetalDensity Approximate MeltingPoint Tensile Strength Metal Typical Weld Proof Stress Typical Weld Metal0.2% WELD DEPOSITPROPERTIES: . 1 k ue 0321407 321406 30 69 5kg Tube* 5kg Tube* 2.4 x914 1.6 x914 o iePc prxmt Part No Approximate Pack Rod Size Packaging Data: m)Wih/yeRods/kg Weight/Type (mm) 5 –8%ferrite ° C 3 GAS AND TIG WELDING CONSUMABLES 193 3 C ° 15 – 20 % ferrite (mm) Weight/Type Rods/kg Packaging Data: Packaging Rod Size Pack Approximate No Part 1.6 x 9142.4 x 914Tube* 5kg Tube* 5kg 69 30 321403 321404 COMPARABLE CIGWELD PRODUCTS: COMPARABLE Satincrome 309Mo-17 electrode AWS A5.4: E309Mo-17 Murex Speedex 309L AWS A5. 4: E309L-16 Autocraft 309LSi GMAW wire AWS A5.9: ER309LSi FCAW wires Shieldcrome 309LT AWS A5.22: E309LT1-1/4 * Resealable WELD DEPOSIT PROPERTIES: WELD DEPOSIT 0.2% Metal Weld Typical Proof Stress Weld Typical Metal StrengthTensile PointApproximate Melting 1400 440 MPa. 590 MPa. ANALYSIS: TYPICAL ROD C: 0.015%Cr: 23.5%S: 0.005% Mn: 1.90% Ni: 13.5% Fe: Balance Si: 0.45% P: 0.020% Weld Metal DensityWeld All Weld Metal Microstructure 7.95 gms / cm Austenite with included angle. ° -70 ° and joint areas. progressively add the filler rod to the weld pool. grinding lines run with the length (longitudinally) of the electrode’s axis.grinding lines run with the length (longitudinally) of the electrode’s length of the needle The point should be approximately 2-3 x the diameter of the tungsten electrode. and progressively add Comweld 309L filler rod to the weld pool. Ensure the rod is melted by the molten weld pool and not the flame. residual flux by grinding and wire brushing. the best cleaning and finishing results use For “ChromeBright”CIGWELD No. pickling paste (Part 321918). Resealable 5kg Plastic Tube. 5kg Plastic Resealable (TIG) for Gas and GTA Suitable Welding. AWS AS / End Stamped with Class ‘309L’. Label for Pack RED COLOUR CODED Instant I.D. Classifications: Applications: Description and COMWELD 309L COMWELD 6.“ChromeBright” the best cleaning and finishing results use CIGWELD For No. pickling paste (Part 321918). 4.5.Argon. Grade Welding (DC-) and Use Direct Current Electrode Negative Preheat surfaces to be welded. Heat a spot on the base metal until it shows signs of melting and 3. or Ceriated tungsten electrode,Thoriated Use a ground to a sharp needle point making sure the Procedure for Gas Tungsten Arc (TIG) Welding: (TIG) Arc Tungsten for Gas Procedure 1.2. clean all areas to be joined. Thoroughly the butt welding of thick plate, For bevel edges to 60 4.5. joint sections. Preheat thicker joint until molten Heat a small area of the 6. Allow completed joint to cool and remove 1.2.3. clean all areas to be welded. Thoroughly Adjust flame to a neutral setting. flux to filler rod Apply a Stainless Steel AS 1167.2:A5.9: AWS/ASME-SFA ER309L. quality low Comweld 309L stainless steel is a high Arc (TIG) Tungsten carbon rod for the Gas or Gas R309L. welding of highly alloyed 309 or 309L type stainless steels. Comweld 309L is also suitable for the dissimilar joining of other 300 series austenitic stainless steels to ferritic steels. Welding: for Gas (Oxy-acetylene) Procedure ▲ ▲ ▲ ▲ www.cigweld.com.au 194 GAS AND TIG WELDING CONSUMABLES www.cigweld.com.au .Frtebt edn ftikpae,beveledgesto60 For thebuttweldingofthickplates, Thoroughly cleanallareastobejoined. 2. 1. Procedure forGas Tungsten Arc (TIG) Welding: For thebestcleaningand Allowcompletedjointtocoolandremoveresidualfluxbygrindingwirebrushing. 6. Heatasmallareaofthejointuntilmolten Preheatthicker jointsections. 5. 4. ApplyaStainlessSteelfluxtofillerrod Adjustflametoaneutralsetting. Thoroughly cleanallareastobewelded. 3. 2. 1. Procedure forGas(Oxy-acetylene) Welding: 444and3Cr12. steels gradessuchas409, aswellferriticstainless including 302and304; welding ofother300seriesstainlesssteels Comweld 316Lisalsosuitableforthegeneral in particularmatching316and316Lalloys. welding ofMolybdenumbearingstainlesssteels; carbon rodfortheGasor Tungsten Arc (TIG) R316L. Comweld 316Lstainlesssteelisahighqualitylow ER316L. AWS/ASME-SFA A5.9: AS 1167.2: ▲ ▲ ▲ ▲ .Frtebs laigadfnsigrslsueCGED“hoergt ikigpse(atN:321918) picklingpaste(Part No: For thebestcleaning andfinishingresultsuseCIGWELD “ChromeBright” Heataspot onthebasemetaluntilitshowssignsofmeltingand 6. Preheatsurfacestobewelded. UseDirectCurrentElectrodeNegative(DC-)and Welding Grade Argon. 5. 4. groundtoasharpneedlepointmakingsurethe Usea Thoriated orCeriatedtungstenelectrode, 3. Description and Applications: Classifications: COMWELD 316L for InstantI.D. GOLD COLOURCODEDPack Label Class ‘316L’. End Stampedwith AS / AWS Welding. Suitable forGasandGTA (TIG) Resealable 5kgPlastic Tube. iihn eut s IWL CrmBih”pcln at Pr o 321918). picklingpaste(Part No. finishing resultsuseCIGWELD “ChromeBright” the flame. melted bythemoltenweldpoolandnot Ensuretherodis rod totheweldpool. and progressivelyaddComweld316Lfiller and jointareas. progressively addthefillerrodtoweldpool. point shouldbeapproximately2-3xthediameteroftungstenelectrode. The lengthoftheneedle grinding linesrunwiththelength(longitudinally)ofelectrode’s axis. ° -70 ° W 52:E316LT1-1/4 AWS A5.20: Shieldcrome 316LT FCAWwires ER316LSi AWS A5.9: Autocraft 316LSiGMAWwire Balance E316L-16 Fe: AWS A5.4: 2.50% Murex Speedex316L Mo: E316L-17 AWS A5.4: 0.50% Si: Satincrome 316L-17electrode 0.001% S: COMPARABLE CIGWELDPRODUCTS: 12.6% Ni: 1.57% Mn: 0.015% P: 19.00% Cr: 0.012% C: TYPICAL ROD ANALYSIS: 640MPa. 470MPa. 1400 Approximate MeltingPoint Tensile Strength Metal Typical Weld Proof Stress Typical Weld Metal0.2% WELD DEPOSITPROPERTIES: * Resealable irsrcueAustenitewith 7.95gms/cm Microstructure Metal All Weld Weld MetalDensity . 1 k ue 0321401 30 5kg Tube* 2.4 x914 1.6 x914 o iePc prxmt Part No Approximate Pack Rod Size included angle. Packaging Data: m)Wih/yeRods/kg Weight/Type (mm) 5RdHniak-322054 - 25 RodHandipack k ue 9321400 69 5kg Tube* 7 –10%ferrite ° C 3 GAS AND TIG WELDING CONSUMABLES 195 3 50:50) ≈ & ferrite ( (mm) Weight/Type Rods/kg Packaging Data: Packaging Rod Size Pack Approx. No Part included angle. 1.6 x 10002.4 x 1000Tube* 5kg Cardboard Tube* 5kg Cardboard 69 30 321393 321394 * Resealable C: 0.012%Cr: 22.80%N: 0.14% Mn:Cu: 1.06% 0.06% Ni: 8.63% P: 0.018%CIGWELD PRODUCTS: COMPARABLE Fe: Balance Si: 0.44% Autocraft 2209 GMAW wire Mo:AWS A5.9: 3.10% E2209 S: 0.007% JOINING PROCESS: JOINING Arc (TIG) Gas Tungsten welding. TYPICAL ALL WELD DEPOSIT MECHANICAL PROPERTIES: 0.2% Proof Stress StrengthTensile Metal DensityFERRITE NUMBER: 600 MPa. 30-50 FN (Procedure dependent) 765 MPa. ANALYSIS: TYPICAL ROD 7.95 gms / cm Microstructure Austenite ° -70 ° grinding lines run with the length (longitudinally) of the electrode’s axis.grinding lines run with the length (longitudinally) of the electrode’s needle length of the The point should be approximately 2-3 x the diameter of the tungsten electrode. melting and progressively add the filler rod to the weld pool. For the GTA (TIG) welding of (TIG) welding GTA the For type duplex 22%Cr/5%Ni/3%Mo steels. stainless tube. cardboard Resealable 5kg (TIG) welding. Suitable for GTA ‘ER2209’ Class AWS End stamped with for easy identification. Classifications: Applications: Description and COMWELD 2209 STAINLESS STEEL TIG ROD TIG STEEL STAINLESS 2209 COMWELD 4.5.Argon. Grade Welding Use Direct Current Electrode Negative (DC-) and Preheat thick sections prior to welding.6. Heat a spot on the base metal until it shows signs of No. the best cleaning and finishing results use CIGWELD ChromeBright pickling paste (Part For 321918). 3. or Ceriated tungsten electrode,Thoriated Use a ground to a sharp needle point making sure the AWS/ASME-SFA A5.9: AWS/ASME-SFA No:Werkstoffe ER2209. rod suitable TIG welding Comweld 2209 is a stainless steel 1.4462 of 22Cr/5Ni/3Mo for the gas tungsten arc (TIG) welding type duplex stainless steels. Applications include the welding corrosion and pitting of duplex stainless steels as used where resistance is required. 22209 include Base metals welded with with Comweld A903) and S39230 (2304). S39205 (2205 and Bohler joining of duplex Comweld 2209 is recommended for the he chemical industry stainless steel pipes and tanks used int pitting corrosion in that require high resistance to stress and chloride and hydrogen sulphide media. Welding: (TIG) Arc Tungsten for Gas Procedure 1.2. all areas to be joined. clean Thoroughly the butt welding of thick plates, For bevel edges to 60 ▲ ▲ ▲ ▲ www.cigweld.com.au 196 GAS AND TIG WELDING CONSUMABLES www.cigweld.com.au .The blowpipetipshouldbeheldatabout45 withnosideways theblowpipemovementshouldbestraightforward, Whenwelding in thedownhandposition, 6. The edgesofthejointshouldbeheatedtomeltingpointandComweld AL1100 fillerrodaddedtothemolten 5. 321740)tofillerrodandjointareas. ApplyComweld Aluminium flux(Part Number: oronewithaslighthazeatthetipofcone. Adjustflameto asoftneutralsetting, Thoroughly cleanallareastobeweldedeithermechanicallyorchemically. 4. 3. 2. Heataspotonthebasemetaluntilitshowssignsofmeltingand 1. Preheatthicksections beforewelding. Procedure forGas(Fusion) Welding: UseHighFrequency stabilised Alternating Current(AC-HF) and Welding Grade Argon. 5. 4. groundtoa taperedbluntpoint(halfthediameterofelectrode)making UseaZirconiated tungstenelectrode, 3. .The fluxmustberemovedoncompletionbywashing inhotwater orimmersion(for approximately10minutes) 7. .Frtebt edn ftikpae,beveledgesto65 For thebuttweldingofthickplates, Thoroughly cleanallareastobejoined. 2. 1. Procedure forGas Tungsten Arc (TIG) Welding: metals. *See CIGWELD Aluminium Alloy SelectionChartfordetailedweldingconsumableselectioncriteriaawiderangeof parent Aluminium alloy Comweld AL1100 producesagoodcolourmatchinanodised1XXXseriesweldedjoints. for thejoiningofselectedhighpurity1XXXseries industries.Aluminium sheetsandplatesusedextensivelyintheelectricalchemical and electricalconductivitymake Comweld AL1100 ideal excellentcorrosionresistanceandhighthermal strength, The lowerwelddeposit wrought Aluminium alloys. Tungsten Arc (TIG)weldingofselected*1XXXseries R1100. Aluminium alloyrodrecommendedfortheGasor pure(99.88%min) Comweld AL1100 isapremiumquality, R1100. AWS/ASME-SFA A5.10: AS 1167.2: ▲ ▲ ▲ ▲ Classifications: COMWELD AL1100 Description and Applications: Carton. 2.5 kgCardboard Pack /15kg Class ‘1100. / AWS with AS Embossed Applications. Tungsten(GTAW/ TIG)Welding Arc Suitable forGas Welding andGas Rod. Pure AluminiumAlloy 99.88% oeeto evn,toconfinetheheatinweldarea. movement orweaving, Ensuretherodismeltedbymoltenweldpoolandnotflame. weld pool. progressively addthefillerrodtoweldpool. welding arc. the this isdonebyheatingthenewlypreparedtungstenatapproximately30ampshigherthanrecommendedweldingcurrentunder For bestresultsthetungstenelectroderequiresaradiusor end, ‘balled’ be approximately2-3xthediameteroftungstenelectrode. The lengthofthepointshould sure thegrindinglinesrunwithlength(longitudinally)ofelectrode’s axis. nadlt ouin( 0)o ircai.The acidmustberemovedbywashing withwater afterthefluxhasbeenremoved. in adilutesolution(5-10%)ofnitricacid. The fillerrodissimilarlyinclinedfrom30 ° - 40 ° to theworkpieceandslightlydecreasedasweldprogresses. ° . ° -75 ° included angle. W 51:ER1100 AWS A5.10: Autocraft AL1100 GMAWwire 0.005% 0.03% Cu: Zn: COMPARABLE CIGWELDPRODUCTS: 0.01% Otherseach: 0.01% Mg: 0.06% Fe: 99.88%min Al: 0.01% Ti: 660 0.01% Mn: 0.06% Si: stated. unlessotherwise Single values aremaximumallowable, ROD ANALYSISLIMITS: Approximate MeltingPoint Typical Weld 75MPa. Metal Tensile Strength WELD DEPOSITPROPERTIES: otAoie oortn Clear Post Anodised colourtint Packaging Data: . 1 .k ak1k 0322601 322600 30 30 15kg 15kg 2.5kgPack 2.5kgPack 2.4 x914 1.6 x914 o iePc atnApo.Part No Approx. Carton Pack Rod Size m)Wih/yeSz Rods/kg Size Weight/Type (mm) 890 C ° ° C GAS AND TIG WELDING CONSUMABLES 197 C ° ° C 890 (mm) Weight/Type Size Rods/kg Rod Size Pack Carton Approx. No Part 1.6 x 9142.4 x 9143.2 x 914 2.5kg Pack 2.5kg Pack 15kg 2.5kg Pack 15kg 210 15kg 90 321610 51 321611 321612 Packaging Data: Packaging included angle. WELD DEPOSIT PROPERTIES: WELD DEPOSIT StrengthTensile Metal Weld Typical Melting PointApproximate Anodised colour tint Post 110 MPa. LIMITS: ROD ANALYSIS allowable, are maximum Single values otherwise unless stated. Si: 4.5-6.0%Mn: 0.05% 630 Ti: 0.20% Fe: 0.80%Al: Balance Grey Mg: 0.05% others: Total 0.15% Cu: 0.30% CIGWELD PRODUCTS: COMPARABLE Zn: 0.10% AL4043 GMAW wire Autocraft AWS A5.10: ER4043 ° -75 ° electrode) making sure the grinding lines run with the length (longitudinally) of the electrode’s of the electrode’s electrode) making sure the grinding lines run with the length (longitudinally) axis. should be approximately 2-3 x the diameter of the tungsten length of the point The electrode.‘balled’ end, a radius or best results the tungsten electrode requires For this is done by heating the newly prepared tungsten at approximately 30 amps higher than the recommended welding current under the welding arc. melting and progressively add the filler rod to the weld pool. is reached. heat the casting and tack weld the parts into position when the correct temperature the ends of the fracture. be increased towards approximately 10 minutes) in a dilute solution (5 - 10%) of nitric acid. acid must be removed The after the flux has been removed. with water by washing Aluminium - 5% Silicon Alloy Rod. Alloy - 5% Silicon Aluminium and Gas Welding for Gas Suitable Arc / TIG) Welding (GTAW Tungsten Applications. Embossed with AS / AWS Class ‘4043’. / 15kg Pack 2.5 kg Cardboard Carton. Classifications: Applications: Description and COMWELD AL4043 COMWELD - nominal 5% Silicon alloy rod used extensively - nominal 5% Silicon alloy rod used extensively 3. Use a Zirconiated tungsten electrode,tapered blunt point (half the diameter of ground to a 4.5.Argon. Grade Welding and Alternating Current (AC-HF) stabilised Use High Frequency Preheat thick sections before welding. Heat a spot on the base metal until it shows signs of Aluminium Casting: of a Fractured Welding for the Gas (Fusion) Procedure 1.2.3. either mechanically or chemically. clean all areas to be welded Thoroughly Number:Aluminium flux (Part Apply Comweld 321740) to the areas to be joined. Adjusting the flame to a soft neutral setting,4. at the tip of the cone, or one with a slight haze pre- Begin at the centre of the fracture completing one side and then the other. speed should 5. Welding 6. Allow the repaired casting to cool slowly. or immersion (for in hot water by washing flux residue must be removed on completion The AS 1167.2:A5.10: AWS/ASME-SFA R4043. Aluminium AL4043 is a premium quality Comweld R4043. holes for the repair welding (fractures and blow etc) of selected* aluminium alloy castings. Its lower weld deposit strength and excellent it suitable for the Gas or crack resistance make TIG) welding of cast / Arc (GTAW Tungsten Gas wrought ( mainly 4XX & 6XX series ) alloys and ( selected 1XXX, 5XXX & 6XXX series ) aluminium alloys, except where an accurate colour match is required after anodising. criteria for a wide range of Alloy Selection Chart for detailed welding consumable selection Aluminium *See CIGWELD Aluminium alloy parent metals. Welding: (TIG) Arc Tungsten for Gas Procedure 1.2. clean all areas to be joined. Thoroughly the butt welding of thick plates, For bevel edges to 65 ▲ ▲ ▲ ▲ www.cigweld.com.au 198 GAS AND TIG WELDING CONSUMABLES www.cigweld.com.au .The fluxresiduemustberemovedoncompletionbywashing inhotwater orimmersion(for asmallamountof 7. Atthistime, Atthecorrecttemperaturefluxwillbegintoflowsmoothly. 6. .Frtebt edn ftikpae,beveledgesto65 For thebuttweldingofthickplates, Thoroughly cleanallareastobejoined. 2. 1. Procedure forGas Tungsten Arc (TIG) Welding: distortion. producingsoundwelddeposits withlowparentmetal Comweld AL4047 idealforbrazingorbrazeweldingapplications, excellent flowcharacteristicsmake thelowermeltingrangeand Brazing Flux, Used incombinationwithComweld Aluminium extrudedshapesandcastings. sheets, for thebrazingofmanytypes Aluminium alloy - nominal10%Siliconalloyrodusedextensively Comweld AL4047 isapremiumquality Aluminium R4047. BAlSi-4. R4047. AWS/ASME-SFA A5.8: AWS/ASME-SFA A5.10: AS 1167.2: ▲ ▲ ▲ ▲ .The blow pipeandfillerrodshouldbeheldatapproximatelythesameangleasforfusion 5. ensuringthattheinnerconeiswellclearof Preheatthejointusingenvelopeofflame, oronewithaslighthazeatthetipofcone. Adjustingtheflametoasoftneutralsetting, Applyan Aluminium Brazingfluxtoareasbejoined. 4. Thoroughly cleanallsurfacestobeweldedeithermechanicallyorchemically. 3. 2. 1. Heataspotonthebasemetaluntilitshowssignsof Procedure forBrazing: Preheatthicksectionsbeforewelding. UseHighFrequency stabilised Alternating Current(AC-HF) and Welding Grade Argon. 5. 4. groundtoataperedbluntpoint(halfthediameterof UseaZirconiatedtungstenelectrode, 3. Description and Applications: Classifications: COMWELD AL4047 Carton. 2.5 kgCardboard Pack /15kg ‘4047’. Class / AWS with AS Embossed Applications. Tungsten(GTAW/ TIG)Welding Arc Suitable forGas Welding andGas Aluminium -10%Silicon Alloy Rod. by washing withwater after thefluxhasbeenremoved. The acidmustberemoved minutes)inadilutesolution (5-10%)ofnitricacid. approximately 10 Comweld AL4047 fillerrodshouldbeaddedandthewithdrawn. edn,45 welding, the parentmetal. melting andprogressivelyaddthefillerrodtoweldpool. welding currentunderthearc. prepared tungstenatapproximately30ampshigherthantherecommended thisisdonebyheatingthenewly For bestresultsthetungstenelectrode requiresaradiusor ‘balled’ end, electrode. The lengthofthepointshouldbeapproximately2-3xdiametertungsten axis. electrode) makingsurethegrindinglinesrunwithlength(longitudinally)ofelectrode’s ° and 30 ° - 40 ° respectively. ° -75 ° oa tes .5 l Balance Al: 0.20% Zn: 0.30% Cu: 0.10% Mg: 0.15% Total others: 0.80% Fe: 0.15% Mn: 577–582 11.0-13.0% Si: stated. unlessotherwise Single values aremaximumallowable, ROD ANALYSISLIMITS: MPa. 150 Approximate MeltingRange Metal TensileTypicalStrength Weld WELD DEPOSITPROPERTIES: otAoie oortn Grey–Black Post Anodised colourtint included angle. Packaging Data: . 1 .k ak1k 1321622 51 15kg 2.5kgPack 3.2 x914 2.4 x914 1.6 x914 o iePc atnApo.Part No Approx. Carton Pack Rod Size m)Wih/yeSz Rods/kg Size Weight/Type (mm) 0 o adpc k 322070 – 8Pks 100 RodHandipack 0RdHniak8Ps–322071 – 8Pks 50 RodHandipack .k ak1k 0321621 90 321620 15kg 210 2.5kg Pack 15kg 2.5kg Pack 890 C ° ° C GAS AND TIG WELDING CONSUMABLES 199 C ° ° C 890 2.5kg Pack 15kg 90 321641 40 Rod Handipak 8 Pks – 322078 . ° (mm) Weight/Type Size Rods/kg Rod Size Pack Carton Approx. No Part 1.6 x 9142.4 x 914 2.5kg Pack3.2 x 914 15kg 2.5kg Pack 210 15kg 321640 51 321642 Packaging Data: Packaging included angle. - 40 Post Anodised colour tintAnodised Post White WELD DEPOSIT PROPERTIES: WELD DEPOSIT StrengthTensile Metal Weld Typical Melting PointApproximate 270 MPa. LIMITS: ROD ANALYSIS allowable, are maximum Single values otherwise unless stated. Si: 0.25% 640 Mn: 0.05-0.20%Zn: 0.10% others:Total 0.15% Mg: 4.5-5.5% Al: Balance Fe: 0.40% Cr: 0.05-0.20% CIGWELD PRODUCTS: COMPARABLE Ti: 0.05-0.20% AL5356 GMAW wire Autocraft AWS A5.10: Cu: ER5356 0.10% ° ° -75 ° to the work piece and slightly decreased as the ° approximately 10 minutes) in a dilute solution (5 - 10%) of nitric acid. acid must be removed The after the flux has been removed. with water by washing weld progresses. filler rod is similarly inclined from 30 The electrode) making sure the grinding lines run with the length (longitudinally) of the electrode’s of the electrode’s electrode) making sure the grinding lines run with the length (longitudinally) axis. should be approximately 2-3 x the diameter of the tungsten length of the point The electrode.‘balled’ end, a radius or best results the tungsten electrode requires For this is done by heating the newly prepared tungsten at approximately 30 amps higher than the recommended welding current under the welding arc. melting and progressively add the filler rod to the weld pool. to the molten weld pool. pool and not the flame. Ensure the rod is melted by the molten weld movement or weaving,with no sideways to confine the heat in the weld area. Aluminium - 5% Magnesium - 5% Magnesium Aluminium Alloy Rod. and Gas Welding for Gas Suitable Arc Welding / TIG) (GTAW Tungsten Applications. Embossed with AS / AWS Class ‘5356’. / 15kg Pack 2.5 kg Cardboard Carton. Classifications: Applications: Description and COMWELD AL5356 COMWELD 7. or immersion (for in hot water by washing flux must be removed on completion The AS 1167.2:A5.10: AWS/ASME-SFA R5356. AL5356 is a high quality,Comweld Aluminium for - nominal 5% Magnesium alloy rod suitable Arc (TIG) welding of a Tungsten the Gas or Gas R5356. Aluminium alloys. wide range of cast and wrought and It produces intermediate deposit strength for the Gas good ductility and corrosion resistance TIG) of a / (GTAW Welding Arc Tungsten or Gas wide range of 3XXX, 5XXX, 6XXX and 5XX Aluminium alloys.Alloy Aluminium See CIGWELD Selection Chart for detailed welding consumable Aluminium selection criteria for a wide range of alloy parent metals. Welding: (TIG) Arc Tungsten for Gas Procedure 1.2. clean all areas to be joined. Thoroughly the butt welding of thick plates, For bevel edges to 65 ▲ ▲ ▲ ▲ 3. Use a Zirconiated tungsten electrode,tapered blunt point (half the diameter of ground to a 4.5.Argon. Grade Welding and Alternating Current (AC-HF) stabilised Use High Frequency Preheat thick sections before welding.Welding: for Gas (Fusion) Procedure Heat a spot on the base metal until it shows signs of 1.2.3. either mechanically or chemically. clean all areas to be welded Thoroughly 4. Adjust flame to a soft neutral setting, or one with a slight haze at the tip of the cone. Number:Aluminium flux (Part Apply Comweld 321740) to filler rod and joint areas. AL5356 filler rod added to melting point and Comweld edges of the joint should be heated The 5. When welding in the downhand position,6. the blowpipe movement should be straight forward, 45 blowpipe tip should be held at about The www.cigweld.com.au 200 GAS AND TIG WELDING CONSUMABLES www.cigweld.com.au .Applytotheweldpool bymeltingoffsmallquantitiesfromtheendofrodata45 UseDirectCurrentElectrodeNegative(DC-)and Welding Grade Argon. 6. 5. groundtoasharpneedlepointmakingsurethe Usea Thoriated orCeriatedtungstenelectrode, 4. Bevelallbreaksandcrackstoforma75 Chipfileorgrindallscaleandoxidefromareastobejoined. 2. 1. Procedure forGas Tungsten Arc Welding (TIG): Removefluxresiduebywashing inhotwater orimmersingfor10minutesinadilutesolutionof reheattoadullredandallowcoolslowly. Whenweldingiscompleted, 9. 8. Continuethiscircularmovementoftheflameplayingitonweldmetaland the basemetal 7. DipendofheatedrodintoaCastIronandusingslightcircularmovementtheflameto Heattheendoffillerrod. Adjustflametoneutralsetting. 6. 5. 4. .Bevelallbreaksandcrackstoforma75 2. Chipfileorgrindallscaleandoxidefrom 1. Procedure forGas(Oxy-acetylene) Welding: excellent. finished weldstothatoftheparentmetalis Colourmatchof in thedownhandposition. extremely fluidandweldingshouldbecarriedout Moltencastironis worn ormissingsections. fillinginsurfaceporosityandbuildingup sections, Excellentforthin specially castcomponents. motorandgearhousings machine bases, of & repairby TIG oroxy-acetylenewelding, RC11. Applicationsincludemaintenance iron castings. iron alloyforjoiningandbuildingupgreycast machinablecast generalpurpose, A highstrength, AS 1167.2: .Beforecommencingtoweldpreheatadullredheat=approximately650 3. .Beforecommencingtoweldpreheatadullredheat=approximately650 3. .We edn scmltd reheat toadullredandallowcoolslowly. Whenweldingiscompleted, 7. Description and Applications: Classifications: CASTIRONROD COMWELD GENERALPURPOSE, point shouldbeapproximately2-3xthediameteroftungstenelectrode. The lengthoftheneedle grinding linesrunwiththelength(longitudinally)ofelectrode’s axis. removed. The acidmustberinsedoffbywashing inwater afterthefluxhasbeen nitric acid(5-10%). until theyarethoroughlyfused. the puddle. lowerthefillerrodontobasemetalandallowabout5mmoftomeltin At thispoint, itwillbecomesoftandhavetheappearanceofbeingwet. When thematerialisreadytomelt, bringtomeltingpoint. end oftherodandbottomedges'V', areas tobejoined. you wouldmeltacandlewithmatch). ° ° -90 -90 ° ° 'V' orgroove. 'V' orgroove. :008 :001 e Balance Fe: 3.25% Si: 0.011% P: 0.75% Mn: 1150 0.008% S: MPa. 230 3.37% C: TYPICAL ROD ANALYSIS: Approximate MeltingPoint Metal TensileStrength All Weld TYPICAL PROPERTIES: Gas (Fusion)and Tungsten Arc Welding (TIG). JOINING PROCESS: Blue TIP COLOUR: . 0 .k ak8321420 8 2.5kgPack 5.0 x700 Packaging Data: o iePc prxmt Part No Approximate Pack Rod Size m)Wih/yeRods/kg Weight/Type (mm) ° ° C. C. ° angle (as 890 C ° ° C. GAS AND TIG WELDING CONSUMABLES 201 C. ° ° C 890 (mm) Weight/Type Handipack Packaging Data: Packaging Rod Size Pack Easyweld No Part 6.3 x 500 2.5kg Pack 321695 6.3 x 500 2 Rod Handipack 322085 TYPICAL PROPERTIES: TYPICAL Melting PointApproximate ANALYSIS: TYPICAL ROD Pb:(Lead) 57.50% 300 Sn: (Tin) 32.50% Zn: 10.00% (Zinc) C. ° removing any rust, slag, residue and flux foreign material. of 300 coated. is not hot enough the bar will not melt off effectively. If the base metal will result. will run too freely and excessive coating hot the bar If the base metal is too greatly strengthens and improves the finish. Description and Applications: and Description COMWELD GALVANISING BAR GALVANISING COMWELD COMWELD Galvanising Bar is an alloy which when Bar is an alloy Galvanising COMWELD a heated base metal,applied on melt and will alloy coating. produce a strong corrosion-resistant be used as a pre-treatment to alloy can This and forms a strong protect base metals the surface.permanent bond to COMWELD can be used where any welding Bar Galvanising parts is done.of galvanised It can be used with gas or electric welding. Procedure: 1. clean all areas to be galvanised Thoroughly 2. a temperature Preheat the base metal to 3. the area to be Rub the end of the bar on 4. weld area. cool slightly then wire brush or wipe the deposit to completely cover the Allow the molten alloy to 5. This a flame. Do not melt the alloy with www.cigweld.com.au 202 GAS AND TIG WELDING CONSUMABLES www.cigweld.com.au .Allowthejointtocoolandremovefluxresiduewithawirebrushorbyimmersionindilute Continueaddingtherodtobuildupbrazedesiredsizeandshape. 6. 5. Meltingofthebasematerialisnotrequiredinbrazeweldingandcareshouldbetaken tocontrol 4. Diptheendofheatedrodintoflux Preheattheedgestobejoinedadullredcolour. 3. 321822)andforcast For bestresultsonsteeluseComweldCopperandBrassflux(Part Number: Thoroughly cleanallareastobejoined. 2. 1. Procedure forBraze Welding: etc-itisamustfortheworkshop. steel, malleableiron, joining ofcastiron, Comweld ManganeseBronzeistheidealmaintenancerodforawiderangeofbrazeweldingapplicationsincluding be used. For theseapplicationsComweld Tobin BronzeorComcoat T should of dezincificationthebronzecausingfailurejoint. Comweld ManganeseBronzeisnotrecommendedforthejoiningofcopperpipeswhichcarryhotwater orseawater because castironandmalleableiron. recommended forthebrazeweldingofsteel, itis high bond(transversetensile)strength, Becauseofits general purposebronzefillerrod. RCuZn-C. Comweld ManganeseBronzeisalowfuming, RBCuZn-C. AWS/ASME-SFA A5.8 / A5.27: Parts 1&2: AS 1167. ▲ ▲ ▲ ▲ Packaging Data: Description and Applications: Classifications: COMWELD MANGANESEBRONZEROD . 5 k ak5321204 321203 321202 321199 321195 5 8 20 37 83 5kgPack 5kgPack 5kgPack 5kgPack 6.3 x750 5kgPack 5.0 x750 3.2 x750 2.4 x750 1.6 x750 o iePc prxmt Part No Approximate Pack Rod Size m)Wih/yeRods/kg Weight/Type (mm) BLUE End Tip ColourforInstantI.D. Systems.Hot Water Not SuitableforCopperPipesin of SteelsandCastMalleableIrons. Recommended forBraze Welding General PurposeBrazing Alloy. acid solutionfollowedbyawater rinse. the heatinjoint. taken placeontherequiredjointsurfaces. Ensurethat ‘tinning’ has heatbothedgesofthejobtoanequaldegree. atthesametime, and, Adjustflametoslightlyoxidising. iron useaBronzeflux. n .%F:05%C:Balance Cu: 0.10% Si: RCuZn-C AS 1167.1&.2: 0.50% Fe: Comcoat CFluxCoatedManganeseBronze 35% 0.10% Mn: COMPARABLE CIGWELDPRODUCTS: 1.0% Sn: 40.5% Zn: 165MPa TYPICAL ROD ANALYSIS: 890 Approximate MeltingPoint 460MPa Elongation 0.2% ProofStress Weld Metal Tensile Strength TYPICAL WELD DEPOSITPROPERTIES: Gas (Braze) Welding only. JOINING PROCESS: edMtlDniy8.39gms/cm Weld MetalDensity ° C. 890 C ° 3 GAS AND TIG WELDING CONSUMABLES 203 3 ° C 890 C. ° 50 321191 19 321186 5 Rod Blister Pack – 322206 Comweld Manganese Bronze Bare Rod AS 1167.1 & 2: R Cu Zn-C JOINING PROCESS: JOINING only. Welding Gas (Braze) DEPOSIT PROPERTIES: WELD TYPICAL StrengthTensile Metal Weld 0.2% Proof StressElongation PointApproximate Melting 460 MPa 890 ANALYSIS: TYPICAL ROD 165 MPa Zn: 40.5%Sn: 1.0%CIGWELD PRODUCTS: COMPARABLE Mn: 0.10% 35% Fe: 0.50% Si: 0.10% Cu: Balance Weld Metal DensityWeld 8.39 gms / cm . 15 Rod Handipack – 322021 5kg Pack 2.5kg Pack the same time, heat both edges of the job to an equal degree. ‘tinning’ has taken Ensure that place on the required joint surfaces. the heat in the joint. rinse. acid solution followed by a water Flux Coated Manganese Bronze Rod. Bronze Manganese Flux Coated Alloy. Brazing Purpose General Welding for Braze Recommended and Malleable Irons. of Steels and Cast Copper Pipes in Not Suitable for Hot Water Systems. for Instant I.D BLUE Flux Colour (mm) Weight/Type Handipack Pack Rods/kg Rod Size Pack Easyweld Blister Approximate No Part 2.4 x 5003.2 x 750 20 Rod Handipack – 322020 Packaging Data: Packaging Classifications: Applications: Description and COMWELD COMCOAT C COMCOAT COMWELD AS 1167. 1 & 2: Parts A5.8/A5.27: AWS/ASME-SFA RB Cu Zn-C. Comweld Comcoat C a self fluxing, low fuming, R Cu Zn-C. Manganese Bronze filler rod. of its high bond (transverse tensile) Because strength, it is recommended for the braze welding of steel, cast iron and malleable iron. because of or sea water for the joining of copper pipes which carry hot water Comweld Comcoat C is not recommended of the joint.dezincification of the bronze causing failure T should be Bronze or Comcoat Tobin these applications Comweld For used. is the ideal maintenance rod for a wide range of self fluxing braze welding Comweld Comcoat C Manganese Bronze iron,applications including the joining of cast malleable iron, steel, etc - it is a must for the workshop. Welding: for Braze Procedure 1.2.3. clean all areas to be joined. Thoroughly Adjust flame to slightly oxidising. Preheat the edges to be joined to a dull red colour. end of the flux coated rod and, Melt the at 4. to control taken Melting of the base material is not required in braze welding and care should be 5.6. Continue adding the rod to build up the joint to the desired size and shape. in a dilute Allow the joint to cool and remove the flux residue with a wire brush or by immersion ▲ ▲ ▲ ▲ ▲ www.cigweld.com.au 204 GAS AND TIG WELDING CONSUMABLES www.cigweld.com.au .Allowthejointtocoolandremovefluxresiduewithawirebrushorbyimmersion inadilute Continueaddingtherodtobuildupjointdesiredsizeandshape. 5. 4. Diptheendofheatedrodintoflux Preheattheedgestobejoinedadullredcolour. 3. For bestresultsonCopperandalloysuseComweldBrassflux Thoroughly cleanallareastobejoined. 2. 1. Procedure forBraze Welding: steel inlowstressapplicationssuchasthe ‘filling’ ofcarbodypanels. Comweld Tobin Bronzeisidealforbrazeweldingjointsinbrassandbronzealsousedtheofmild Bronze isthepreferredfillerrodforhigherstrengthbrazeweldingofferrousmetals. ComweldManganese Itisalsosuitableforthenon-criticalbrazingofmildsteelinlowstressapplications. bronze alloys. RCuZn-A. Comweld Tobin Bronzeisalowfumingrodrecommendedforthefusionweldingorbrazeofselectedbrassand RBCuZn-A. AWS/ASME-SFA A5.8/A5.27: Parts 1&2: AS 1167. ▲ ▲ ▲ ▲ ▲ Description and Applications: Classifications: COMWELD TOBIN BRONZEROD Packaging Data: . 5 5kgPack 5kgPack 5.0 x750 5kgPack 3.2 x750 2.4 x750 1.6 x750 o iePc ayedApoiaePart No Approximate Easyweld Pack Rod Size m)Wih/yeHniakRods/kg Handipack Weight/Type (mm) WHITE End Tip ColourforInstantI.D. Not SuitableforCastIrons. of Steels. Suitable forLowStrength brazing and Bronzes. Braze Welding ofSelectedBrasses Recommended fortheFusionor Alloy Low Strength Copper-ZincBrazing acid solutionfollowedbyawater rinse. taken placeontherequiredsurfaces. Ensurethattinninghas heatbothedgesofthejobtoanequaldegree. atthesametime, and, 321822)andadjusttheflametocontainaslightexcessofoxygen. (Part Number: . 5kg Pack 5RdHniak–322038 – 15 RodHandipack n 75 i .0 n 0.50% Sn: RCuZn-A AS1167.1 &2: Comcoat T fluxcoated Tobin Bronze 45% 0.30% Si: COMPARABLE CIGWELDPRODUCTS: Balance Cu: 37.5% Zn: 110MPa TYPICAL ROD ANALYSIS: 900 Approximate MeltingPoint 400MPa Elongation 0.2% ProofStress Weld Metal Tensile Strength TYPICAL WELD DEPOSITPROPERTIES: Gas (FusionandBraze) Welding only. JOINING PROCESS: edMtlDniy8.41gms/cm Weld MetalDensity 0321249 20 7321247 321246 37 83 321250 8 ° C. 890 C ° 3 GAS AND TIG WELDING CONSUMABLES 205 3 ° C 890 C. ° 19 321236 5 Rod Blister Pack – 322207 Weld Metal DensityWeld 8.41 gms / cm Bronze Bare Rod Tobin Comweld AS1167.1 & .2: R Cu Zn-A JOINING PROCESS: JOINING only. Welding and Braze) Gas (Fusion DEPOSIT PROPERTIES: WELD TYPICAL StrengthTensile Metal Weld 0.2% Proof StressElongation 400 MPa PointApproximate Melting 900 ANALYSIS: TYPICAL ROD 110 MPa Zn: 37.5%Cu: Balance CIGWELD PRODUCTS: COMPARABLE Si: 0.30% 45% Sn: 0.50% the same time, heat both edges of the job to an equal degree. place Ensure that tinning has taken on the required surfaces. rinse. acid solution followed by a water Flux Coated Tobin Bronze Rod. Bronze Tobin Flux Coated ‘Self Fluxing’ for the Recommended of Selected Welding Fusion Braze & Bronzes. Brasses brazing Strength Suitable for Low of Steels. Cast Irons. Not Suitable for for Instant I.D. WHITE Flux Colour (mm) Weight/Type Handipack Pack Rods/kg 2.4 x 500 3.2 x 750 5kg Pack Packaging Data: Packaging Classifications: Applications: Description and COMWELD COMCOAT T COMCOAT COMWELD Rod Size Pack Easyweld Blister Approximate No Part 4.5. size and shape. Continue adding the rod to build up the joint to the desired brush or by immersion in a dilute Allow the joint to cool and remove the flux residue with a wire AS 1167. 1 & 2: Parts A5.8/A5.27: AWS/ASME-SFA RB Cu Zn-A. or braze welding Bronze filler rod recommended for the self fluxing fusion welding Tobin T is a low fuming Comweld Comcoat R Cu Zn-A. of selected brass and bronze alloys. of mild steel in low stress applications. It is also suitable for the non-critical brazing metals. C is the preferred filler rod for the higher strength braze welding of ferrous Comweld Manganese Bronze or Comcoat rod for welding selected brass and bronze alloys and is also Bronze is the ideal self fluxing filler Tobin T Comweld Comcoat ‘filling’ of car body panels. in low stress applications such as the used for the braze welding of mild steel Welding: for Braze Procedure 1.2.3. clean all areas to be joined. Thoroughly oxidising. Adjust the flame to slightly Preheat the edges to be joined to a dull red colour. Melt the end of the flux coated rod and, at ▲ ▲ ▲ ▲ ▲ www.cigweld.com.au 206 GAS AND TIG WELDING CONSUMABLES www.cigweld.com.au .Allowthejointtocoolandremovefluxresiduewithawirebrushorbyimmersion inadilute Continueaddingtherodtobuildupjointdesiredsizeandshape. 5. 4. Diptheendofheatedrodintoflux Preheattheedgestobejoinedadullredcolour. 3. 321822)andforcast For bestresultsonsteeluseComweldCopperandBrassflux(Part Number: Thoroughly cleanallareastobejoined. 2. 1. Procedure forBraze Welding: bearings andshaftsetc. valve seats, Its superior wearresistancemakes itidealforthebuildupofwornferrousmetalcomponents includinggearteeth, failinthe parentmetal. whentestedtodestruction, Itproducesjointsinmildsteelwhich, maintenance brazingalloy. ComweldNickel Bronzeisregardedasthenumberone Because ofitshighstrengthandexcellentwearresistance, based alloyswherehightemperaturesareallowable. It isalsoanexcellentchoiceforthefusionweldingofCopperbasedalloyssimilarcompositionandbrazingNick castandmalleableirons. recommended forthehighstrengthbrazeweldingofsteel, Nickel Silver)isapremiumqualitybronzefillerrod RCuZn-D. Comweld Nickel Bronze(sometimestermed RBCuZn-D. AWS/ASME-SFA A5.8/A5.27: Parts 1&2: AS 1167. ▲ ▲ ▲ ▲ Packaging Data: Description and Applications: Classifications: COMWELD NICKELBRONZEROD Instant I.D. CRIMSON End Tip Colourfor Alloys ofSimilarComposition. Fusion Welding ofCopperBased Steels andCastorMalleableIrons. High Strength Braze Welding of Brazing Alloy. Wear Resistant High Strength, . 5 k ak8321226 321225 321224 8 19 35 5kgPack 5kgPack 5kgPack 5.0 x750 3.2 x750 2.4 x750 o iePc prxmt Part No Approximate Pack Rod Size acid solutionfollowedbyawater rinse. taken placeontherequiredjointsurfaces. Ensurethat ‘tinning’ has heatbothedgesofthejobtoanequaldegree. atthesametime, and, Adjustflametoslightlyoxidising. iron useaBronzeflux. m)Wih/yeRods/kg Weight/Type (mm) edMtlDniy8.39gms/cm Weld MetalDensity n 35 n .0 i 0.20% Si: RCuZn-D AS 1167.1&.2: Balance Cu: 170HV Comcoat NFluxCoatedNickel Bronze 0.20% Mn: COMPARABLE CIGWELDPRODUCTS: 18% 10.0% Ni: 43.5% Zn: 250MPa TYPICAL ROD ANALYSIS: 910 560MPa Approximate MeltingPoint Hardness Elongation 0.2% ProofStress Weld Metal Tensile Strength TYPICAL WELD DEPOSITPROPERTIES: Gas (FusionandBraze) Welding only. JOINING PROCESS: ° C. 890 C ° 3 el GAS AND TIG WELDING CONSUMABLES 207 el 3 ° C 890 C. ° 19 321215 3 Rod Pack – 322208 Weld Metal DensityWeld 8.39 gms / cm COMPARABLE CIGWELD PRODUCTS: COMPARABLE Bronze Bare Rod Comweld Nickel AS 1167.1 & .2: R Cu Zn-D JOINING PROCESS: only. Welding and Braze) Gas (Fusion PROPERTIES: WELD DEPOSIT TYPICAL StrengthTensile Metal Weld 0.2% Proof StressElongationHardness PointApproximate Melting 560 MPa 910 ANALYSIS: TYPICAL ROD 250 MPa Zn: 43.5%Ni: 10.0% 18% Mn: 0.20% 170 HV Cu: Balance Si: 0.20% 8 Rod Handipack – 322030 10 Rod Handipack – 322029 2.5kg Pack the same time, heat both edges of the job to an equal degree. ‘tinning’ has taken Ensure that place on the required joint surfaces. rinse. acid solution followed by a water Flux Coated Nickel Bronze Rod. Bronze Nickel Flux Coated High Strength, Wear Excellent Resistance. of Welding Braze High Strength or Malleable Irons. Steels and Cast of Copper Based Welding Fusion Composition. Alloys of Similar for Instant I.D. PINK Flux Colour (mm) Weight/Type Handipack Pack Rods/kg 2.4 x 500 3.2 x 750 Packaging Data: Packaging Classifications: Applications: Description and COMWELD COMCOAT N COMCOAT COMWELD Rod Size Pack Easyweld Blister Approximate No Part 4.5. size and shape. Continue adding the rod to build up the joint to the desired brush or by immersion in a dilute Allow the joint to cool and remove the flux residue with a wire based alloys where high temperatures are allowable. based alloys where high temperatures wear resistance,Because of its high strength and excellent number one maintenance Comweld Comcoat N is regarded as the brazing alloy. It produces joints in mild steel which, when tested to destruction, fail in the parent metal. it ideal for the build up of worn ferrous metal components including gear teeth,resistance makes Its superior wear seats, valve bearings and shafts etc. Welding: for Braze Procedure 1.2.3. all areas to be joined. clean Thoroughly Adjust flame to slightly oxidising. Preheat the edges to be joined to a dull red colour. Melt the end of the flux coated rod and, at AS 1167. 1 & 2: Parts A5.8/A5.27: AWS/ASME-SFA RB Cu Zn-D. Nickel Comweld Comcoat N ( sometimes termed R Cu Zn-D. the high strength braze welding of steel and cast or bronze filler rod recommended for fluxing’ Nickel ‘self Silver) is a malleable irons. of Nick welding of Copper based alloys of similar composition and for the brazing It is also an excellent choice for the fusion ▲ ▲ ▲ ▲ ▲ www.cigweld.com.au 208 GAS AND TIG WELDING CONSUMABLES www.cigweld.com.au .For thick platebeveledges60 Thoroughly cleanallareastobejoinedorrebuiltofforeignmaterial. 2. Allowtocoolandremovefluxresiduewithawirebrush. 1. Gas Tungstenfor (TIG): ArcProcedure Welding 8. Heataspotonthebasemetaluntilitshowssignsofmeltingand progressivelyaddthefillerrod Diptheheatedendofrodintoflux. 7. 6. Generallypreheatisnotrequiredbecauseofthelowermeltingpointandlowthermal 5. .Heataspotonthebase metaluntilitshowssignsofmeltingandprogressivelyaddthefillerrod UseDirectCurrentElectrode Negative(DC-)and Welding Grade Argon. 5. 4. groundtoasharpneedlepointmakingsurethe Usea Thoriated orCeriatedtungstenelectrode, 3. .For thick platebeveledges60 Adjusttheflametoneutralorslightlyoxidising(excessoxygen). For bestresultsuseCOMWELDCopperandBrassflux(321822). 4. Thoroughly cleanallareastobejoinedorrebuiltofforeignmaterial. 3. 2. 1. Procedure forBraze Welding: valves, andisalsousedonhotwater systemapplications. gearwheels, shafts andpumps, naval brassfittings, includingpropellers, repairandfabrication, required suchasmarineengineering, COMWELD SiliconBronzeisusedextensivelyinapplicationswheresuperiorcorrosionresistanceandtensilestrength Anarrowhot-shortrange(800 The deoxidisingeffectofthesiliconandglassy skinformedbyitsoxide. Lowthermalconductivity(hencepreheatisnotnecessary). 3. 2. 1. Outstanding features ofthisalloyare: also tosteel. extruded sectionbasemetalstothemselvesand tubeand copper-silicon andcopper-zinc sheet, brass, producing excellentjointsoncopper, siliconbronzefillerrod general purpose, COMWELD SiliconBronzeisapremiumquality, C65600). RCuSi-A(UNSNo. RCuSi-A. AWS/ASME-SFA A5.7: AS 1167Parts 1&2: ▲ ▲ ▲ Description and Applications: Classifications: COMWELD SILICONBRONZEROD CANARY YELLOW End Tip Colour.CANARYEnd Tip YELLOW (Everdur andCusilman). Suitable for Welding Si-Bronze Silicon -Bronze alloy. Premium QualityDeoxidised otewl ol Ensurethattheweldpoolisassmallpossible to theweldpool. conductivity. otewl ol Ensurethattheweldpoolisassmallpossible. to theweldpool. point shouldbeapproximately2-3xthediameteroftungstenelectrode. The lengthoftheneedle grinding linesrunwiththelength(longitudinally)ofelectrode’s axis. ° ° ° -90 -70 C-950 ° ° included angle. included angle. ° C) justbelowsolidus. i .0 n .0 n 0.90% Zn: 90HV(90HB) 0.02% Pb: 0.90% Sn: 1.00% Mn: Balance 8.85gms/cm Cu: 3.40% Si: 0.25% Fe: TYPICAL ROD ANALYSIS: Hardness 970–1020 370MPa. Weld MetalDensity Approximate MeltingRange Weld Metal Tensile Strength TYPICAL WELD DEPOSITPROPERTIES: (TIG). Gas (FusionandBraze) Tungsten Arc Welding JOINING PROCESS: Packaging Data: . 5 k ak1 321295 19 5kgPack 3.2 x750 o iePc prxPart No Approx Pack Rod Size m)Wih/yeRods/kg Weight/Type (mm) 890 C ° ° C 3 GAS AND TIG WELDING CONSUMABLES 209 www.cigweld.com.au 210 SOLDERS AND FLUXES 211 221 216 214 Page No Page SOLDERS AND AND SOLDERS FLUXES Description Mate Solder KitComweld Metal Comweld Aluminium Flux 215 Comweld 40/60 Soft Solder 40/60 Soft Comweld Soft SolderComweld 50/50 Solder Comweld 965 and Brass FluxComweld Copper Flux No.Comweld Silver Brazing 2Comweld G.P. Silver Brazing Flux FluxComweld 965 Soldering VAPAFLUX Comweld 212 213 217 218 219 220 www.cigweld.com.au 270° COMWELD 40/60 SOFT SOLDER 10.1% C ▲ General Purpose Low Cost Solder. COLOUR CODE & IDENTIFICATION: ▲ For Sheet Metal & Plumbing Cored Wire Reels — Green label Applications. Sticks — marked 40/60 ▲ Wide Range of Packaging Options. Handipack (H/P) Coil, Yellow backing card and label. JOINING PROCESS: Soldering only. Classifications: SOLDERING IRON bit temperature: 294°C. AS 1834 Part 1 40Sn. TYPICAL ROD ANALYSIS: Sn: 40% (Tin) Pb: 60% (Lead) Description and Applications: SOLDERS AND FLUXES TYPICAL PROPERTIES: COMWELD 40/60 Solder is a low cost general Tensile Strength 42 MPa purpose solder for general sheet metal work, Shear Strength 37 MPa plumbing (not water pipes) such as gutters and Approximate Melting Range 183–234 C flashings and automotive radiator repairs. Other ° general applications include the soldering of very Electrical Conductivity 10.1% IACS light gauge tin coated plate (tin plate) the joining of lead based alloy pipe, the trophy & medallion industry and model making & hobby areas. Packaging Data: Rod/Wire Size Pack Part No Procedure for Soldering: (mm) Weight/Type 1. Thoroughly clean all areas to be joined of 12 x 6 x 400 foreign material. (W x B x L) 250g Stick 322305 2. Apply COMWELD 965 Soldering Flux (321890) to the work area. If using flux cored solder 3.2 250g Acid core Wire 322313 this will be automatic at step four (4). 3.2 500g Acid core Wire 322318 3. Heat the work surfaces directly by the use of a soldering iron or indirectly by the use 1.6 15g Resin core H/P 322220 of a soft gas flame, such as LPG. Do not overheat. 4. Apply solder to the work area. The molten solder should easily flow and be evenly dispersed in the joint area. Do not over fill with solder. 5. Remove heat source and allow to cool naturally until solder returns to a solid state. 6. Remove all flux residues with water.

Acid Cored & Resin Cored! What are the Differences? COMWELD ‘RESIN-CORED’ solder wire is suitable for safe use on electrical and electronic work such as computers, video recorders, televisions, telephone and telecommunications equipment and other consumer goods without the need to remove the flux residue. The RESIN residue remaining after soldering is non-corrosive and non-conductive and as such means that there cannot be any damage to delicate electrical wires and no new electrical paths can form to cause short-outs or electrical malfunction of the equipment.

The flux inside COMWELD ‘ACID-CORED’ wires does not actually contain acid, but the name is given to this flux because it has been formulated to provide a higher level of chemical cleaning action and fluxing activity needed to remove oxide and oxide skins from hard to solder metals such as heavily tarnished copper, copper alloys and difficult materials such as stainless steels that the relatively mild RESIN type flux could not cope with. The flux residues of the ACID-CORED wire are to some extent corrosive and, as such should not be used for electrical work. If possible we recommend that the residues be washed off with water (preferably warm) after soldering.

212 www.cigweld.com.au SOLDERS AND FLUXES SOLDERS AND 10.9% 212° COMWELD 50/50 SOFT SOLDER C ▲ Higher Quality General Purpose COLOUR CODE & IDENTIFICATION: Solder. Cored Wire Reels — Orange Label ▲ For Electrical & Electronic Sticks — marked 50/50. Applications. JOINING PROCESS: ▲ Wide Range of Packaging Options. Soldering only. SOLDERING IRON bit temperature: 272°C. Classifications: TYPICAL ROD ANALYSIS: Sn: 50% (Tin) Pb: 50% (Lead) AS 1834 Part 1 50Sn. TYPICAL PROPERTIES: Tensile Strength 45 MPa Description and Applications: Shear Strength 40 MPa COMWELD 50/50 Solder is a higher quality general Approximate Melting Range 183–212°C purpose solder for general sheet metal work, and Electrical Conductivity 10.9% IACS plumbing (not water pipes) applications where better free flowing characteristics are important. The Resin Cored COMWELD 50/50 solder is Packaging Data: especially suited for electrical and electronic work where residues which remain after soldering are Rod/Wire Size Pack Part No non-corrosive and non-conductive. (mm) Weight/Type 12 x 6 x 400 Procedure for Soldering: (W x B x L) 250g Stick 322306 1. Thoroughly clean all areas to be joined of 3.2 250g Solid Wire 322310 foreign material. 2. Apply COMWELD 965 Soldering Flux 250g Acid Core Wire 322317 1.6 (321890) to the work area. If using flux 250g Resin Core Wire 322319 cored solder this will be automatic at step four (4). 3. Heat the work surfaces directly by the use of a soldering iron or indirectly by the use of a soft gas flame, such as LPG. Do not overheat. 4. Apply solder to the work area. The molten solder should easily flow and be evenly dispersed in the joint area. Do not over fill with solder. 5. Remove heat source and allow to cool naturally until solder returns to a solid state. 6. Remove all flux residues with water.

Acid Cored & Resin Cored! What are the Differences? COMWELD ‘RESIN-CORED’ solder wire is suitable for safe use on electrical and electronic work such as computers, video recorders, televisions, telephone and telecommunications equipment and other consumer goods without the need to remove the flux residue. The RESIN residue remaining after soldering is non-corrosive and non-conductive and as such means that there cannot be any damage to delicate electrical wires and no new electrical paths can form to cause short-outs or electrical malfunction of the equipment.

The flux inside COMWELD ‘ACID-CORED’ wires does not actually contain acid, but the name is given to this flux because it has been formulated to provide a higher level of chemical cleaning action and fluxing activity needed to remove oxide and oxide skins from hard to solder metals such as heavily tarnished copper, copper alloys and difficult materials such as stainless steels that the relatively mild RESIN type flux could not cope with. The flux residues of the ACID-CORED wire are to some extent corrosive and, as such should not be used for electrical work. If possible we recommend that the residues be washed off with water (preferably warm) after soldering.

www.cigweld.com.au 213 270° COMWELD 965 SOLDER (SOFT SILVER SOLDER) 17% C

▲ Highest Strength Soft Solder. COLOUR CODE & IDENTIFICATION: ▲ Lead, Zinc and Cadmium Free. Blue Labels and backing cards. ▲ Non Toxic Solder For Electrical, JOINING PROCESS: Surgical and Food Equipment Soldering only. Applications. SOLDERING IRON bit temperature: 281°C. ▲ Wide Range of Packaging Options. TYPICAL ROD ANALYSIS: Sn: 96.5% (Tin) Ag: 3.5% (Silver) Classifications: TYPICAL PROPERTIES: Tensile Strength 60 MPa AS 1834 Part 1 96.5Sn / 3.5Ag. 3 SOLDERS AND FLUXES Density 7.5g/cm Approximate Melting Point 221°C Description and Applications: Electrical Conductivity 17% IACS COMWELD 965 Solder is a tin / silver eutectic solder which has the highest strength of all soft solders. Due to it’s high strength, good electrical Packaging Data: and thermal conductivity, non toxicity (lead, zinc Rod/Wire Size Pack Part No and cadmium free) and also the fact that it (mm) Weight/Type remains bright and shiny, make COMWELD 965 Solder the most universal of soft solders. 3.2 250g Solid Wire 322320 Comweld 965 Solder is used for the joining and 500g Solid Wire 322321 repair of copper, bronze, brass, nickel, monel, steel, stainless steel, pewter, chrome plate, metal 1.6 250g Acid Core Wire 322324 sculpture, model making, costume jewellry and 15g HandiPack Coil 322221 or a combination of metals with the exception of Acid Core Wire aluminium and magnesium. It is used in the manufacture and repair of refrigeration, air conditioning, heating, surgical and food equipment and for reliable electrical connections subject to high service stresses and temperatures. Comweld 965 Solder is often preferable due to its much lower melting point then silver brazing alloys, which eliminates the need for excessive heating during joining. Non Toxic Solder.

Procedure for Soldering: 1. Thoroughly clean all areas to be joined of foreign material. 2. Apply COMWELD 965 Soldering Flux (321890) to the work area. If using flux cored solder this will be automatic at step four (4). 3. Heat the work surfaces indirectly by the use of a soldering iron or by the use of a soft gas flame, such as LPG or Air-Acetylene. 4. Do not overheat. 5. Melt off small amount of alloy and play the flame onto the solder until it flows into the joint and bonds. 6. Continue until joint is complete. 7. Remove all flux residues with water. Acid Cored Wire! Does it contain Acid? The flux inside COMWELD ‘ACID-CORED’ wires does not actually contain acid, but the name is given to this flux because it has been formulated to provide a higher level of chemical cleaning action and fluxing activity needed to remove oxide and oxide skins from hard to solder metals such as heavily tarnished copper, copper alloys and difficult materials such as stainless steels that the relatively mild RESIN type flux could not cope with. The flux residues of the ACID-CORED wire are to some extent corrosive and, as such should not be used for electrical work. If possible we recommend that the residues be washed off with water (preferably warm) after soldering.

214 www.cigweld.com.au SOLDERS AND FLUXES 215 ° C 234 321690 % 17 3 C C. ° ° 14mr bottle of coiled around a 965 Soldering Flux 1.6mm x 14g Solid Wire 1.6mm x 14g Solid 1.6 (mm) Weight/Type Rod/Wire SizeRod/Wire Pack No Part Packaging Data: Packaging Electrical Conductivity 17% IACS IDENTIFICATION: Jar,Clear Plastic Blue Print. White Label with White Lid & JOINING PROCESS: Soldering only. temperature:SOLDERING IRON bit 281 ANALYSIS: TYPICAL ROD Sn: (Tin) 96.5% TYPICAL PROPERTIES: StrengthTensile Density Ag: 3.5% (Silver) 60 MPa 7.5g/cm Approximate Melting Point 221 such as LPG or Air-Acetylene. such as LPG or bonds. advisable to protect your skin from contacting this flux. If contact is made with the skin, wash as soon as possible. under cold water Highest Strength Soft Solder. Strength Highest Lead, Free. Zinc and Cadmium Electrical, For Solder Toxic Non Equipment and Food Surgical Applications. COMWELD METAL MATE SOLDER KIT SOLDER MATE METAL COMWELD Description and Applications: Description and Classifications: AS 1834 Part 1AS 1834 Part a COMWELD Metal Mate Solder Kit contains 96.5Sn / 3.5Ag. with a 14 gram 965 solid solder coil complete Flux 14 mr bottle of COMWELD 965 Soldering suitable which provides a very compact package for the for all of the applications recommended standard Comweld 965 Soft Solder. COMWELD 965 Solder is a tin / silver eutectic all soft solder which has the highest strength of solders. high strength, Due to it’s good electrical and thermal conductivity, non toxicity (lead, zinc it and cadmium free) and also the fact that remains bright and shiny, COMWELD 965 make Solder the most universal of soft solders. and Comweld 965 Solder is used for the joining repair of copper, bronze, brass, nickel, monel, of metals with the exception of aluminium and magnesium. costume jewellry and or a combination steel, stainless steel, pewter, chrome plate, of refrigeration,It is used in the manufacture and repair metal sculpture, model making, air conditioning, heating, surgical and food equipment and for high service stresses and temperatures. reliable electrical connections subject to due to its much lower melting point then silver brazing alloys,Comweld 965 Solder is often preferable which eliminates the need for excessive heating during joining. Solder. Toxic Non for Soldering: Procedure 1.2.3. areas to be joined of foreign material. clean all Thoroughly Apply COMWELD 965 Soldering Flux to the work area. by the use of a soft gas flame, Heat the work surfaces indirectly by the use of a soldering iron or 4.5. Do not overheat. solder until it flows into the joint and Melt off small amount of alloy and play the flame onto the 6.7. Continue until joint is complete. with plenty of cold water. Remove all flux residues immediately after soldering by washing It is ▲ ▲ ▲ www.cigweld.com.au 216 SOLDERS AND FLUXES www.cigweld.com.au iuenti cddpfloe ycl ae is,thenahotwater rinseorwirebrushwithhotwater orsteam. Dilute nitricaciddipfollowedbycoldwater rinse, Flux Removal: water oralcoholtoforma The fluxcanbemixedwithmethylatedspirits, thin pastewhichcanbeappliedtotherodorworkingareabymeansofapaintbrush. Neversprinklefluxoverthejob. heated fillerrod. orbypickingupasmallquantityontheendof Apply fluxsparinglytothecleanedsurfaceofjointinpasteform, Procedure: AL4043 (5%Silicon)and AL5356 (5%Magnesium). AL1188(Pure), COMWELD Aluminium Fluxisrecommendedforusewiththe followingCOMWELD Aluminium weldingrods, number ofdifferenttypesaluminiumweldingfluxesbeingstocked tohandledifferent typesofaluminiumweldingalloys. Iteliminatestheneedfora COMWELD Aluminium Fluxisanallpurposefluxforfusionwelding sheetandcastaluminium. White Powder inaBlackPlasticJar. ▲ ▲ Description and Applications: Identification: FLUX COMWELD ALUMINIUM Form. Useable ineitherPowder orPaste Alloys. Fusion WeldingFor Aluminium akWih/yePartNo 321740 250 gramBlackPlasticJar Pack Weight/Type ETN ON:545 MELTING POINT: Packaging Data: 545 C ° ° C SOLDERS AND FLUXES 217 C ° ° C 645 Packaging Data: Packaging MELTING POINT:MELTING 645 Pack Weight/TypePack 250 gram Black Jar 321822 No Part For Universal Braze Welding Welding Braze Universal For Applications. or Paste Powder Useable in either Form. Description and Applications: Description and Identification: COMWELD COPPER & BRASS FLUX & BRASS COPPER COMWELD Pink Powder in Black Plastic Jars or Drums. in Black Plastic Jars Pink Powder developed for the braze welding of copper,COMWELD Copper and Brass Flux is specially and bronze and the brazing of brass copper, steel, etc. Bronze, and Brass Flux is particularly suitable for use with COMWELD Manganese COMWELD Copper Tobin Bronze, Bronze and Silicon Bronze rods. Nickel Procedure: parts to be brazed must be clean with all traces of paint,The oil and grease removed. into Dip the heated end of the filler rod flux as required. applied to rod and work before commencing. into a creamy paste and mixed with water Flux may be then apply the fluxed rod.until both edges of the joint begin to melt Wait the rod Continue by melting each edge of the joint and simultaneously. Flux Removal: or wire brush with hot water,Wire brush cup wheel (on an angle grinder) or dilute hydrochloric acid or nitric acid dip, rinse. followed by a water ▲ ▲ www.cigweld.com.au 218 SOLDERS AND FLUXES www.cigweld.com.au Hot dilutedcausticsodadiporwirebrushwithhotwater orsteam. Flux Removal: Adequatefluxisessentialforproperaction. paint brushbeforecommencingtobraze. Applytowork androdwitha The partstobebrazedmustthoroughlycleanwithalltracesofoilandgreaseremoved. Procedure: The fluxisagoodtemperatureindicatorandwillmeltattheproperbrazingtemperature. Dissimilar metalsintheabovegroupscanbeeasilybrazed. nickel alloysandcopperbrass. stainlesssteel, carbon steel, 2andSilverBrazing Alloys withahighsilvercontent(42-50%)produceexcellentjointson COMWELD SilverBrazingFluxNo. White Paste ineitheraBlack/ White PlasticJar. ▲ ▲ Description and Applications: Identification: COMWELD SILVER BRAZINGFLUX No.2 Used inaPaste Form. Stainless Steels&DissimilarMetals. For SilverBrazing ofCarbonSteel, .k ht lsi a 321843 321841 PartNo 321840 3.5kg White PlasticJar 500 gramBlackJar 200 gramBlackJar Pack Weight/Type ETN ON:450 MELTING POINT: Packaging Data: 640 C ° ° C SOLDERS AND FLUXES 219 C ° ° C 645 Packaging Data: Packaging MELTING POINT:MELTING 485 Pack Weight/TypePack 200 gram Black Jar500 gram Black Jar JarWhite Plastic 3.5kg 321850 No Part 321851 321853 For Silver Brazing of Steel, Brazing Silver For Nickel, Brass, Bronze, Copper, and Steels. Stainless Form. Used in a Paste Description and Applications: Description and Identification: COMWELD G.P. SILVER BRAZING FLUX BRAZING G.P.COMWELD SILVER COMWELD General Purpose Silver Brazing Flux is recommended for use with Cadmium bearing and Cadmium free silver COMWELD General Purpose Silver Brazing content (2-40%).brazing alloys with a low to medium silver medium to high temperature brazing It is an excellent flux for used for induction brazing.and has been specially formulated to be Purpose Silver Brazing Flux and the COMWELD General excellent joints on carbon steel,above mentioned silver brazing alloys produce stainless steel, alloys and copper and nickel brass. temperature. flux is a good temperature indicator and will melt at the proper brazing The Procedure: grease removed. parts to be brazed must be thoroughly clean with all traces of oil and The work and rod with a Apply to paint brush before commencing to braze. Adequate flux is essential for proper action. Flux Removal: or steam. with hot water Hot diluted caustic soda dip or wire brush ▲ ▲ Jar. White Plastic a Black / in either White Paste www.cigweld.com.au 220 SOLDERS AND FLUXES www.cigweld.com.au rmcnatn hsfu.I otc smd ihtesi,wash undercoldwater assoonpossible. Ifcontactismadewiththeskin, from contactingthisflux. Itisadvisabletoprotectyourskin Remove allfluxresiduesimmediatelyaftersolderingbywashing withplentyofcoldwater. Flux Removal: required. COMWELD 965issoldinhandysqueeze-typebottleswhichenablestherightamountoffluxtobedepositedwhenandwhere Procedure: 4 partswater. maybedilutedifrequiredintheratio1partfluxt etc. bronze, brass, ifusedoncopper, It isaveryactivefluxandtherefore, almost allmetalsandcombinationsofmetals. enablesexcellentjointstobemadeon whenusedinconjunctionwith COMWELDSoftSolders, COMWELD 965SolderingFlux, Pink LiquidinBlackPlasticBottlesandDrums. ▲ ▲ ▲ Description and Applications: Identification: COMWELD 965SOLDERINGFLUX Used inaLiquidForm Only. Flux. Highest Quality Australian Made Solders. For UsewithallComweldSoft ir ote321894 321890 PartNo 1 litreBottle 125 mrBottle Pack Weight/Type Packaging Data: o SOLDERS AND FLUXES 221 C d. ° Packaging Data: Packaging FLASH POINT FLASH POINT CUP): CLOSED (TRUE Volume/TypePack Plate CanTin 19 litre 17 321885 No Part For Braze Welding of Steel. Welding Braze For & Comweld Manganese Used with Rods. Bronze Nickel Only. Form Used in a Liquid Identification: Applications: Description and COMWELD VAPAFLUX COMWELD Clear Liquid in a Tin Plate Can. Tin Clear Liquid in a time saving method of applying flux when braze welding steel. provides an effective and Vapaflux COMWELD It is intended (the flux in the flame) and will impart a high fluidity to the bronze when deposite in the flame itself to be applied as vapour dip for the flux, method prevents loss of time in removing the rod from the work to This and saves the fuel gas and oxygen consumed while dipping for flux. cut production time and defects. It is particularly effective for production brazing and will powder which is usually necessary with ordinary is the elimination of the costly after-cleaning One of the major advantages flux use. Bronze rods. for use with COMWELD Manganese Bronze and COMWELD Nickel It is recommended Procedure: Dispenser which Vapaflux for best results when used with the COMWELD has been specially formulated Vapaflux COMWELD to the flame.delivers the correct quantity from the blowpipe It is not suitable for direct application. Flux Removal: or coated with synthetic enamels,Where the welds are to be chrome plated the flux residue should be removed prior to treat- ment. containing 5% phosphoric acid. in water Quench the joint will prevent rusting. This usual method of wire brushing The joint surface. may be employed to clean the water with warm ▲ ▲ ▲ www.cigweld.com.au 222 MISCELLANEOUS PRODUCTS 223 Page No Page MISCELLANEOUS PRODUCTS MISCELLANEOUS Description ChromeBright (Pickling Paste) (Pickling ChromeBright 224 www.cigweld.com.au CHROMEBRIGHT (PICKLING PASTE) ▲ For Removal of Weld Scale on QUALITY STANDARDS: Stainless Steel. Made in Australia under an approved Quality Assurance ▲ Easy to Use One Step Treatment, Management System to ISO 9002. Brush on then Rinse with Water TYPICAL CHEMICAL ANALYSIS: 15-90 minutes Later. HF: ≤ 50g/L HNO : ≤ 300g/L ▲ 3 Thickened Paste Allows For Vertical CH3COOH: ≤ 30g/L Use. H2O and Others (dye, thickener etc): Remainder ▲ PALE Purple Coloured Paste for Easy I.D. Identification: Packaging Data: ChromeBright is supplied in a white plastic bottle, Pack Weight/Type Part No with a blue coloured label and lid. The 2.5kg plastic bottle is packed inside a blue and white 2.5kg White Plastic Bottle 321918

MISCELLANEOUS PRODUCTS printed cardboard carton which contains a quality acid resistant application brush.

Description and Applications: All stainless steel welding processes usually give rise to a brown or black oxide film adjacent to the weld. The discolouration must be removed to restore the attractive appearance of the steel and a convenient method of doing this is to use ChromeBright Pickling Paste. ChromeBright is a thickened pickling paste, pale purple in colour for use with all grades of stainless steel. ChromeBright is used to remove the black oxide marks or weld scale created during the welding and brazing of stainless steel. ChromeBright is also used to clean rust stains, various oxide films and the discolouration of weathered stainless steels to ensure the steel maintains its bright appearance. When used correctly ChromeBright applied to the weld or surrounding area will produce a uniform and pleasing matt surface appearance.

Safety Precautions: The pickling operation must take place outdoors or in a well ventilated area because during the pickling operation, there is a risk of gas emission (mainly nitrous gas) which is dangerous to inhale. When working with ChromeBright pickling paste, individuals should be equipped with chemical resistant rubber gloves, rubber boots, rubber apron and a full face covering chemical resistant faceshield. In cases where a closed vessel has to be pickled on the inside, it is essential that good ventilation be provided, and that operators wear respirators equipped with an ABE-AUS filter of the “acid gases” type. Neoprene and Natural Rubber gloves and aprons offer the best protection.

Bottles containing ChromeBright must be stored in an upright position and must always be carefully closed. The paste should be kept beyond the reach of children. ChromeBright is very aggressive and must be handled with great caution. If an accident does occur and paste splashes onto the skin or into the eyes, the affected area must be immediately and continuously rinsed with large volumes of running water. Use Calcium Gluconate gel and or tablets as required. Seek immediate medical attention. Inform the doctor or medical attendant that the paste contains nitric and hydrofluoric acids.

Recommendations for Neutralising ChromeBright Residues: As the active pickling paste components are nitric acid and hydrofluoric acid, the best neutralising agents are limestone or hydrated lime. While hydrated lime is the more efficient agent, it has the disadvantage of tending to block drains and pipes. The active acids combine with limestone to form nitrate of lime and calcium fluoride. Neutralising 1 kilogram of pickling paste requires approximately 0.5 kilogram of limestone.

224 www.cigweld.com.au MISCELLANEOUS PRODUCTS CHROMEBRIGHT (PICKLING PASTE) CONT. .

Procedure for Pickling:

1) Using a stainless steel wire brush, 4) Using the brush provided, apply thoroughly clean the work piece of a thin layer of ChromeBright to loose weld scale, welding slag and the work piece and all other areas other foreign material. to be cleaned. 5) The paste should be applied for between 15 – 90* minutes before removal. 2) Before opening the plastic bottle, shake for approximately 6) Wearing protective clothing, rinse 20 seconds to form a consistent the pickled surface carefully with gel paste. water, whilst using a hard nylon bristle brush, stainless steel wool or Scotch-Brite pads to remove all 3) Do not apply ChromeBright traces of weld scale. to the work piece until the surface is cool.

WARNING: Local liquid trade waste requirements may require the pickling paste residue to be neutralised before disposal. See CIGWELD’s recommendation for neutralising Chrome Bright residues.

Application Times: Application time will depend upon the welding process and thickness of plate being welded. e.g.: Gas Tungsten Arc (GTAW,-TIG) and Gas Metal Arc (GMAW,-MIG) will require less time than Manual Metal Arc (MMAW,-Stick) welding. Likewise 10mm plate will require more time than 1.6mm plate. A bottle (2.5kg) of ChromeBright will pickle approximately 100 metres of weld depending on the thickness of the layer applied. For pickling sheets of stainless steel, using a thinner layer, approximately 15 square metres can be treated with one bottle of ChromeBright.

www.cigweld.com.au 225 226 TECHNICAL AND TRADE INFORMATION 227 yalty. terial GP 6 GP 399 229 228 254 286 233 243 286 249 276 370 392 12.9.112.9.2 of Steel... Welding 12.9.3 of Stainless Steel... Welding 12.9.4Aluminium... of Welding 12.9.5 of Cast Iron... Welding 12.9.6Alloys... of Copper & Copper Welding of Dissimilar Metals... Welding 310 357 320 348 368 12.2 joints... Basic types of welded 12.10 Hardfacing Information... 12.1 & Definitions... Terms 12.312.4 & Symbols... Positions Welding 12.5 Defects in welding... 12.6 Distortion, causes & control... 12.7Welding... Safety in 12.8Tables... Consumables Classification 12.9 Shielding Gas Information... Guide... Welding 237 258 12.11 Deposition Data... 12.12 & Figures... Facts Technical Technical and Trade Information... Trade and Technical TECHNICAL AND TRADE TRADE AND TECHNICAL INFORMATION Notice about the Technical Information and Copyright in this section. Technical Notice about the CIGWELD Pty. Ltd. A.B.N. CIGWELD printed material to be used as an aid in 56 007 226 815 authorise the use of the following educational training and teaching. authority recognises that this printed material may be reproduced by printing or other means,This or otherwise in whole electronic or in part for educational purposes only. the original document from which this ma When reproduced material is printed or copied in whole or in part CIGWELD require that or references. reproduced to be named in credits was is not misleading and that all associatedWhere material is reproduced in part every effort shall be made to ensure that the extract safety information is included. CIGWELD does not authorise the reproduction of this material, electronic or otherwise, for sale or commercial use by competitors or other companies. like use of CIGWELD printed material,The reproduced in print or other forms for commercial use, may be subject to the payment of a ro www.cigweld.com.au 228 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au gives animpact-strengthvalue in (weightofpendulumxheightuponreleasetowhichswings afterstrikingspecimen) the test, Measuringtheenergyabsorbedduring supported atbothendsandstruckwithapendulumonthesideoppositenotch. Notch (CVN)orCharpy Test point bringsthespecimentoanothercritical- Anincreaseinloadaftertheyield thespecimencontinuestoelongatewithoutanincreaseinload. Beyond theyieldpoint, This propertyisassessedintermsof Determinedinatensiletest, hold anewshapeafterexternalforceshavebeenremoved. Ductility isthecharacteristicofmetalthatallowsittowithstandstretchingandotherdeformationwithoutbreaking Rockwell Hardness Typical unitsofmeasurebeing to ahardnessvalue. Indentsizeistranslated hardened steelballoradiamonduponthesurfaceofspecimenassignsvalue toametal’s hardness. Measuringtheindentsizeofa A metal’s hardnessisitscapacitytoresistsurfaceindentationbyacontactingmedium. its loadisincreasedgraduallyandthespecimenstretchesindirectproportiontountilitreache Duringthetest, in area. tensilestrengthandreductio yieldstrength, yieldpoint, elongation, a specimen revealsseveralfeatures-includingelasticlimit, understretchloading, Inatensiontest, isitscapacitytowithstandexternalforceswithoutbreaking. A metal’s “strength” Resistance. are frequentlycitedin Welding ConsumableSpecificationrequirements)are The properties consideredmostoften(andthosethat service characteristicsequaltoorbetterthanthoseofthebasemetal. Mechanical propertiesareoftheutmostconcerninweldingconsumablequalificationsincewelddepositsmustoftenprovide The mechanicalpropertiesofametaldescribeitssuitabilityforanygivenapplicationandprovide performanceforecast. MECHANICAL PROPERTIES OF WELD METAL tlwrtmeaue,impacttestsareoftencarriedoutatarangeoflowtemperatures. at lowertemperatures, cross-sectional areaofthespecimen. Yield pointandtensilestrengthvalues (inpsiorMPa) areobtainedbydividingtheloadatthesepointsorigina breaks. pcmn h nraei ag egh iie yteoiia egh 0,eul h lnainpretg.Ductilitycan equalstheelongationpercentage. also bemeasuredinabendtest. x100, dividedbytheoriginallength, The increaseingaugelength, specimen. onatest boundingthepointatwhichfracturewilloccur, Gaugemarksaremade50mm(2inches)apart, measure ofductility. .ImpactResistance 4. Ductility: 3. Hardness: 2. Strength: 1. . EXPLANATION . OF TERMS RELATING TO . Yield Poin .A n on pt h il on,i h odi eae,thespecimen willreturntoitsoriginaldimensions. iftheloadisrelaxed, Atanypointuptotheyieldpoint, t. (HR A ,HR h pcmn emwt oc tiscnr “-oc”peaaini otcmo) is preparationismostcommon), abeamwithnotchatitscentre(“V-notch” The specimen, . B & HR joules orfoot-pounds Impact Strength orImpact Toughness C Scales), Vickers Hardness Tensile Strength Sincesteelsoftenbecomemorebrittle(lessabletoabsorbenergy) . (HV or , 20 & HV Ultimate TensileStrength tegh ades DuctilityandImpact Hardness, Strength, determinedmostoftenina , 30 Scales) and Percent ofElongation Brinel Hardness - atwhichthespecimen Charpy Vee . is the s l n TECHNICAL AND TRADE INFORMATION 229 Also known as “Base Material”Also known as Piece”. Work or of two plates. material to achieve a required dimension. Also known as “Buttering” “Cladding”. and crack formation or dilution effects in subsequent weld layers. up”. “build See also finished weld. because of magnetic forces.because of on Normally occurs steel. when welding carbon DC current surface of the weld electrode to the adjacent pool. Gap”. “Arc Also known as making an arc weld. welded joints and weldments after welding, but prior to any subsequent thermal, mechanical or chemical treatments. “Back Filling”Also known as “Backing Pass” or to from the weld root side of a welded joint allow complete fusion and complete joint that side. penetration upon subsequent welding from a joint during welding to help obtain a sound weld. used in pipe welding. Base MetalAngleBevel metal alloy that is being welded. The Build up between the prepared edges angle formed The Buffer Layer Layers of weld metal deposited when surfacing Consumableinsert on components which prevent Layers of weld metal Preplaced filler metal that is completely fused the into the root of a joint and becomes part of Autogeneous WeldAutogeneous Back bead A fusion weld made without filler metal. Backgouging a back weld pass. A weld resulting from metal and base metal of weld removal The Backing StripBacking Ring A material (metal, carbon, ceramic etc.) for backing up BackstepSequence As above,the form of a ring, but in generally passes are made in the opposite direction Weld to the progress of welding. Arc BlowVoltageArc path deflection of an arc from its normal The Arc Length the welding arc. voltage across The TimeArc distance from the tip of the welding The As-welded time during which an arc is maintained in The to the condition of weld metal, Pertaining ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ A. C. B. TERMS AND DEFINITIONS IN WELDING IN DEFINITIONS AND TERMS www.cigweld.com.au 230 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au TERMS AND DEFINITIONS IN WELDING CONT. G. E. I. H. F. D. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ uinThe meltingtogetheroffillermetalandbase Fusiblematerialforremoval ofoxidesimpuritiesand electrodeholder. Fusion Conductorbetweensourceofcurrentand The surfacepreparedon the edgeofajointfor Flux welding. Lead Electrode AlsoknownasDC+orDCEPand machine. connectedtothepositivepoleonwelding Preparation Edge The electrodeleadandweldingare DCstraightpolarity(Negative=1/3Heat) AlsoknownasDC-orDCENand machine. connectedtothenegativepoleonwelding The electrodeleadand weldingelectrodeare Positive Electrode Direct Current Achemicalcomposition changeofthedepositedweld Negative Electrode fromthesurfacebeingwelded. Current Direct Distancethatfusionextendsintothebasemetal time. Dilution The weightofmaterialdepositedinaunit Fusion Depth of depositedintheweldmetaltoweightof The ratiooftheweightfillermetal Rate Adepressionattheterminationofweldbead. Deposition Efficiency Deposition Crater edn recurringunweldedspaces. Isweldingwhereincontinuityisbroken by 770to12,000nanometers. Electromagneticenergywithwavelengths from butwhosemechanicalpropertiesor hasnotmelted, Welding Intermittent Radiation The regionbeneathoraroundtheweldbeadwhich Infra-Red The processofcoveringasurfacewith Zone Heat affected The electricalconductorbetweenthearc Hardfacing Ground Lead metal orabaseonlytoproduceweld. to creategasforshieldingandslagshapecontour. (Positive =2/3Heat) DC reversepolarity. metal duetoadmixtureofthefillerandbasemetal. expressedinpercent. filler metalmelted, microstructure hasbeenalteredbytheheatofwelding. wear-resistant metalbyweldingtoreducewear. Alsoknownas “Work Lead”. connection. welding currentsourceandworkpiece TECHNICAL AND TRADE INFORMATION 231 tightness against leakage. preparation of a butt weld. Normally measured 25mm from the weld metal centre line. the weld metal centre measured 25mm from Normally alloy is completely liquid. one sided weld joint. welding is completed. welding commences. material that is free of external forces. Root Bend TestRunoff / RunonTab Weld A test in which the root surface is bent around WeldSeal a specified radius. additional plate that extends beyond the Is ArcShort is finished or started.Tab) End (Also known as an end of the weld joint on which the weld (short circuiting)transfer to seal a joint for A weld made primarily Sidewall short circuits. electrode is deposited during repeated Is metal transfer where molten metal from an Side BendTest the included inside surface of a joint wall The A test in which the side of a transverse section of specified radius. the weld is bent around a Parent MetalParent PeeningPenetration“Base Metal”. Same as Post-heating mechanical working of metals by light hammering. The from the metal surface depth a weld extends into a joint The Preheating Application of heat to the weldment after ProcedureQualification Application of heat to the base metal before Residual Stress method can meet prescribed standards. establish that welds made by a defined To Root Bead member or Stress that is present in a joint A weld which is part or all of the root joint. InterpassTemperatureLiquidus of deposited metal before the next pass is started. a multiple run weld, In the lowest temperature LongitudinalSequenceMelt-Through or an at which a metal lowest temperature The order in which weld passes of a continuous The Open Circuit weld are made along its length. Voltage root re-inforcement obtained in a Is the visible terminals of a power voltage between The source when no current is flowing. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ L. O. S. R. M. P. TERMS AND DEFINITIONS IN WELDING CONT. WELDING IN DEFINITIONS AND TERMS www.cigweld.com.au 232 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au TERMS AND DEFINITIONS IN WELDING CONT. V. U. W. T. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ edn r Acontrolledelectrical dischargebetweenthe Writtenverificationthatawelderhasproduced weldsmeetingaprescribedstandardofweld Welding Arc Aweldbeadmadewithslowoscillationmotion Certification Welder Welding inanuphilldirection. Weave Bead Welding inadownhilldirection. Adepressionontheweldfacedroppingbelow Vertical-up maynotextendtothesurfaceofbasemetal. Vertical-down Acrackintheheataffectedzonewhichmayor Underfill Asmallweldmadetoholdpartsinproper Crack Aconcaverootsurface. Underbead Aweldbeadmadewithoutweaving. Tack Weld Suck-Back Metaltransferwheremoltenmetalfroman Metalparticlesexpelledduringweldingwhich Stringer Bead Spray Transfer Non-metallicsolidmaterialtrapped inweld Spatter Slag Inclusion okPeeTejb partorcomponent beingwelded. The job, The conductorbetween sourceofcurrentand Work Piece Work Lead Welding ProcedureSpecification(WPS) Welding ProcedureQualificationRecord(WPQR) odciemdu,calledanarcplasma. conductive medium, sustained bytheestablishmentofagaseous electrode andtheworkpiecethatisformed performance. diameter oftheelectrode. bestlimitedinwidthto2-3timesthe of theelectrode, the surfaceofbasemetal. alignment untilfinalweldsaremade. electrode ispropelledacrossthearcinsmalldroplets. do notformpartoftheweld. metal orbetweenweldandbasemetal. the workpieceortable. reproduction bytrainedwelders. a specificweldingapplicationtoensure A documentprovidingthedetailedvariables for procedure specification. conducted onthatweldwhichqualifyawelding acceptable testweldandtheresultsoftests A recordofweldingvariables usedtoproducean TECHNICAL AND TRADE INFORMATION 233 OBTUSE ANGLE FILLET OBTUSE ACUTE ANGLE FILLET ACUTE TERMINOLOGY OF WELD JOINTS: TERMINOLOGY OF BASIC TYPES OF WELDED JOINTS: TYPES OF BASIC BASIC TYPES TYPES BASIC OF WELDED JOINTS www.cigweld.com.au TRUE MITRE CONCAVE CONVEX 234 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au BASIC TYPES OF WELDED JOINTSCONT. FILLET WELD DEFINITIONS: FILLET WELD BUTT WELD -PREPARATIONS: THICKNESS THROAT ZONE (H.A.Z) HEAT AFFECTED THROAT THICKNESS EFFECTIVE ≤ ROOT REINFORCMENT LEG LENGTH

WELD FACE DEPTH OFPENETRATION TOE TOE

PARENT M ≤

ETAL LEG LENGTH TECHNICAL AND TRADE INFORMATION 235

TOE PARENT METAL PARENT

DEPTH OF ROOT DEPTH OF ROOT BEAD "PENETRATION" WELD FACE WELD H.A.Z. DEPTH OF PENETRATION ≤ ≤ REINFORCMENT HEAT AFFECTED ZONE (H.A.Z) HEAT THROAT THICKNESS THROAT EFFECTIVE THICKNESS THROAT BASIC TYPES OF WELDED JOINTS CONT. JOINTS WELDED OF TYPES BASIC (i) BUTT WELD DEFINITIONS: (i) BUTT BUTT WELD - PREPARATIONS cont.: WELD - PREPARATIONS BUTT www.cigweld.com.au 236 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au . BASIC TYPES OF WELDED JOINTSCONT. OTHER WELDS: LGWLSSLOT WELDS PLUG WELDS TECHNICAL AND TRADE INFORMATION 237 ISO STANDARD 6947 ISO STANDARD AS 3545 STANDARD AUSTRALIAN AMERICAN WELDING SOCIETY AWS A3.0 ▲ ▲ ▲ WELDING POSITIONS AND SYMBOLS AND POSITIONS WELDING PLATE POSITIONS: PLATE PLATE AND PIPE PLATE TO POSITIONS AND AS/AWS ISO STANDARDS: AND PIPE WELDING PLATE TO POSITIONS ISO: www.cigweld.com.au 238 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au PIPE POSITIONS-FIXEDPOSITION: PIPE POSITIONS-ROTATED ORROLLED: WELDING POSITIONS AND SYMBOLSCONT. TECHNICAL AND TRADE INFORMATION 239 . WELDING POSITIONS AND SYMBOLS CONT. SYMBOLS AND POSITIONS WELDING COMPARISON OF BASIC DRAWING (PRINTS) WELDING SYMBOLS: (PRINTS) DRAWING OF BASIC COMPARISON WELDING DIRECTIONS OR POSITIONS: DIRECTIONS WELDING www.cigweld.com.au 240 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au COMPARISON OFBASIC DRAWING (PRINTS) WELDING SYMBOLScont.: WELDING POSITIONS AND SYMBOLSCONT. TECHNICAL AND TRADE INFORMATION 241 WELDING POSITIONS AND SYMBOLS CONT. SYMBOLS AND POSITIONS WELDING HOW WELDING SYMBOLS ARE USED: SYMBOLS WELDING HOW www.cigweld.com.au 242 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au WELDING POSITIONS AND SYMBOLSCONT. HOW WELDING SYMBOLS ARE USED cont.: USED SYMBOLS ARE HOW WELDING TECHNICAL AND TRADE INFORMATION 243 Incomplete penetration. cracking. Weld Misalignment. Joint Lack of fusion. ▲ ▲ ▲ ▲ eg: X-Ray or Ultrasonic testing. on the weld face or in previously deposited weld metal. on the weld face or in previously deposited eg: testing. and Magnetic Particle Dye Penetrant Slag inclusions. Porosity. Overlap or over-roll. Definition: A groove at the toe or root of a weld either EXTERNAL DEFECTS: by a visual inspection method Can be identified carelessness or lack of skill. operators Welding (Hot - Cold). Adverse working conditions or lack of preparation. Design Poor Undercut. - Too long an arc length . Too - - Excessive weaving of the electrode. fast a rate of travel. Too - Angle of electrode too inclined to the joint face. - INTERNAL DEFECTS: method a Non-Destructive testing (NDT) Require ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ (ii) Main Defects: (i) Main Causes : Causes: - Excessive amperage. Result: A stress concentration site and a potential site for fatigue Undercut: Types of Defects: Types DEFECTS IN WELDING IN DEFECTS www.cigweld.com.au 244 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Slag Inclusions: Overlap orover-roll: DEFECTS IN WELDING CONT. eut Slaginclusionsreducethecrosssectionalareastrengthof Result: -Failure toremoveslagfromprevious runs. Causes: Hasasimilareffectasundercutandproducesstressconcentrationsite Result: -Incorrectrateoftravel. Causes: ▲ ▲ weld andserveasapotentialsiteforcracking. - Faulty preparation. - Incorrectelectrodeangleorsize. - Insufficientamperage. due totheunfusedweldmetal. - Too lowanamperage. - Too largeanelectrodesize. - Incorrect “angle ofapproach”. eiiin Referstoanynon-metallic materialinacompleted Definition: Animperfectionatthetoeorrootofa Definition: the welddeposit. These inclusionscancreateaweakpointin weld joint. of theparentmetalwithoutfusingtoit. weld causedbymetalflowingontothesurface TECHNICAL AND TRADE INFORMATION 245 and the parent metal or between weld metal passes. Porosity can originate from wet electrodes, can originate from wet Porosity flux electrode impurities on the surface of the breaking down or from parent metal. Also known as ”Piping”, Holes” Worm “Blow or - Incorrect electrode for parent metal. - Inadequate gas shielding of the arc. metals with a high percentage of sulphur and phosphorus. - Parent Surface porosity can allow a corrosive atmosphere to attack the weld metal which may cause failure. Definition: A lack of bonding between the weld metal Definition: internally or externally in the weld. A hole or cavity found ▲ ▲ Result: Severely reduces the strength of the welded joint. Other Causes:- parent metal surface ie. Unclean oil, dust, dirt or rust contamination. Lack of Fusion: Porosity: DEFECTS IN WELDING CONT. WELDING IN DEFECTS www.cigweld.com.au 246 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Weld cracking: Incomplete Penetration: Lack ofFusioncont.: DEFECTS IN WELDING CONT. eut Weakens theweldedjointandbecomesapotentialfatigue Result: -Smallelectrodesusedoncoldandthicksteel. Causes: eut Weakens theweldedjointandbecomesapotentialfatigue Result: -Current toolow. Causes: ▲ ▲ eiiin Planar(Two Dimensional)discontinuitiesproducedbythe Definition: initiation site. - Too largeanelectrodesize. - Insufficientrootgap. initiation site. greaseetc.). dirt, - Uncleansurface(millscale, notallowingproperfusion. - Rateoftraveltoofast, - Incorrectelectrodeangleandmanipulation. - Insufficientamperage. eiiin Afailureoftheweldmetal Definition: to penetrateintotherootofjoint. There aremanytypesofcracks thatcanoccurinthebase fracturing whencold(coldshortness). occur ineithertheplasticcondition(hotshortness)orby Weld metalcrackingcan tearing ofparentorweldmetal. TECHNICAL AND TRADE INFORMATION 247 Hot cracking mainly caused by a failure to fill up Hot cracking mainly at the end of a weld pass. the crater depression inadequate weld metal in the Shrinkage stresses and cracking. crater causes crater usually in the Cold cracking that is (HAZ) of the parent metal. Heat-affected zone Usually a hot cracking phenomenon. Cracking runs along the length of the weld. (eg. Wrong consumable or welding current, inadequate preheat etc.) phosphorus tend to crack easily , so Hydrogen controlled electrodes are recommended. - Weld size may be too small for the parts being welded. Weld - content (over 0.45%). - Base metal may contain a high carbon of sulphur or - Metals which contain high percentages - Electrodes may be wet or damp. Crater Cracking: Crater Underbead Cracks: Longitudinal Crack: Main Causes: and techniques. - Incorrect welding procedures Some common types of cracking include: of cracking Some common types Weld crackingWeld cont.: DEFECTS IN WELDING CONT. WELDING IN DEFECTS CRACK TYPES: CRACK 1. CRACK CRATER 2. CRACK FACE 3. ZONE CRACK HEAT-AFFECTED 4. LAMELLAR TEAR 5. LONGITUDINAL CRACK 6. CRACK ROOT 7. CRACK SURFACE ROOT 8. CRACK THROAT 9. CRACK TOE 10. TRANSVERSE CRACK 11. UNDERBEAD CRACK 12. CRACK WELD INTERFACE 13. CRACK WELD METAL www.cigweld.com.au 248 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Misalignment: DEFECTS IN WELDING CONT. ass -Poor assemblyofthepartstobewelded. Causes: eut Misalignment isaseriousdefectsincefailuretomeltboth Result: ▲ - Inadequatetackweldsthatbreakorinsufficient Normallydefinedasanunnecessaryorunintentional are notplacedintheircorrectpositionforwelding. is producedwhentherootfacesofparentplate(orjoint) and Misalignment isacommonfaultinpreparedbuttwelds, Definition: in servicemayleadtoprematurefatiguefailureofthejoint. edges oftherootwillresultinstressconcentrationsiteswhich clamping thatresultsinmovement. variation inthealignmentofpartsbeingwelded. TECHNICAL AND TRADE INFORMATION 249 change shape. Angular Longitudinal Transverse Under very high load, be stressed to the point metals may shape or form where they will not return to their original “yield point”.and this point is known as the (YIELD STRESS) when cooled they As metals are heated they expand and contract. During welding, heating and cooling of metals and the metal occurs unevenly resulting in high stresses distorts. and contraction *Distortion is the result of uneven expansion of heated metals. Under light loading metals remain elastic (they return to Under light loading metals remain elastic has been their original shape or form after the load removed).“elastic range”. is known as the This ▲ ▲ ▲ ▲ ▲ ▲ A) The cause of distortion - when under load metals strain or move and cause of distortion - when under load The A) Distortion Types - the three main types of distortion are:- Types Distortion Distortion: DISTORTION, AND CAUSES CONTROL Distortion to some degree is present in all forms of welding.Distortion to some degree is barely noticeable, In many cases it is so small that it but in occur. for the distortion that will subsequently has to be made before welding commences other cases allowance is a brief outline of the subject. is very complex and the following study of distortion The (i) ANGULAR DISTORTION If these high stresses pass the elastic range and go over the yield point,If these high stresses pass the elastic range distortion of the metals will occur. some permanent A metals yield stress is reduced at high temperatures. www.cigweld.com.au 250 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au B) The DISTORTION(iii) TRANSVERSE (ii) LONGITUDINALDISTORTION Distortion: CAUSE AND CONTROLCONT.DISTORTION, Control ofdistortion (i) The controlofdistortion ▲ ▲ ▲ ▲ (iii) After welding (iii) After (ii) During welding (i) Before welding Pre-setting Uniform pre-heating clampsandfixtures Jigs, Tack Welding can bebroken upinto threeareas:- before welding canbefacilitatedby: TECHNICAL AND TRADE INFORMATION 251 welding can be facilitated by: during Backstep welding Intermittent “Chain” welding Intermittent “Staggered” welding Balanced sequence welding A correct welding procedure to reduce the size of the weld beads ▲ ▲ ▲ ▲ ▲ (ii) The Control of distortion The (ii) Distortion cont.: Distortion DISTORTION, CONT. CONTROL AND CAUSES www.cigweld.com.au 252 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au the coolingoflargerdepositweldmetal. andthecontractionstressessetupby A smallnumberofheavyrunswillcausemoredistortionduetothegreaterheatinput, previous layer. The correctweldingprocedureusesagreaternumberofweldrunspositionedtorefinethegrainsize oftheweldmetalin ITRIN CAUSES AND CONTROLCONT.DISTORTION, Distortion cont.: (iii) Thecontrol of distortion ▲ ▲ ▲ ▲ ▲ ▲ Mechanical straightening Normalising Stress Relieving Annealing Flame straightening (alsoknown ascontra-heating) Slow Cooling after welding canbefacilitated by: TECHNICAL AND TRADE INFORMATION 253 air. still C) and then ˚ for cold working or machining purposes.for cold working or job or finished The in a furnace so as the metal reaches work is normally heated .025% carbon steel @ 723-820 its critical range (for the work is very slowly cooled. the work is very slowly below the critical range, followed by slow cooling. This to be lowered process allows the yield point of the metal allowing it to stretch or yield, so reducing the residual stresses in the work. and fatigue. metal so it improves its resistance to shock just above the In normalising the welded parts are heated for approximately critical point (820˚C for .025% carbon steel) to cool in 1 hour per 25mm thickness and then allowed -- Bend Pressing - Hammering Rolling Annealing - heat treatment process designed to soften metals is a Mechanical Straightening includes: Stress Relieving - parts to a temperature is the uniform heating of welded Normalising - the is a process used to refine the grain structure of Distortion cont.: Distortion DISTORTION, CONT. CONTROL AND CAUSES www.cigweld.com.au 254 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au B) ELECTRICSHOCK- “PREVENTION”: RADIATION:A) ARC SAFETY IN WELDING (i) PROTECTION REQUIREDINCLUDES: the following:- Arc radiation isaresult ofULTRA-VIOLET (UV)andINFRA-RED(IR)RAYS andexposure cancause N.B. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ body frompotentialburnseg. Always wearprotectivefullcoveringclothingto shieldyour UV andIRraysaway reducingthechancesof Arc Flash. Safety glasseswhichwillhelptorefract(bendaway) the shade number. An approvedweldinghelmetwiththecorrectfilterand cataractsorblindness. inflammation ofthecornea, ARC FLASH(Welders Flash)orEYEBURN whichcanresultin Thermal SkinBurns(severesunburn) Skin Cancer standing inwater. Don’t weldwhilestandingonawetsurfaceor Never coilorloopweldingcablesaroundyourbody. and grease. Keep glovesandprotectiveclothingdryfreeofoil beforewelding. especiallybarecables, Repair anydamagedorlooseconnections, Never touchlivemetalpartswithbareskinorwetclothing. A weldingflashcanoccurbyindirectlyviewingthearcevenfora relatively shorttimeeg. - Screentheweldingzonewheninopenspaces. - Skullcap(foroverheadwelding). - Always wearleathergloves. - Leatherapronandjackets. - Overalls/flameresistantwoolorcotton. - Reflectionsofthearcfromshinysurfacesin - Lookingaway fromthearc(closeeyesthenturnaway). - Unconsciouslylookingoutthecornerofeye welding area. TECHNICAL AND TRADE INFORMATION 255 electrode coatings. steel,galvanised zinc-primed steel. sheaths on air carbon arc gouging electrodes, copper alloys. air carbon arc gouging, oxyfuel flames; exhaust from car engines. titanium and aluminium welding in inert gas atmospheres hydrocarbon solvents. ContaminantIron fumeChromium Source NickelZinc fume of iron from base metal and Vaporisation Copper fume Stainless steel, electrode coatings, platings. Stainless steel, steel. nickel-clad of zinc alloys, Vaporisation electrode coatings Vanadium,Manganese, Molybdenum on electrode wires, of coatings Vaporisation TinCadmiumLead rods, Welding alloying elements in steels. Carbon Monoxide Plating Ozone Combustion products of gas metal arc welding, steel, Tin-coated some nonferrous alloys. Fluxes, coatings on electrodes, flux in wires Nitrogen dioxidePhosgene Gas metal arc welding, air carbon arc gouging; Gas metal arc welding; oxyfuel flame processes. of metal covered with chlorinated Welding Exposure to fumes and gases can damage the lungs and respiratory system or cause asphyxiation. Exposure to fumes and gases can damage the lungs and respiratory system or Caused by the melting, consumables, of the and other reactions vapourisation arc. applicable) involved in the welding (where base metals and gases Some common contaminants: C) FUMES & GASES: C) FUMES SAFETY IN WELDING CONT. WELDING IN SAFETY www.cigweld.com.au 256 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au )HA,FIRE&SPARKS: D) HEAT, Fumes andGases: SAFETY IN WELDING CONT. i RTCINRQIE RMHA,FIRE (i) PROTECTIONAND SPARKS: REQUIREDFROMHEAT, (i) PROTECTION REQUIREDFROMFUMES AND GASES:- N.B. SYMPTOMS INCLUDE:- oe Ifanyofthesesymptomsare observedpleaseseekprofessional medical Note: ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ burns) andmoltenweldmetal(spatter)fallingorspittingontoexposedskin. Burns canresultfromhandlinghotjustweldedwork(themostcommonofwelding well asburningunprotectedskin. as These sparkscanreachcombustiblematerialsandstartfires, and evenfurtherwhenworkinginelevated positions. up to15metresaway fromthesourceofweldingonground Welding sparkscantravellongdistancesandhavebeenknowntoreach sparksandheatradiatedfrom thearc. burns byhotandmoltenmetal, operatorsareatcontinualriskof Are causedbyweldingandrelatedprocesses, Weakness Chills Fever Nausea Use afumeextractionunit/orgun. respirator (especiallyinconfinedspace). oranairsupplied Use aweldingfumerespirator, Keep yourheadoutandaway fromthefumes. Adequate ventilation. containing gasesorflammableliquids. Never connecttheearthleadtoelectricalcircuitsofpipes postapersononthegroundasfire-watcher. If inanelevated position, (atleast15metresor50feetaway). area. Remove combustiblematerialsaway fromthewelding and howtousethem. Know wherethenearestfireextinguisherorhoseis Always markjustweldedworkwiththeword “HOT”. Keep safetyglassesonyourheadwheretheybelong. Always wearprotectiveclothing. Welding fumefevercausedbybreathingfumesformedtheweldingofvarious metals canoccurafewhoursafterexposureandlastseveraldays. attention. ▲ ▲ ▲ ▲ Joint andmusclepain Metallic tasteinmouth Dry noseandthroat Fatigue TECHNICAL AND TRADE INFORMATION 257 Keep fire Keep extinguishing equipment at a handy location near the job. Conduct engine exhaust to outside atmosphere. primary Keep terminals and live parts effectively covered. an Never strike electrode on any gas cylinder. . Never use oxygen for venting containers. SAFETY IN WELDING CONT. WELDING IN SAFETY Leads and cables should be kept clear of passageways. In confined spaces, adequate ventilation and constant are observation essential. Never watch the Never watch arc except through filters of the correct shade. Repair or replace or Repair cables defective immediately. www.cigweld.com.au 258 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au teghi loe otefloigmnmmvle.E:E1X esl:40Ma/Yed 3 P n 4X,Tnie 480MPa / Yield: Tensile: 330MPa andE48XX, 410MPa / 400 MPa.Yield: Tensile: E41XX, EG: Strength isallowedtothefollowingminimumvalues. (1) and(2)indicatesthatforeachincreaseof1%inthevalue ofelongationovertheminimumadecrease10MPa in Tensile energy gradenumber: The fifthdigitindicatestheImpact See Table 1fordetails. penetration. medium D.C.+, & Powder A.C. HydrogenControlledLowIron EG: be used. type and Welding Current/Polarity to 8 Zealand. obtainablefromtheStandards Association of Australia orStandardsNew current publishedversionof AS/NZS 1553Part 1. For fulldetailsCIGWELDrecommendyourefertothe The followinglayoutoutlinesthisclassificationsysteminpartonly. The secondgroupseparatedbythehyphenas NB. 4H5Risoptional. ie. shown isoptional. E4818-4H5R. eg: into twoalphanumericgroupsseparatedbyahyphen. AS/NZS 1553.1classifiesManualMetal Arc Welding (MMAW/Stick)electrodesbyusingaseriesoflettersanddigitsbroken O D C R E E E T L CONSUMABLES CLASSIFICATION TABLES AS/NZS 1553Part 1-1995Covered Electrodes for Welding LowCarbonSteel rd o values grade No: = thefourthdigitindicatesFlux matMinimumaverage Impact energy CVN 47J@+20 A 47J@-40 4 47J@-20 2 47J@0 0 47J@-50 5 47J@-60 47J@-30 6 3 Notrequired. Z strength inMPa. The firsttwodigitsindicateapproximately1/10thoftheminimumtensile ea o ag Ma tegh(P)Elongation Strength(MPa) Range(MPa) Metal No: Weld Tensile 48 1430-550 41 impact 500 -620 ° ° ° ° ° C ° ° C C C C C C teghMinimum Strength (2) (1) E4818-4H 420 350 (2) (1) il Minimum Yield 5 R 22% 22% Metal (DWM) Diffusible HydrogenContentofDeposited Weld The secondletter&sixthnumberindicatesthe not >10mlsH Tested electrodesshallexhibit Moisture Resistant. R an environmentof27 for aperiodofnotlessthan9hours. H H = thelastletterindicatescoatingis 10 5 ≤ ≤ 10 mlsH 5 mlsH 2 Welding Positions The thirddigit= /100g of DWM afterexposureto /100g ofDWM Flat&H/VFillets 1 2 Especiallygood 4 ° 2 All Positional Vertical-Down C &80%RelativeHumidity 2 /100g ofDWM /100g ofDWM Designators Optional and Yield TECHNICAL AND TRADE INFORMATION 259 Cellulose Deep Low Iron Powder Hydrogen Controlled Titania (Viscous) Fluid Slag Fluid Slag Potassium Iron Oxide & Iron Oxide Low Iron Powder High Iron Powder Stiff Slag (Viscous) Hydrogen Controlled Hydrogen Controlled V = VerticalV = H = HorizontalVertical-Down = V-DOWN Fillet = Horizontal-Vertical H/V-FILLET V-DOWN V-DOWN AS/NZS 1553.1 Electrode Classification Summary - Table 1 Table - Summary Classification 1553.1 Electrode AS/NZS the Manufacturer the Manufacturer the Manufacturer Specified EXX99 by As Specified As Specified by As Described by As EXX48 F,V, OH, H A.C. & D.C. + Basic Hydrogen Controlled, Medium EXX28 F & H/V-FILLET A.C. & D.C. + Basic Hydrogen Controlled, Medium EXX11EXX12 F,V, OH, HEXX13 F,V, OH, HEXX14 F,V, OH, HEXX15 A.C. & D.C. + F,V, OH, H A.C. & D.C. + or -EXX16 F,V, OH, H A.C. & D.C. + or -EXX18 A.C. F,V, & D.C. OH, + or - H High Cellulose SlagTitania,Stiff High EXX19 F,V, OH, H SlagTitania,Fluid High EXX20 D.C.Basic, + Low Iron Powder,Titania Medium F,V, OH, HEXX24 A.C. & D.C. + Deep F & H/V-FILLET Medium EXX27 A.C. & D.C. + F & H/V-FILLET Low A.C. & D.C. + or - A.C. & D.C. + or - F & H/V-FILLET Medium A.C. & D.C. + or - Basic Hydrogen Controlled,EXX46 Basic, A.C. & D.C. + or -Titania Iron Oxide Medium High Iron Oxide F,V, OH, H High Iron Powder, Medium High Iron Powder Medium Deep A.C. & D.C. + Low Deep Basic, Medium EXX10 F,V, OH, H D.C. + High Electrode Welding of Current Type of Flux Covering Type Penetration * Legend to Abbreviations:* Legend to F = Flat OH = Overhead Classification Positions and PolarityType and Slag AS/NZS 1553 Part 1-1995 Covered Electrodes for Welding Low Carbon Steel cont. Low Carbon Welding for Electrodes 1-1995 Covered 1553 Part AS/NZS CONSUMABLES CLASSIFICATION TABLES CLASSIFICATION CONSUMABLES www.cigweld.com.au CONSUMABLES CLASSIFICATION TABLES

AS/NZS 1553 Part 2-1995 Covered Electrodes for Welding Low Carbon Steel

AS/NZS 1553.2 classifies Manual Metal Arc Welding (MMAW / Stick) electrodes by using a series of letters and digits broken into two alpha numeric groups separated by a hyphen. eg: E4818-4H5R. NB. The second group separated by the hyphen as shown is optional. ie. 4H5R is optional.

The following layout outlines this classification system in part only. For full details CIGWELD recommend you refer to the current published version of AS/NZS 1553 Part 2. obtainable from the Standards Association of Australia or Standards New Zealand.

E The first two digits indicate approximately 1/10th of the minimum tensile strength in MPa. The third digit = L E Weld Minimum Tensile Proof Stress at Minimum Test Welding Positions C Metal No: Strength (MPa) 0.2% Offset (Mpa) Elongation Condition 4 Especially good T 48 480 390 Refer to AS1553.2 Vertical-Down R 55 550 460 Refer to AS1553.2 O 62 620 530 Refer to AS1553.2 2 Flat & H/V Fillets D 1 All Positional E 69 690 600 Refer to AS1553.2 76 760 670 Refer to AS1553.2

TECHNICAL AND TRADE INFORMATION E5518-B2 H5 R Optional Designators

8 = the fourth digit indicates the Flux The first letter & fifth R = the last letter indicates the coating is type and Welding Current / Polarity to digit indicates the Moisture Resistant. Tested electrodes shall exhibit be used. EG: Hydrogen Controlled Low chemical composition not > 10 mls H2 /100g of DWM after exposure to Iron Powder A.C. & D.C.+, medium of deposited weld an environment of 27°C & 80% Relative Humidity penetration. metal. Refer table on for a period of not less than 9 hours. Refer Table 1 on page 259. page 261. The second letter & sixth number indicates the Diffusible Hydrogen Content of Deposited Weld Impact Property Requirements DWM Metal (DWM) Classification Minimum Charpy V-notch H ≤ 5 mls H /100g of DWM Impact Requirements 5 2 E55XX-C1 27j@-60˚C* E55XX-C1L 27j@-73˚C* E55XX-C2 27j@-73˚C* E55XX-C2L 27j@-100˚C* E55XX-C3 27j@-40˚C* E55XX-NM 27j@-40˚C E62XX-D1 27j@-50˚C* E69XX-D2 E69XX-D3 E62XX-M 27j@-50˚C E69XX-M E76XX-M E83XX-M1 68j@-18˚C E48XX-W 27j@-18˚C E55XX-W ALL OTHER CLASSIFICATIONS NOT REQUIRED *Stress relieved impact properties

260260 www.cigweld.com.au TECHNICAL AND TRADE INFORMATION 261 1 1 0.8 0.8 0.6 0.8 0.6 0.8 0.6 0.8 0.6 0.8 0.6 0.8 0.8 0.6 0.8 0.8 NiCKEL STEEL ELECTRODES Chemical Composition Mass % Chemical Composition OTHER LOW-ALLOY STEEL ELECTRODES LOW-ALLOY OTHER NICKEL MOLYBDENUM STEEL ELECTRODES NICKEL MOLYBDENUM CARBON - MOLYBDENUM STEEL ELECTRODES CARBON - MOLYBDENUM MANGANESE MOLYBDENUM STEEL ELECTRODES MANGANESE MOLYBDENUM 1 0.4 CHROMIUM - MOLYBDENUM STEEL ELECTRODES CHROMIUM - MOLYBDENUM 0.60.60.60.90.9 0.4 0.6 0.4 0.4 0.9 0.6 0.9 0.6 0.90.9 0.4 0.8 0.6 0.6 0.8 1.00 Min 0.80 Min 0.50 Min 0.30 Min 0.20 Min 0.10 Min CONSUMABLES CLASSIFICATION TABLES CLASSIFICATION CONSUMABLES Chemical Composition Requirements of Deposited Weld Metal – AS1553.2 Metal – Weld of Deposited Requirements Composition Chemical E5516-B1 0.05-0.12 0.04 0.03 0.9 0.6 0.4-0.65 0.4-0.65 E5515-B1 E8318-M1 E4816-WE4818-W E5516-WE5518-W maximums. Single values are 0.12 0.12 0.025 0.04 0.025 0.03 0.4-0.7 0.5-1.3 0.4-0.7 0.35-0.8 0.2-0.4 0.4-0.8 0.15-0.3 0.45-0.7 0.08 0.3-0.60 0.3-0.75 E4815-C2L E4816-C2LE5516-NM 0.05E6216-D1E6915-D2 E6916-D2 0.04E6918-D2 0.1E5515-D3 E5516-D3E5518-D3 0.03 0.12EXXXX-G 0.03E6216-ME6218-M 0.15E6916-M 1.25E6918-M 0.04E7616-M 0.02 0.12E7618-M E8316-M 0.04E8318-M 0.80-1.25 0.5E8316-M1 0.03 0.1 0.4 0.03 0.1 1.25-1.75 0.6 3.0-3.75 0.1 0.03 0.03 1.65-2.0 0.1 0.6 0.80-1.10 0.03 0.1 0.03 1.0-1.75 0.6 0.03 0.05 0.03 0.03 0.012 0.6 0.60-1.25 0.40-0.65 0.03 0.75-1.70 0.03 0.015 0.02 0.8 1.3-1.8 0.6 1.3-2.25 0.8-1.6 1.40-1.80 0.1 0.6 1.40-2.10 0.25-0.45 0.6 0.65 0.15 1.25-2.5 0.35 0.25-0.45 1.75-2.5 3.0-3.8 0.35 0.40-0.65 0.25-0.50 0.4 0.3-1.5 0.65 0.05 0.05 0.3-0.55 0.25-0.5 0.2-0.3 0.05 0.05 0.05 E4818-C1L E5516-C2E5518-C2 E4818-C2L E5516-C3E5518-C3 0.12E5518-NM E6215-D1 E6218-D1 0.04 0.12 0.03 0.03 1.25 0.03 0.40-1.25 0.6 0.8 3.0-3.75 0.80-1.10 0.15 0.35 0.05 E6215-B3 E6216-B3E6218-B3L E5515-B4LE5516-B5E4115-5Cr E4116-5Cr 0.05-0.12E4118-5Cr E4115-7Cr E4116-7Cr 0.04E4118-7Cr E4115-9Cr E4116-9Cr 0.05 0.07-0.15E4118-9Cr 0.03 0.1E5516-C1 0.04E5518-C1 0.04E4815-C1L 0.1E4816-C1L 0.5-1.2 0.03 0.1 0.03 0.03 0.03 0.6 0.12 0.4-0.7 0.04 0.03 0.9 0.05 0.04 0.3-0.6 0.04 1 0.04 0.04 1 1 0.03 2.0-2.5 0.9 1 0.03 0.90-1.20 0.9 1.25 0.4-0.6 1.25 0.4 0.9 1.0-1.25 1.75-2.25 0.6 0.4 4.0-6.0 0.4-0.65 0.05 0.5 0.4 2.0-2.75 6.0-8.0 0.45-0.65 2.0-2.75 8.0-10.5 0.45-0.65 0.85-1.2 0.75 0.75 0.75 E4810-A1 E4848-A1 E5518-B1 E5518-B2 E5518-B2L E6218-B3 ClassificationE4811-A1 E4813-A1 E4815-A1 E4816-A1 CE4818-A1E4820-A1 E4827-A1 E4828-A1 E4845-A1 E4846-A1 S 0.12E5515-B2 PE5516-B2 0.04E5515-B2L E5516-B2L Mn 0.03E6215-B3L 0.05-0.12E6216-B3L Si 0.9 0.04 0.05 Ni 0.04 0.03 0.8 0.05 0.5-1.2 0.03 Cr 0.04 0.6 0.5-1.2 Mo 0.03 0.6 0.5-1.2 V 0.4-0.65 0.6 1.0-1.5 Cu 0.4-0.65 1.0-1.5 0.4-0.65 2.0-2.5 0.90-1.20 www.cigweld.com.au 262 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au lcrdsi o pcfe,andE7018M typesarerequiredtomeet24%. electrodes isnotspecified, 17%. isalsoimprovedfrom of anE7024ductility “elongation” Inthecase requirements forimprovedimpacttoughness. This numberindicatesthattheelectrodemeets only. E7018andE7024typeelectrodes APPLICABLE toE7016, See Table 2fordetails. mediumpenetration. D.C.+, & Controlled LowIronPowder A.C. Hydrogen EG: Polarity tobeused. Flux typeand Welding Current/ 8 USA. 33126, Florida Miami, LeJeuneRoad, current publishedversionof AWS 550N.W. A5.1 obtainablefromthe American Welding Society, For fulldetailsCIGWELDrecommendyourefertothe The followinglayoutoutlinesthisclassificationsysteminpartonly. H4Ris ie. The alphanumericgroupafterthefourdigitnumber(orfiveincaseofE7018-1)isoptional. optional. NB. E7018H4R. eg: into twoalphanumericgroupsseparatedbyahyphen. AWS A5.1-91 classifiesShieldedMetal Arc Welding (SMAW/MMAW)electrodesbyusingaseriesoflettersand digitsbroken (1) (2.4mm) whichis53-77ksi. O D C R E E E T L 71- 20ftLb@-50 E7018-1 AWS A5.1-91 CarbonSteelElectrodes forShieldedMetal Arc Welding CONSUMABLES CLASSIFICATION TABLES 71- 20ftLb@-50 E7016-1 72- 20ftLb@0 E7024-1 = thefourthdigitindicates rd CVNImpactRequirements. Grade Yield onE6022electrodesisnotspecifiedandE7018Mmayhavearangeof53-72ksiforall diametersotherthan3/32 The firsttwodigitsindicatetheminimumrequiredtensilestrengthinksi. ea o tegh(s)Srnt ki Elongation Strength(ksi) Strength(psi) Metal No: Weld Minimum 70 06,0 48 60,000 60 Average MinimumResults (2) 00058 70,000 ° ° iiu lnainfrE02 61,E04adE04tpsi 7.ElongationonE6022 E7014andE7024typesis17%. E6013, Minimum elongationforE6012, ° F (27J@-46 F (27J@-18 F (27J@-46 Tensile Minimum E7018-1H ° ° ° C) C) C) (1) (1) Yield Minimum 4 R less than9hours. 80 moisture afterexposuretoanenvironmentof or conditionedshallexhibitnot>0.3%(by Wt) of Tested electrodesasreceived Moisture Resistant. R Metal (DWM) diffusible hydrogencontentofDeposited Weld The secondletter&sixthnumberindicatesthe 22% 22% H H H = thelastletterindicatescoatingis ° 16 8 4 F &80%relativehumidityforaperiodofnot (2) (2) ≤ ≤ ≤ 16 mlsH 8 mlsH 4 mlsH Welding Positions Flat&H/VFillets 1 2 Especiallygood 4 The thirddigit= 2 2 2 All Positional Vertical-Down /100g ofDWM /100g ofDWM /100g ofDWM Designators Optional ≤ TECHNICAL AND TRADE INFORMATION 263 t, Fluid Slag Dense Slag Iron Powder Iron Powder Iron Powder Thin Friable Slag Friable Thin Slag Friable Thin Dense-Fluid Slag Self Removing Slag Easily Removable SlagEasily Removable Deep “Single-Pass Welds Welds Only” “Single-Pass Heavy Honeycombed Slag Heavy Honeycombed Slag Basic Slag Heavy & Friable Basic Slag Heavy & Friable “High Deposition Efficiency” “Military Hydrogen Controlled” H = HorizontalVertical-Down = V-DOWN Fillet = Horizontal-Vertical H/V-FILLET V-DOWN AWS A5.1 Electrode Classification Summary - Table 2 Table - Summary Classification Electrode A5.1 AWS E6010 F,V, OH, H D.C. + High Cellulose Sodium Deep E6011E6012 F,V, OH, HE6013 F,V, OH, HE7014 A.C. & D.C. + F,V, OH, HE7015 A.C. & D.C. + or - F,V, OH, HE7016 A.C. & D.C. + or - High Cellulose Potassium F,V, OH, HE7018 Sodium,Titania High A.C. & D.C. + or - F,V, OH, H Potassium,Titania High Deep F,V, OH, H Low Iron Powder, Titania D.C. + E6019 Medium A.C. & D.C. + Medium E6020 A.C. & D.C. + F,V, OH, HE6022 Low Low Hydrogen Potassium Low Hydrogen Sodium F & H/V-FILLETE7024 A.C. & D.C. Low Hydrogen Potassium + or - A.C. F & H/V-FILLET & D.C. + or -E6027 Medium Medium F & H/V-FILLET PotassiumTitania Iron Oxide A.C. & D.C. -E7027 Medium A.C. F & H/V-FILLET & D.C. + or - High Iron OxideE7028 Medium A.C. F & H/V-FILLET & D.C. + or -E7048 High Iron Oxide A.C. F & H/V-FILLET Iron Powder, Titania & D.C. + or - High Iron Oxide Iron Powder Medium to A.C. F,V, & D.C. OH, + High Iron Oxide Iron Powder H Medium Low Deep Medium A.C. Low Hydrogen Potassium, & D.C. + Medium Low Hydrogen Potassium, Medium E7018M F,V, OH, H D.C. + Low Hydrogen Iron Powder Medium Electrode Welding of Current Type of Flux Covering Type Penetration Classification Positions and Polarity“Use” or Type and Slag AWS A5.1-91 Carbon Steel Electrodes for Shielded Metal Arc Welding cont. Welding Arc Metal for Shielded Electrodes Carbon Steel A5.1-91 AWS CONSUMABLES CLASSIFICATION TABLES CLASSIFICATION CONSUMABLES * Legend to Abbreviations:* Legend to F = Flat OH = OverheadVertical V = E7018M type electrodes are intended to meet most military requirements and have greater toughness,E7018M type electrodes are intended to meet most military requirements and have greater lower coating moisture conten both as-received and after exposure, and also conform to mandatory diffusible hydrogen limits for deposited weld metal. www.cigweld.com.au 264 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au metal. mandatory diffusiblehydrogenlimitsfordepositedweld andalsoconformto as-received andafterexposure, both lowercoatingmoisturecontent, toughness, meet mostmilitaryrequirementsandhavegreater EX018-Melectrodesareintendedto A5.5-96 fordetails. refertopage5of AWS CrandMo, Ni, the caseofMn, (3) #Mclassificationchemicallimitscanvary widelyin exhibit onlyaminimumofone(1)elementlisted. (2) *Gclassificationsrequirethewelddepositto 60 ksi(415MPa). (1) Yield onE7010-P1andE7018-W1isrequiredtobe Notes: USA. 33126, Florida Miami, LeJeuneRoad, refer tothecurrentpublishedversionof AWS 550N.W. A5.5 obtainablefromthe American ForWelding Society, you fulldetailsCIGWELDrecommend The alphanumericgroupafterthefourdigitnumberindic NB. The followinglayoutoutlinesthisclassificationsysteminpartonly. chemical analysisrequirements. E7010-A1orE8010-P1. eg: alpha numericgroupsseparatedbyahyphen. See Table 3fordetails. medium penetration. &D.C.+, Low IronPowder A.C. HydrogenControlled EG: be used. type and Welding Current/Polarity to 8 Welding Positions The thirddigit= classifies AWS A5.5-96 O D C R E E E T L CONSUMABLES CLASSIFICATION TABLES AWS A5.5-96 Low Alloy Steel CoveredElectrodes Arc WeldingSteel Low Alloy AWS A5.5-96 1 Especiallygood Flat&H/VFillets 4 2 = thefourthdigitindicatesFlux edMtlMn esl Yield Strength Tensile Min. Weld Metal 0xBL7,0 710100097 110,000 110 57 75,000 70xx-B2L 00P 0006 0 0,0 87 100,000 100 60 70,000 7010-P1 0xC 0006-0101000107 120,000 120 68-80 80,000 80xx-C3 08 0007-010811000108-120 120,000 12018M1 78-90 90,000 9018M Vertical-Down All Positional o tegh(s)(s)N:Srnt pi (ksi) Strength (psi) No: (ksi) Strength (psi) No: 09,0 7108 2,0 108-120 98-110 88-100 120,000 110,000 100,000 12018M 11018M 10018-M 77 67 57 90,000 80,000 70,000 90 80 70 80 = thefirsttwodigitsindicateminimumrequiredtensilestrengthinksi. E8018-C1 Shielded Metal Arc Welding (SMAW/MMAW) yeCM iC oV Mo Cr Ni Mn C Type 5 .504-.060-.5------0.05 ------0.35 ------0.15 --- 6.00-7.25 --- 0.40-1.00 0.80-1.10 3.00-3.75 0.40-1.40 0.05 2.00-2.75 1.25 0.08 1.25 C5L 0.05 C3L 0.05 C2L C1L 8 .510 - .01.008-.00.05 --- 0.85-1.20 --- 0.45-0.65 8.00-10.50 --- 0.45-0.65 --- 6.00-8.00 ------4.00-6.00 0.40-0.65 --- 0.90-1.20 1.00 1.75-2.25 --- 0.40-0.65 2.00-2.50 1.00 1.00-1.50 --- 0.05 --- 1.00 0.05 --- B8L 0.90 0.90 0.05 B7L 0.90 B6L 0.05 0.05 B4L 0.05 B3L B2L M01 .012 .011 .004-.50.02 0.40-0.65 0.10 0.80-1.10 0.80-1.25 0.10 NM M 101 .016 .038 .502-.00.05 0.20-0.30 0.65 3.00-3.80 0.80-1.60 0.10 M1 G* --- 1.00 min 0.50 min 0.30 min 0.20 min 0.10 min 0.10 min 0.20 0.30min min 0.50 1.00min --- G* 101 .520-.5------2.00-2.75 1.25 0.12 C1 101 .010 - - .006 --- 0.40-0.65 ------0.60-1.00 0.12 A1 301 .018 .0--04-.5------0.40-0.65 0.25-0.45 0.25-0.45 ------0.90 0.90 0.90 1.00-1.80 1.65-2.00 1.00-1.75 0.12 0.15 0.12 D3 D2 D1 401 .511-.0------0.05 ------0.35 1.10-2.00 0.15 --- 1.25 0.80-1.10 3.00-3.75 0.40-1.25 0.10 1.25 0.12 C4 0.12 C3 C2 900-.312 - .01.008-.00.15-0.30 --- 0.85-1.20 --- 0.85-1.20 8.00-10.50 --- 0.45-0.65 8.00-10.50 --- 0.05 0.45-0.65 --- 6.00-8.00 ------4.00-6.00 1.00-1.25 1.25 ------0.90-1.20 0.40-0.60 1.00 --- 0.40-0.65 0.08-0.13 2.00-2.50 0.40-0.65 1.00 0.05-0.10 --- B9 1.00-1.50 0.40-0.65 --- 1.00 0.05-0.10 B8 0.40-0.70 ------0.05-0.10 B7 0.07-0.15 0.90 B6 B5 0.90 0.05-0.12 0.90 0.05-0.12 B3 0.05-0.12 B2 B1 102 .010 .005 0.10 0.50 0.30 1.00 1.20 0.20 P1 # (1) .006-.512-.001-.002-.50.05 0.25-0.55 0.15-1.50 1.25-2.50 0.60-2.25 0.10 Classification SuffixesbyMajorChemical Analysis (%) Chromium-Molybdenum SteelElectrodes Carbon-Molybdenum SteelElectrodes edMtlMn esl Yield Strength Tensile Min. Weld Metal electrodes byusingaseriesoflettersanddigitsbroken intotwo Manganese- MolybdenumSteelElectrodes Nickel-Molybdenum SteelElectrodes G =GeneralandMMilitary Nickel SteelElectrodes Pipeline Electrodes ates TECHNICAL AND TRADE INFORMATION 265 E80 Series, 80,000 psi (550 MPa) E90 Series, 90,000 psi (620 MPa) E70 Series, MPa) 70,000 psi (480 E100 Series, 100,000 psi (690 MPa) E110 Series, and E120 Series, 110,000 psi (760 MPa) 120,000 psi (830 MPa) AWS A5.5 Electrode Classification Summary - Table 3 Table - Summary Classification Electrode A5.5 AWS E9018M F,V, OH, H D.C. + Low Hydrogen, Iron Powder Medium E7010-XE7011-XE7015-XE7016-XE7018-X F,V,E7020-X OH, H F,V,E7027-X OH, H F,V, OH, H F,V, OH, HE8010-X F,V, F & H/V-FILLET OH, H F & H/V-FILLET A.C. & D.C. + D.C. + A.C. & D.C.E8015-X + or - A.C. A.C. & D.C.E8016-X + or - & D.C. F,V, + D.C. OH, + H A.C.E8018-X & D.C. + F,V, High Cellulose Potassium OH, H High Iron Oxide, Iron Powder F,V, OH, H High Iron Oxide F,V, Low Hydrogen Potassium OH, High Cellulose Sodium H Iron Powder, Low Hydrogen D.C. + Low Hydrogen Sodium A.C. & D.C. + D.C. + A.C. Medium & D.C. + Deep Medium Medium to Deep Medium High Cellulose Sodium Deep Low Hydrogen Potassium Medium Low Hydrogen, Iron Powder Low Hydrogen Sodium Deep Medium Medium Medium E9015-XE9016-XE9018-X F,V, OH, H F,V, OH, H F,V, OH, H A.C. & D.C. + D.C. + A.C. & D.C. + Low Hydrogen Potassium Low Hydrogen, Iron Powder Low Hydrogen Sodium Medium Medium Medium E8011-GE8013-G F,V, OH, H F,V, OH, H A.C. A.C. & D.C. & D.C. + + or - Potassium,Titania High High Cellulose Potassium Medium Deep E9010-GE9011-GE9013-G F,V, OH, H F,V, OH, H F,V, OH, H A.C. A.C. & D.C. & D.C. + D.C. + or - + Potassium,Titania High High Cellulose Potassium High Cellulose Sodium Medium Deep Deep E10018M F,V, OH, H D.C. + Low Hydrogen, Iron Powder Medium E11018M F,V, OH, HE12016M D.C. + F,V, OH, H A.C. & D.C. + Low Hydrogen, Iron Powder Low Hydrogen Potassium Medium Medium E10015-XE10016-XE10018-X F,V, OH, H F,V, OH, H F,V, OH, H A.C. & D.C. + D.C. + A.C. & D.C. + Low Hydrogen Potassium Low Hydrogen, Iron Powder Low Hydrogen Sodium Medium Medium Medium E10010-GE10011-GE10013-G F,V, OH, H F,V, OH, H F,V, OH, H A.C. A.C. & D.C. & D.C. + D.C. + or - + Potassium,Titania High High Cellulose Potassium High Cellulose Sodium Medium Deep Deep E11010-GE11011-GE11013-GE11015-GE11016-G F,V, OH, HE11018-G F,V, OH, H F,V, OH, H F,V,E12010-G OH, H F,V,E12011-G OH, H F,V,E12013-G OH, HE12015-G A.C. A.C. & D.C. & D.C. + D.C. + or - + E12016-G F,V, OH, HE12018-G F,V, OH, H A.C. & D.C. F,V, + D.C. OH, + H A.C. & D.C. F,V, + OH, H F,V, OH, H Potassium,Titania High High Cellulose Potassium F,V, OH, H A.C. A.C. & D.C. & D.C. + D.C. + or - High Cellulose Sodium + Low Hydrogen Potassium Low Hydrogen, Iron Powder A.C. & D.C. + D.C. Low Hydrogen Sodium + A.C. & D.C. + Potassium,Titania High High Cellulose Potassium Medium Deep High Cellulose Sodium Medium Low Hydrogen Potassium Medium Deep Low Hydrogen, Iron Powder Low Hydrogen Sodium Medium Medium Deep Medium Medium Deep Medium Electrode Welding of Current Type of Flux Covering Type Penetration E12018M1 F,V, OH, H A.C. & D.C. + Low Hydrogen, Iron Powder Medium Classification Positions and Polarity“Use” or Type and Slag AWS A5.5-96 Low Alloy Steel Covered Arc Welding Electrodes cont. Electrodes Welding Arc Covered Alloy Steel Low A5.5-96 AWS CONSUMABLES CLASSIFICATION TABLES CLASSIFICATION CONSUMABLES Legend to Abbreviations:Legend to F = Flat,Vertical, V = H = Horizontal, OH = Overhead, Fillet = Horizontal-Vertical H/V-FILLET www.cigweld.com.au 266 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au lsiiain()(n S)NominalRange% (Si) (Mn) (C) Classification lcrd,S=Solid Wire followedbyanumberorletterwhichdefinesthechemicalcompositionofwire. E =Electrode, ES6-GC/M-W503AH of theweldmetalinMPa. The firsttwo digitsindicateapproximately1/10ththetensilestrength Weld metalproperties. of Australia orStandardsNewZealand. For fulldetails The followingtableoutlinesthisclassificationsysteminpartonly. obtainablefromtheStandards Associat CIGWELD recommendsthatyourefertothecurrentpublishedversionof AS/NZS 2717Part ES4-GM-W503AH. 1. e.g.: numeric groupsseparatedbyhyphens. AS/NZS 2717.1classifies CONSUMABLES CLASSIFICATION TABLES lsiiainTnieYedElongation Yield Tensile Classification AS/NZS 2717Part 1-1996Ferritic SteelElectrodes For GasMetal Arc Welding edMtlMnmmMnmmMinimum Minimum Minimum Weld Metal S3 .504-. .007 2.50Cr/1.05Mo0.17Cu 1.25Cr/0.50Mo0.17Cu 0.40-0.70 0.40-0.70 0.40-1.2 0.40-1.2 0.05 0.05 ESB3L ESB2L SG=Gnrl compositionisagreed betweenthesupplier&customer =General, ESMG Si .212 .008 3.37Ni/0.17Cu 2.37Ni/0.17Cu 0.95Ni/0.07Cr0.17Mo0.02V0.17Cu 0.40-0.80 0.40-0.80 0.40-0.80 1.25 1.25 1.25 0.12 0.12 0.12 ESNi3 ESNi2 ESNi1 SC .010 .00.20Ni/9.25Cr1.02Mo0.37Cu 0.20Ni/7.00Cr0.55Mo0.37Cu 0.20Ni/5.25Cr0.55Mo0.37Cu 0.90 0.90 0.90 1.00 1.00 1.00 0.10 0.10 0.10 ES9Cr ES7Cr ES5Cr S501 .518 .026 .0i/03C .5o/00V/01C .5a Ti /Zr Al 4.80Ni/0.30Cr0.95Mo0.01V0.12Cu0.05ea, Ti /Zr Al 4.80Ni/0.30Cr0.95Mo0.01V0.12Cu0.05ea, Ti /Zr Al 2.25Ni/0.25Cr0.20Mo0.02V0.12Cu0.05ea, Ti /Zr Al 1.75Ni/0.15Cr0.40Mo0.02V0.12Cu0.05ea, 0.20-2.60 0.20-2.60 0.20-0.55 0.20-0.50 1.25-1.80 1.25-1.80 1.25-1.80 1.25-1.80 0.12 0.10 0.09 0.08 ESM5 ESM4 ESM3 ESM2 S200-.216-.005-.00.07Ni/0.50Mo0.25Cu 0.50-0.80 1.60-2.10 0.07-0.12 ESD2 S300-.204-. .007 2.50Cr/1.05Mo0.17Cu 1.25Cr/0.50Mo0.17Cu 0.40-0.70 0.40-0.70 0.40-1.2 0.40-1.2 0.07-0.12 0.07-0.12 ESB3 ESB2 ieCro agns iio OtherElements Silicon Manganese Carbon Wire S .601 .018 .011 0.25Cu 0.80-1.15 1.40-1.85 0.06-0.15 ES6 S .701 .020 .008 0.25Cu 0.70Al 0.25Cu 0.25Cu 0.25Cu/0.10Ti /0.07Zr0.10Al 0.50-0.80 0.30-0.60 0.40-0.70 0.60-0.85 0.45-0.75 1.50-2.00 0.90-1.40 0.90-1.40 1.00-1.50 0.90-1.40 0.07-0.15 0.07-0.19 0.07-0.15 0.07 0.06-0.15 ES7 ES5 ES4 ES3 ES2 5 0 P 6 P 22% 360MPa 500MPa W50 8 3 P 3-4 P 14% 15% 17% 16% 19% 730-840MPa 660-740MPa 610-700MPa 540MPa 830MPa 20% 470MPa 760MPa 690MPa 620MPa 550MPa notapplicable W83 W76 W69 420MPa W62 W55 W41 I =Inertshieldinggas. M C G Type ofexternalshielding. = Carbondioxide. = Gasfollowedbyeitheroftheselisted: ie hedn a g Argoshield51. = Mixedshieldinggaseg: Gas Metal Arc Welding (GMAW/MIG) wires byusingaseriesoflettersanddigitsbroken intothree(3)alpha H H P =postweldedheattreatment. A Indicating theapplicableheattreatmentcondition. 2 = hydrogencontrolledweldmetal. = as-weldedcondition. / 100gmsofdepositedweldmetal. The thirddigitindicatesImpactenergygradeNo: mateeg Mn average Min. Impact energy 59HN327J@-73 27J@-60 27J@-45 W559XH-Ni3 W559XH-Ni2 W559XH-Ni1 69HM 68J@-50 68J@-50 68J@-50 68J@-50 W699XH-M5 W839XH-M4 W769XH-M3 W699XH-M2 59HD 27J@-30 W559XH-D2 rd o CVNimpacts grade No: 47J@+20 A 47J@-30 3 47J@-20 2 47J@-40 4 47J@-60 47J@-50 6 5 47J@0 0 Notrequired. Z ≤ 15 mlsof ° ° ° ° ° ° ° ° ° ° ° ° ° ion ° C ° C C C C C C C C C C C C C C TECHNICAL AND TRADE INFORMATION 267 C) C) C) C) ° C) C) ° ° ° ° ° Optional Designators F (27J @ -29 F (27J @ -29 F (27J @ -29 F (27J @ -29 F (27J @ -18 F (27J @ -18 ° ° ° ° ° ° 4 mls H2 /100g of DWM 8 mls H2 /100g of DWM 16 mls H2 /100g of DWM ≤ ≤ ≤ The second letter & sixth number The indicates the Diffusible Hydrogen Metal Weld Content of Deposited (DWM) H4 H8 H16 As agreed between supplier & purchaser shielding gas and “M”shielding gas and indicates mixed shielding 2 gas. 2 gas or the wire is self shielded. 4 2 4 = Composite Metal Cored Wire,= Composite Metal Cored by a hyphen then a number or letter which followed C . (X) is optional for these classifications. 2 = indicates “Mixed Gas”= indicates and is classified for use The third letter indicates “Shielding Gas” third letter indicates The M Argon + 20-25% CO with “Carbon Dioxide”C = indicates and is classified for use with 100% CO = Solid Wire, = Solid S G = General, composition is not specified and is agreed between the supplier and the customer. G = General, Only, Single Pass composition is agreed between the supplier and the customer. G = General, composition is not specified and is agreed between the supplier and the customer. = Rod, R ER70S-6 H E70C-6M H Argon + 20-25% CO Wire Carbon Manganese Silicon Other Elements ER70S-2ER70S-3ER70S-4ER70S-5ER70S-7 0.06-0.15 0.07 0.07-0.15 0.07-0.19 0.90-1.40 1.00-1.50 0.07-0.15 0.90-1.40 0.90-1.40 0.45-0.75 1.50-2.00 0.60-0.85 0.40-0.70 0.30-0.60 / 0.02-0.12Zr / 0.05-0.15Al 0.05-0.15Ti 0.50-0.80Al / 0.50-0.90 0.50Cu 0.50Cu 0.50Cu 0.50Cu ER70S-G ER70S-6 0.06-0.15 1.40-1.85 0.80-1.15 0.50Cu AWS Strength Tensile Strength Yield % (CVN) Charpy-V-Notch Class. psi MPa psi MPa Elong. Impact Requirements ER70C-3X 0.12 1.75 0.90 0.50Cu ER70C-6X 0.12 1.75 0.90 0.50Cu ER70C-G(X) ER70S-7 70,000 480 58,000 400 22 -20 20ft Lb @ ER70S-3 70,000 480 58,000 400 22 20ft Lb @ 0 ER70S-2 70,000 480 58,000 400 22 -20 20ft Lb @ ER70S-4ER70S-5 70,000 70,000 480 480 58,000 58,000 400 400 22 22 Not Required Not Required E70C-3X 70,000 480 58,000 400 22 0 20ft Lb @ E70C-6X 70,000 480 58,000 400 22 20ft Lb @ -20 ER70S-G 70,000 480 58,000 400 22 ER70C-GS(X) ER70S-6 70,000 480 58,000 400 22 20ft Lb @ -20 Classification (C) (Mn) (Si) % Range Allowable E70C-G(X) 70,000 480 58,000 400 22 As agreed between supplier & purchaser = Electrode, E70C-GS (X) 70,000 480 Not Specified Not Required AWS A5.18-1993 Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding Arc Gas Shielded and Rods for Electrodes Carbon Steel A5.18-1993 AWS CONSUMABLES CLASSIFICATION TABLES CLASSIFICATION CONSUMABLES As Welded Mechanical Properties (Minimum) Mechanical Properties Welded As Single values are maximum.Single values X represents shielding gas indicators e.g. “C” CO indicates E AWS A5.18-93 classifies Gas Metal Arc Welding (GMAW / MIG) wires by using a series of letters and digits broken into two broken of letters and digits wires by using a series (GMAW / MIG) Welding Arc classifies Gas Metal A5.18-93 AWS separated by a hyphen.(2) alpha numeric groups e.g.: ER70S-6 and E70C-6M in part only. layout outlines this classification system following The to the full details CIGWELD recommend you refer For Society,Welding American from the A5.18 obtainable 550 N.W.AWS of current published version LeJeune Road, Miami, Florida 33126, USA. gases in the defines the chemical composition of the wire. www.cigweld.com.au 268 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au ETP-GCp-W504A.CM1 H Welding Positions: Group 1 obtainablefromtheStandards Association of Australia. current publishedversionof AS 2203Part 1. For fulldetailsCIGWELDrecommendyourefertothe The followinglayoutoutlinesthisclassificationsysteminpartonly. ETP-GCp-W504A.CM1H10. e.g. numeric groupsseparatedbyhyphensandthelastgroupafullstop. AS 2203.1classifiesFluxCored Arc Welding (FCAW/cored)wiresbyusingaseriesoflettersanddigitsbroken intofouralpha AC current directcurrent a n p noexternal Welding Current: mixedgas N M C G Group 2 CONSUMABLES CLASSIFICATION TABLES Singlerunonly Flat&H/VFillets S D P T E AS 2203Part 1-1990Cored Electrodes for Arc Welding Ferritic SteelElectrodes = GasShielding: negative DC- positive DC+ direct current shielding gas carbon dioxideCO , , All Positional Tubular Electrode 2 The thirddigitindicatestheImpactenergygradenumber: mateeg Minimumaverage Impact energy tensile strengthinMPa. Group 3 ea o ag Ma .%ofe Ma Elongation 0.2%offset(MPa) Range(MPa) Metal No: See Table 4fordetails. Chemistry. indicates the Weld Metal Group 4 rd o CVNimpactvalues grade No: ed esl teghMn ro tesa Minimum Proof Stressat Min. Tensile Strength Weld 5 9 5 6 22% 360 490-650 W50 8 3 7 5 13% 14% 15% 16% 19% 22% 750 680 610 540 470 310 830-970 760-900 690-830 620-760 550-690 W83 W76 430-550 W69 W62 W55 W40 47J@-40 4 47J@-20 3 47J@0 2 47J@-60 5 47J@+20 Notrequired. 1 0 thefirsttwodigitsindicate approximately1/10thoftheminimum , , 10 ° H Deposited Weld Metal(DWM). Indicates theDiffusibleHydrogenContentof H H ° ° ° C ° 15 5 10 C C C C P -Postweld heattreatment A - As welded condition Condition of Weld Metal. ≤ ≤ ≤ 15 mlsH 10 mlsH 5 mlsH 2 2 2 /100g ofDWM /100g ofDWM /100g ofDWM TECHNICAL AND TRADE INFORMATION 269 0.25-0.55 0.25-0.55 0.40-0.65 0.40-0.65 Nickel Steel Cored Wires Steel Cored Nickel Carbon Steel Cored Wires Carbon Steel Cored Other Low Alloy Steel Cored Wires Alloy Steel Cored Other Low Carbon-Molybdenum Steel Cored Wires Steel Cored Carbon-Molybdenum Chromium-Molybdenum Steel Cored Wires Chromium-Molybdenum Steel Cored Manganese-Molybdenum Steel Cored Wires Manganese-Molybdenum Steel Cored AS 2203.1 Weld Metal Chemistry Wt% Summary - Table 4 ASTable - Wt% Summary Metal Chemistry Weld 2203.1 G 1.00 min. 0.80 min. min. 0.50 0.30 min. min. 0.20 0.10 min. / 1.8Al B3 0.12 1.25 0.80 2.00-2.50 0.90-1.20 B1B2 0.12 0.12 1.25 1.25 0.80 0.80 0.40-0.65 1.00-1.50 0.40-0.65 0.40-0.65 A1 0.12 1.25 0.80 5Cr7Cr9Cr 0.10 0.10 0.10 1.50 1.50 1.50 1.00 1.00 1.00 0.40 0.40 0.40 4.00-6.00 6.00-8.00 8.00-10.50 0.45-0.65 0.45-0.65 0.85-1.20 0.50Cu 0.50Cu 0.50Cu Ni1Ni2Ni3 0.12 0.12 0.12 1.50 1.50 1.50 0.08 0.08 0.08 0.80-1.10 1.75-2.75 2.75-3.75 0.15 0.35/ 1.8Al 0.05V 0.05V / 1.8Al B3L 0.05 1.25 0.80 2.00-2.50 0.90-1.20 B2L 0.05 1.25 0.80 1.00-1.50 0.40-0.65 B2C 0.10-0.15 1.25 0.80 1.00-1.50 0.40-0.65 B3C 0.10-0.15 1.25 0.80 2.00-2.50 0.90-1.20 CM1CM2 0.20 > 0.20 1.75 1.75 0.90 0.90 0.50 0.50 0.20 0.20 0.30 0.30 0.08V / 1.8Al 0.08V / 1.8Al 9X.W 0.12 0.50-1.30 0.35-0.80 0.40-0.80 0.45-0.70 0.30-0.75Cu Weld Carbon Manganese Silicon Nickel Chromium Molybdenum Other 9X.K19X.K29X.K39X.K49X.K59X.K6 0.159X.K7 0.15 0.15 0.10-0.25 0.15 0.80-1.40 0.15 0.50-1.75 0.60-1.60 0.15 0.75-2.25 1.20-2.25 0.80 0.80 0.50-1.50 0.80 0.80 1.00-1.75 0.80 0.80-1.10 1.00-2.00 0.75-2.00 0.80 1.25-2.60 0.08 1.75-2.60 0.15 0.20-0.70 0.40-1.10 0.15 2.00-2.75 0.20-0.60 0.15 0.15-0.55 0.15 0.20-0.65 0.30-0.65 0.25-0.65 0.35 0.05V 0.05V 0.05V 0.15 0.05V / 1.8Al 0.05V 0.05V / 1.8Al 9X.D19X.D29X.D3 0.12 0.15 0.12 1.25-2.00 1.65-2.25 1.00-1.75 0.80 0.80 0.80 Metal No: (C) (Mn) (Si) (Ni) (Cr) (Mo) Elements AS 2203 Part 1-1990 Cored Electrodes for Arc Welding Ferritic Steel Electrodes cont. Steel Electrodes Ferritic Welding Arc for Electrodes 1-1990 Cored Part AS 2203 CONSUMABLES CLASSIFICATION TABLES CLASSIFICATION CONSUMABLES Single values shown are maximum. shown Single values www.cigweld.com.au 270 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au lrd 32,USA. Florida 33126, Miami, LeJeuneRoad, current publishedversionof AWS 550N.W. A5.20 obtainablefromthe American Welding Society, For fulldetailsCIGWELDrecommendyourefertothe The followinglayoutoutlinesthisclassificationsysteminpartonly. E70T-1 orE71T-1M JH4. eg: alpha numericgroupsseparatedbyahyphen. AWS A5.20-95 classifiesFluxCored Arc Welding (FCAW/cored)wiresbyusingaseriesoflettersanddigitsbroken intotwo O D C R If no ‘M’ isshownthantheelectrodeusedwitheither E E E T L AWS A5.20-95 CarbonSteelElectrodes forFluxCored Arc Welding CONSUMABLES CLASSIFICATION TABLES g =DC+ pa rnfr rutiletypefluxformulti- spraytransfer, 1=D.C.+, eg. lcrd hedn,polarityandimpactproperties are electrode shielding, 1 M Gnrl lsiiain andmeansthatthe Classification, G = “General” S niae h edn oaiyt eue,Arc GS) indicatesthe Welding Polarity tobeused, h hr ii ru 1t 4 ortheletter/sG = thethirddigitgroup(1to14, rnfr lxtp n h o of Weld Passes. FluxtypeandtheNo. Transfer, classified forusewith Argon +20-25%CO h hr etridcts“ie a”andis = thethirdletterindicates “Mixed Gas” CO edMtl Minimum Tensile Strength Weld Metal Snl”Pass weldingonly. S = “Single” 2 or theelectrodeisselfshielded. o pi (MPa) “psi” No: See Table 6fordetails. minimum tensilestrengthinpsix10,000. 7 60,000(415) 6 6 or7=thefirstdigitindicates pass welding. not specified. E71T-1MJH 70,000 (480) 2 . 4 Flat&Horizontal 1 0 Welding Positions J =thefourthletterindicatesthatelectrode Diffusible HydrogenContentofDeposited Weld The seconddigit The secondletter&sixthnumberindicatesthe meets thefollowingrequirementsofimproved mattuhes 20ftLb@-40 impact toughness, indicates the All Positional H H H 4 8 16 See Table 5fordetails. ≤ ≤ ≤ 4 mlsH 8 mlsH 16 mlsH Metal (DWM) 40 ° C). 2 2 2 /100g ofDWM /100g ofDWM /100g ofDWM The secondletter electrode isFlux indicates the T ° Designators F (27J@- = Tubular Optional Cored. TECHNICAL AND TRADE INFORMATION 271 C) C) C) C) C) C) ° ° ° ° ° ° F (27J @ - ° F (27J @ -29 F (27J @ -29 F (27J @ -29 F (27J @ -29 F (27J @ -29 F (27J @ -18 ° ° ° ° ° ° shielding gases. 2 gases or the use of 2 shielding gas. may Argon based gases 2 Argon + 20-25% CO Argon above those recommended,Ar / CO in 2 gas with these types of electrodes may result in the following; gas with these types of electrodes may 2 reduce yield and tensile strength and may degrade impact properties. reduce yield and tensile strength and may 1) deoxidiser levels in weld deposits may increase, 1) deoxidiser levels levels may increase, 2) weld deposit hardness which will raise yield and tensile and silicon levels may increase 3) weld deposit manganese strength, properties. and may degrade impact 1) deterioration of arc and out-of-position characteristics, 1) deterioration of arc and out-of-position levels of manganese and silicon which will 2) resultant weld deposits may show decreased These electrodes are designed primarily for use with CO electrodes are These Higher levels of CO 100% CO be used to improve out-of-position characteristics. be used to improve out-of-position By using Argon based gas mixtures with these electrode types the following problems may occur; with these electrode types the following Argon based gas mixtures By using These electrodes are designed primarily for use with These T-GT-G 60 70 415 480 48 58 330 400 22 22 not specified not specified T-6*T-7*T-8* 70 70 70 480 480 480 58 58 58 400 400 400 22 22 22 20ft Lb @ -20 20ft Lb @ -20 not specified T-3*T-4* 70 70 480 480 n.s. 58 n.s. 400 n.s. 22 not specified not specified T-GST-GS 60 70 415 480 n.s. n.s. n.s. n.s. n.s. n.s. not specified not specified AWS Strength Tensile Strength Yield % (CVN) Charpy-V-Notch T-10*T-11*T-13*T-13* 70T-14* 70 60 480 70 480 70 415 480 n.s. 480 58 n.s. n.s. n.s. 400 n.s. n.s. n.s. n.s. 20 n.s. n.s. n.s. n.s. not specified not specified not specified not specified not specified Class. ksi MPa ksi MPa Elong. Impact Requirements T-9/9M 70 480 58 400 22 20ft Lb @ -20 T-1/1M 70 480 58 400 22 20ft Lb @ 0 T-2/2MT-5/5M 70 70 480 480 n.s. 58 n.s. n.s. 400 22 not specified 20ft Lb @ -20 C),T-1/1M, are met for T-5/5M, T-6, T-8, types. T-12/12M and T-9/M T-12/12M 70-90 480-620 58 400 22 @ -20 20ft Lb ° As Welded Mechanical Properties - Table 5 Table - Mechanical Properties Welded As AWS A5.20-95 Carbon Steel Electrodes for Flux Cored Arc Welding cont. Welding Arc Cored for Flux Electrodes Carbon Steel A5.20-95 AWS CONSUMABLES CLASSIFICATION TABLES CLASSIFICATION CONSUMABLES E7XT-1M Warning: 40 * Self Shielded wire types. The above designations may be classified with the ‘J’ indicator provided the lower CVN Impact requirements of 20ft Lb @ -40 ‘J’ indicator provided the lower above designations may be classified with the The Shielding Gas Types Gas Shielding E7XT-1 Warning: www.cigweld.com.au CONSUMABLES CLASSIFICATION TABLES

AWS A5.20-95 Carbon Steel Electrodes for Flux Cored Arc Welding cont. AWS A5.20 Electrode Classification Summary - Table 6 AWS A5.20 Arc Transfer Slag No. of Weld Discernible Class. Polarity Type Base Passes Features and Applications T-1 Larger diameters (2mm [5/64”] & larger) are used for flat & H/V and DC + Spray Rutile Multiple welding only. Very smooth / quiet arc with low spatter loss, flat to T-1M slightly convex weld bead contour, full covering easy removed slag, and high deposition rates. Essentially the same as T-1 / T-1M types, but with higher manganese or T-2 DC + Spray Rutile Single silicon or both. Higher levels of deoxidisers allow welding of heavily and oxidised steels such as, rimmed, rusty and mill scaled steels. SINGLE T-2M pass only. DC + Spray Rutile Single # High speed gasless welding in flat & H/V and 20 T-3* ° down inclined Fluoride positions on sheet metal. Limited mech. props. DC + Globular Alumina Multiple T-4* Very low Sulphur weld deposits (resistant to hot cracking) & very high Fluoride deposition rates. Bridging of poor fit-up joints. T-5 Larger diameters (>2mm) are used for flat & H/V welding. Good DC + / - Globular Basic Multiple and mechanical properties (eg. impacts 27J @ -29°C / T-5M 20ft Lb @ -20°F ) Slightly convex weld bead contour, easy removed thin slag, resistant to hot & cold cracking.

TECHNICAL AND TRADE INFORMATION Good low temperature impact properties (eg. 27J @ -29°C / 20ft Lb @ Rutile DC + Spray Multiple -20°F ). Excellent slag removal in deep groove joints. Good root run T-6* Basic penetration. Flat & H/V only. DC - Spray Alumina Multiple Dia. (>2mm) used for flat & H/V welding. High deposition rates and T-7* Fluoride very low sulphur weld metal resistant to cracking. DC - Spray Alumina Multiple Very good low temperature strength, notch toughness and crack T-8* Fluoride resistance (eg. 27J @ -29°C / 20ft Lb @ -20°F ). T-9 DC + Spray Rutile Multiple Essentially the same as T-1 / T-1M types, but deposit weld metal with and improved impact properties (eg. 27J @ -29°C / 20ft Lb @ -20°F ). To T-9M obtain X-Ray quality, joints are to be relatively clean and free of oil, excessive oxide & mil-scale. T-10* DC - small droplet --- Single High speed gasless welding in flat & H/V and 20° vertical inclined Globular positions on larger thickness than the T-3 class. T-11* DC - Spray --- Multiple General purpose wire for use on material less than 20mm (3/4) unless preheat & interpass temp’s are maintained. T-12 Essentially the same as T-1 / T-1M types, but modified to increase and DC + Spray Rutile Multiple impact properties and to meet lower manganese requirements of the T-12M ASME Boiler and Pressure Vessel code section IX, A-1 analysis group of 1.6% Mn. T-13* DC - Short arc --- Single Root pass welding only on circumferential pipe welds. T-14* DC - Spray --- Single # High speed all positional welding of sheet metal such as, galvanised, zinc and other coated steels ≤ 6mm (1/4). T-G DC + / - not N.S. Multiple For electrodes not covered by any present classification. The wire must specified meet the chemical requirements to ensure a carbon steel deposit and the specified tensile strength. T-GS DC + / - not N.S. Single For single pass electrodes not covered by any present classification. The specified wire must meet the specified tensile strength requirements. No other requirements are specified. * Self shielded wire types. # Suitable only for material thickness below 6mm (1/4”)

272 www.cigweld.com.au TECHNICAL AND TRADE INFORMATIONTECHNICAL AND TRADE CONSUMABLES CLASSIFICATION TABLES

AWS ASME SFA A5.17 Standard for Submerged Arc Wires & Fluxes

7 Represents the minimum tensile Indicates the condition of heat treatment Indicates the lowest temperature, at strength of the Weld Metal in Psi in which tests were conducted. which the Impact Strength of the x 10,000 A = As Welded Condition Weld Metal exceeds 27 joules of 6 = 60,000 Psi P = Post Weld Heat Treated energy. Refer to AWS A5.17 Table 6 for specific requirements. 7 = 70,000 Psi Refer to AWS A5.17 Table 8.4 for PWHT requirements. 4 = -40º C

FLUX F7A4-EM12K Indicates Silicon, Fully Killed Steel Electrode

E = Solid Electrode EC = Composite Electrode

Table 1 Table 6 Chemical Composition Requirements for Solid Electrodes Impact Test Requirements Electrode Minimum Classification C Mn Si S P Cu Average Low Manganese Electrodes Test Energy Digit Temp C Level EL8 0.10 0.25-0.60 0.07 0.03 0.03 0.35 (Joules) EL8K 0.10 0.25-0.60 0.1-0.25 0.03 0.03 0.35 Z No Impact Requirements EL12 0.04-0.14 0.26-0.60 0.10 0.03 0.03 0.35 0-1827 Medium Manganese Electrodes 2-2927 EM12 0.06-0.15 0.8-1.25 0.1 0.03 0.03 0.35 4 -40 27 EM12K 0.05-0.15 0.8-1.25 0.1-0.35 0.03 0.03 0.35 5-4627 EM13K 0.06-0.16 0.9-1.4 0.35-0.75 0.03 0.03 0.35 6-5127 EM14K 0.06-0.19 0.9-1.4 0.35-0.75 0.025 0.025 0.35 8-6227 (Ti 0.03-0.17%) High Manganese Electrodes EH11K 0.07-0.15 1.4-1.85 0.8-1.15 0.03 0.03 0.35 EH12K 0.06-0.15 1.5-2.00 0.25-0.65 0.025 0.025 0.35 EH14 0.10-0.20 1.70-2.20 0.1 0.03 0.03 0.35

www.cigweld.com.au 273 274 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au tnad The publicationisavailable fromtheStandards Association of Australia orStandards NewZealand. standard. howeverforthecompleteclassificationCIGWELDrecommendsthatusersrefertocurrentversionof this classification, The followinglayoutoutlines 1996-Classifies Welding ConsumablesasusedforBuild-upandwearresistance. AS/NZS 2576. CONSUMABLES CLASSIFICATION TABLES TECHNICAL AND TRADE INFORMATION 275 AS/NZS class. 6400-C1 6200-A2 6300-C1 1315-A4 1560-A4 1865-B7 AS/NZS Class. 2360-B5 / B7 2360-B7 2360-A4 2460-B7 2565-B7 6300-C1 6400-C1 1125-B7 1215 B7 1315-B5 1315-B7 1435-B5 / B7 1440-B1 1445-B1 1715-B7 1860-A4 1855-B5 / B7 3460-A1 1955-B7 1125-B1 iron rich matrix Titanium Carbides Titanium Group 1 - SteelsGroup Type Alloy CONSUMABLES CLASSIFICATION TABLES (TABLE 7) (TABLE TABLES CLASSIFICATION CONSUMABLES Stoody 600 High Carbon Martensitic Steel with Bronzecraft AC-DCComweld Manganese BronzeComcoat C BronzeComweld Nickel Comcoat N Brass Tensile High Phosphor Bronze Bronze (9-13%Ni) Nickel Cobalarc 9eStoody 143-O Cobalarc BorochromeStoody Fineclad-O Carbide Comp.Tungsten 3 - Group AC/DC Borium Tube Stoody Type Alloy Alloys 4 - Copper Group Martensitic Chromium Carbide Iron Complex Chromium Carbide Iron Carbide granules in an Tungsten Type Alloy 2560-A4 2460-A4 Stoody 850-O IronsWhite 2 - Cr Group Cobalarc CR70Stoody 101 HC G/O Stoody 100 HC Cobalarc 1e Type Alloy Austenitic Chromium Carbide Iron 2355-A4 Cobalarc 350 G/O Stoody Super Build Up Stoody 107 Stoody 105 Cobalarc ToolcraftStoody 110 MC Cobalarc 650Cobalarc 750 Stoody 965 G/O Martensitic Steel Low Carbon Steel Tool High Carbon Martensitic Steel 1435-A4 1855-A4 Stoody 104Stoody Build Up-O Cobalarc MangcraftStoody Dynamang AustexCobalarc 309LT Verti-Cor Stoody SOS 309L Austenitic Manganese Steel Steel Pearlitic Austenitic Stainless Steel A4 1215 www.cigweld.com.au 276 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au h tiesmo n h od rohed tisil,Auhed Argoplasand SpecshieldareBOCGrouptrademarks. Alushield, Stainshield, The stripesymbolandthewords Argoshield, The informationonthispageis reprinted withthepermissionofBOCLtd. BOC SHIELDINGGASINFORMATION Argon Shielding Gasesand Their Properties nitrogen. and isproducedintheairseparationprocessadditiontooxygen Argonforms0.9%ofairby volume standard GTA weldingshieldinggas. Argon isoneofthegasesavailable intheBOCproductrangeandisa tension ofliquidironinargonatmospheres. lowheatinputandrapidcoolingratethehighsurface bead shapeisduetolowarcenergy, This poorweld metal nottoflowoutthetoesofweldcausingaveryunevenshape. There isamarked tendencyforthefiller provide suitablemetaltransfercharacteristicsforsteel. however, Itdoesnot, Argon isusedasaGMAweldingshieldinggasformanynon-ferrousmetals. This allowsforvirtuallyspatter-free weldinginspraytransfermode. themainforceinarcis axial tothefillerwireandacceleratesmoltendropletsmoothlyacrossarc. InGMAwelding (spray orpulsetransfermode), profile. weld depositintothebasemetalgiving ‘finger’ or ‘wine glass’penetration The resultisarelativelynarrowweldbeadwithdeepcentralpenetrationofthe thermal conductivitywhichfacilitateseasyarcinitiation. Argon producesaconstrictedarccolumnandhaslow arc startsandastableweldingarc. withanionisationpotentialof15.7eVgivingeasy heavierthanair, Argon isachemicallyinertgas, These functionsareaffectedbysuchfactorsas: metal fromcontamination. Shielding gasesarethoseusedinarcweldingandcuttingprocessestogeneratetheshieldmolten welding productivityandhelptoreducethetotalweldcost. aspecificmixtureofgaseswillofferimprovementsin form asshieldinggasesinmostapplications, used intheirpure These gasesformthebasisofmixturesusedinBOC Argoshield The maingasesusedintheformulationofashieldinggasare: Specshield ® ag eindt etme h ed ftewligidsr.Whilecarbondioxideandargoncanbe range designedtobestmeettheneedsofweldingindustry. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ Hydrogen. Helium Oxygen Carbon Dioxide Argon finish required. metal transfermode type ofwire material thickness weld economics process chosen weld position material tobewelded ® Stainshield , ® Alushield , Carbon steel shielded GMAweldon Penetration profileof Argon ® Argoplas , column arc GMAW Argon ® and , TECHNICAL AND TRADE INFORMATION 277 GMAW Helium arc column Carbon Dioxide arc column Penetration profile of Penetration Carbon Dioxide on Carbon steel mixtures, 2 arc. Globular and dip transfer arc 2 in GMA welding 2 C, the top of the arc to its molecules dissociate at ° cannot be used to weld readily oxidisable metals such cannot be used to weld readily oxidisable 2 . 2 , as it is commonly known, is not chemically inert.energised and When 2 shielded arc is highly oxidising, it is useful for coping with surface contaminants 2 2 = 2CO + O 2 of steel, and it is recommended that filler wires with a high manganese are used. silicon level or triple de-oxidised wires as aluminium, copper, magnesium or nickel, welding. or for GTA can give a 200-300% increase in carbon content in steels because of carbon pick-up which It is not suitable for stainless the weld metal. In addition, because of the oxidising characteristics of CO subjected to arc temperatures above 6000 subjected to arc temperatures oxygen can be very beneficial in improving arc characteristics and reducing the surface tension of oxygen can be very beneficial in improving arc characteristics and reducing the the weld metal. the arc intensifying the arc plasma, It is an active gas which dissociates in thereby increasing the heat input and travel speed, and improving weld penetration and edge wetting. It spatter-free,promotes the spray transfer mode in GMA welding of steels to give a virtually high productivity process. Because it is oxidising and not inert, CO Helium is also inert but has a higher ionisation potential than argon, of 24.5 eV. As a result, helium arcs have a higher arc voltage than argon for a given arc length, translating into higher heat input and weld travel speeds. produces a wide, high thermal conductivity of helium The low weld bead with good fusion and penetration. High flow rates are necessary to maintain a helium shield because the gas is lighter than air. Although oxygen itself is not used as a shielding gas, it is a vital component in shielding gas mixtures. When used as a low percentage (i.e. 1-7%) additive to argon or argon/ CO Carbon dioxide, or CO and in so doing, recombine at the bottom of the arc molecules These release a into the arc causing a stuttering,disruptive force upward unstable arc and welding spatter. molten filler metal creating a deep oxygen superheats the transferring The penetrating, fluid weld pool and promoting the deposition of convex weld beads. Because the CO form excited species of oxygen and carbon monoxide: form excited species 2CO modes only are used with CO such as rust, paint and primers. and carbon manganese Carbon dioxide can be used for mild steel welding, where it gives a narrow, bead with deep penetration. weld peaked normal not occur in the CO spray transfer of fine metal droplets does The Oxygen Helium Carbon Dioxide Carbon BOC SHIELDING GAS INFORMATION GAS SHIELDING BOC The information on this page is reprinted with the permission of BOC Ltd. information on this page is reprinted The Argoshield, stripe symbol and the words The Stainshield, Alushield,trademarks. Argoplas and Specshield are BOC Group www.cigweld.com.au 278 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au h tiesmo n h od rohed tisil,Auhed ArgoplasandSpecshield areBOCGrouptrademarks. Alushield, Stainshield, The stripesymbolandthewords Argoshield, The informationonthispageis reprinted withthepermissionofBOCLtd. Argon +OxygenMixtures BOC SHIELDINGGASINFORMATION Hydrogen Helium cont. Argon BasedMixtures virtually spatter-free beadsonsheetsteelinspraymode. eerto atr.BOC’s Argoshield penetration pattern. BOC’s Stainshield have beenspecificallydevelopedforhighoxidisingmaterialssuchasaluminium. tr n rnpr salqi,becauseitsboilingpointisverylow-269 store andtransportasaliquid, Itiscostlytoproduce, Helium isararegasfoundinassociationwithcertainnaturalstreamslowconcentrations. gases suchasoxygenandcarbondioxide. whichcantoleratesmallquantitiesofoxidising on stainlesssteelandnickel alloys, Argon/oxygen weldshaveaflatterbeadthanargonorCO siliconandchromium. oxidised withconsequentlossesofmanganese, thesurfaceofweldbeadbecomesincreasingly Above 5%oxygen, Stainshield asfound inBOC’s 3CR12)amixture of1-2%oxygen, For stainlesssteelsandothercorrosionresistant(e.g. wettingtheparentmetaltoflattenweldbeadprofile. has alowersurfacetensionthanwithargon, The moltenweldpool aswellincreasethetemperatureofmoltenmetaltransferredacrossarc. and silicon, 1-7%)preventexcessivelossesofmanganese Discretepercentagesofoxygen(i.e. tendency toundercutferrouswelds. improvetheweldbeadprofileandedgewettingminimise Oxygen isaddedtoargonstabilisethearc, toincreasetheheatinputforGMAweldingofsteelsandstabilisedropletsize. carbon dioxide, suchasoxygenor Itisthereforenecessarytoaddactivegasesargon, undercutting attheedgesofweldbead. causing freeze characteristicsofanargonwelddoesnotpermitthemoltenmetaltowetouttoesweld, thequick whendepositingflatorhorizontalweldsonsteelstainlesssteel, However, the commonlyweldedmetals. Argon isanexcellentbaseforGMAweldingshieldinggasmixturesbecauseitpermitstheuseofspraytransferwithall tolerance tovoltageandcurrentsettings. balance ofgasesinamixturewillproduceshieldinggaswiththeoptimumpropertiesforapplicationandgreater theright Dependingontheapplication, arcstabilityandtheshapestrengthofweld. shielding efficiency, includingthe The characteristicsofeachgasusedinashieldingmixtureaffecttheway thegaswillperform, oxide filmsontheweldpoolsurfaceresultinginacleanerbead. itsaction helpstoremove Becausehydrogenisareducingagent, energy fordeeperpenetrationandweldpoolfluidity. This producesahigherarc butahighthermalconductivity. Hydrogen hasarelativelylowionisationpotential(13.5eV), BOC’s Alushield are alsoinfluencedbythematerialtobewelded. The constituents possibly othergasestofurtherenhanceitsoperatingcharacteristics. It istypicalforbothGMAandGTA weldingtocombineHeliumwith Argon and ® isrecommended. , ® Heavy andBOC’s Stainshield ® 40 issuchanargon/oxygenmixtureoffering ® 69 havebeendevelopedforuse 2 and giveawineglass ® range ofmixtures ° C. weld onCarbonsteel + OxygenshieldedGMA Penetration profileof Argon on Carbonsteel Helium shieldedGMAweld Penetration profileof TECHNICAL AND TRADE INFORMATION 279 Penetration profile of Argon profile of Penetration + Carbon Dioxide shielded steel GMA weld on Carbon Argon profile of Penetration + Oxygen + Carbon Dioxide Argon profile of Penetration + Helium shielded weld on Carbon steel 71T, produces a very hot arc ® Light, are well suited to dip transfer ® 90T and Specshield ® 2 mixtures give Universal, are best 2 ® mixtures are 52 is a high CO 2 mixture flattens the weld bead and improves spray transfer mixture flattens the weld bead and improves ® 2 mixtures,Argoshield such as BOC’s Heavy are argon/helium mixtures. 2 ® conventionally ranging from 2-30% by volume. conventionally ranging 2 mixtures,Argoshield such as BOC’s 2 Light and Alushield Light and should not be exceeded for best results.should not be exceeded With increasing ® 2 weld shows deeper and fuller penetration than argon/carbon dioxide shielded and weld shows deeper and fuller penetration 2 content to provide more heat and broader and deeper penetration, content to provide more 2 The further addition of Oxygen to an argon/CO The an argon/oxygen weld. Argon/helium mixtures are usually used to obtain the most favourable characteristics of both gases in terms of heat input, weld speed, weld bead profile and penetration. mixtures are normally used for heavier The sections of non-ferrous metals such as aluminium, copper, magnesium and nickel. heavier the metal thickness and the more heat The conductive the metal, of helium required in the greater the percentage the mixture. mixtures contain between 25% and 75% helium. Typical Alushield BOC’s spatter levels which are much lower than with carbon dioxide, but with comparable penetration and fusion performance. addition of the oxygen The reduces the droplet diameter and improves the stability of the transfer. characteristics, total heat input, weld bead profile and penetration. allow the fullest flexibility in producing shielding gases best suited to different Argon/oxygen/carbon dioxide mixtures steel applications. oxygen and CO The For mild and carbon manganese steels,For mixtures argon/carbon dioxide CO can be used with the Ideally 25% CO making this mixture ideal for GTA welding of stainless and nickel steels. welding of stainless and nickel making this mixture ideal for GTA relatively small amount of hydrogen does The of welding while offering cleaner not cause damage to the tungsten electrode but is desirable to increase the speed weld beads by the reducing action of the hydrogen on the weld pool surface oxides. Hydrogen is also known to in austenitic stainless steel castings. improve the weld tolerance of variations welding of lighter section metal. In the spray transfer mode, arc with greater welder appeal and they give an excellent light and medium section steels. minimum spatter that is suitable for welding Low oxygen/high CO the spray transfer mode deteriorates.the spray transfer mode Argoshield A mixture of argon/helium/hydrogen, Specshield as found in BOC’s mixture offering excellent penetration.mixture offering excellent Argon/CO CO suited to dip and spray transfer welding and display excellent weld bead suited to dip and spray transfer welding profiles and penetration. perform particularly well in all position They welding typically in the 4-12mm thickness range. High CO successfully used with flux-cored and metal-cored wires. successfully used with An argon/CO Argon Based Mixtures Based Argon BOC SHIELDING GAS INFORMATION GAS SHIELDING BOC The information on this page is reprinted with the permission of BOC Ltd. information on this page is reprinted The Argoshield, stripe symbol and the words The Stainshield, Alushield, Argoplas and Specshield are BOC Group trademarks. Argon + Oxygen + Carbon Dioxide mixtures Argon + Helium Mixtures Argon + Carbon Dioxide Mixtures Argon + Carbon Dioxide Argon + Helium + Hydrogen www.cigweld.com.au 280 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au The shieldinggasshallbecomposedofthefollowingdesignatorandnumberarrangement: The designationsystemshallbebasedonvolumetricpercentages. Gases areidentifiedasfollows: DESIGNATION SYSTEM The objectiveoftheStandardistospecifyaclassificationsystemforshieldinggases forwelding. Shielding Gasesfor Welding (AS4882–2003) SHIELDING GASINFORMATION Shielding gas designator SG-B XYZ- SG SG-B SG- GBX %3componentmix 4componentmix 2componentmix SG-B XYZ-%%% SG-B XY-%% SG-B X-% B XYZ %%% designator Base gas indicates thesingularormajorgasinshieldingmixture identifies theproductasashieldinggas percentages fortwoormorecomponentmixtures a slashshallbeusedtoseparatetheindividualminorcomponents indicates theminorindividualgasindicatorsindecreasingorderof% eintrGas Designator eHelium He Oxygen Nitrogen O N Hydrogen Argon H A CarbonDioxide C Minor gas(es)designator and %amount

TECHNICAL AND TRADE INFORMATION 281

(3) > 66 to 95 to 66 > (3)

(2) > 33 to 66 to 33 > (2)

GROUPS R AND M CONTAINING HELIUM CONTAINING M AND R GROUPS (1) > 0 to 33 to 0 > (1)

IDENTIFICATION NUMBERS FOR GASES IN GASES FOR NUMBERS IDENTIFICATION

Identification Helium content % V/V % content Helium Identification

#Argon may be replaced by up to 95% helium. The helium content is designated by an additional identification number. Refer to Clause 4 of the ISO Standard for further details on both the these notes. these the both on details further for Standard ISO the of 4 Clause to Refer number. identification additional an by designated is content helium The helium. 95% to up by replaced be may #Argon

*Where components not listed are added to one of the groups in this table the gas mixture is designated as a special gas mixture and carries the prefix S. prefix the carries and mixture gas special a as designated is mixture gas the table this in groups the of one to added are listed not components *Where

2 o5 aac Reducing Balance 50 to 0 >

back shielding back

F1 0 lsaacctig Unreactive cutting, arc Plasma 100

2 Balance > 0 to 30 to 0 > Balance 2

100 1 C

o5 o1 Balance 15 to 8 > 50 to 5 > 3

#

0t 5Balance 15 to 10 > 2 oxidation

#

31>2 o5 Balance 50 to 25 > 1 M3 pronounced

#

o2 o8Balance 8 to 0 > 25 to 5 > 4 A More MAG

#

o5>3t 0Balance 10 to 3 > 5 to 0 > 3

#

o1 Balance 10 to 3 > 2

#

21>5t 5Balance 25 to 5 > 1 M2

#

o5>0t Balance 3 to 0 > 5 to 0 > 4

#

o3Balance 3 to 0 > 3

#

o5Balance 5 to 0 > 2 oxidising

#

11>0t Balance 5 to 0 > 1 M1 > 0 to 5 to 0 >

ISO 14175:1997 (E)) ISO 14175:1997 Slightly #

3 Balance > 0 to 95 to 0 > Balance

2 100 welding, back shielding back welding,

1 I 100 I,TG lsaacInert arc plasma TIG, MIG,

back shielding back

2 > 15 to 35 plasma arc cutting, arc plasma 35 to 15 > Balance

#

1 R Balance o1 I,pam r edn Reducing welding arc plasma TIG, 15 to 0 >

#

O 2A eH N2 H2 He Ar O2 CO2

ru dniiainOiiigIetRdcn Unreactive Reducing Inert Oxidising Identification Group

Symbol* Components % V/V % Components yia plctosRemarks Applications Typical CLASSIFICATION OF SHIELDING GASES FOR ARC WELDING AND CUTTING AND WELDING ARC FOR GASES SHIELDING OF CLASSIFICATION Shielding Gases for Welding ( Welding Gases for Shielding SHIELDING GAS INFORMATION GAS SHIELDING www.cigweld.com.au 282 TECHNICAL AND TRADE INFORMATION mi:[email protected] Email: PAC/PAW StainlessSteels GMAW Copperand Alloys and Alloys GMAW Aluminium FCAW Lowand Alloy Steels Welding Consumables-Shieldinggasesforarcweldingandcutting ISO 14175-1997: Shieldinggasesforwelding AS 4882-2003: GMAW StainlessSteels GMAW Lowand Alloy Steels h tiesmo n h od rohed tisil,Auhed Argoplasand SpecshieldareBOCGrouptrademarks. Alushield, Stainshield, The stripesymbolandthewords Argoshield, The informationonthispageis reprinted withthepermissionofBOCLtd. BOC AUSTRALIA -SHIELDINGGASESCLASSIFICATION TABLE SHIELDING GASINFORMATION rdc rdc rnil eeisA48 ISO14175 AS4882 PrincipleBenefits Product Product oeName Code 6 edn ro estl GAI1 SG-A M13 SG-AO-0.7 Versatile fast Versatile, M13 SG-AO-1.5 Specshield®Copper Welding Argon goodappearance, Minimalspatter, 077 Alushield®Light fast Clean, 061 079 Lowdefectlevelsonthickmaterial Stainshield® Stainshield®Heavy 092 075 9 tisil®6 Ideallysuitedtoapplicationswhere Stainshield®69 094 6 lsil®HayFs,goodpenetration on Fast, Alushield®Heavy 069 9 tisil®6 Minimalspatterlevelsandsurface Stainshield®66 093 7 rohed 2Idealforfluxcoredwelding Argoshield®52 070 4 rols 5Ideallysuitedtoplasmacutting Argoplas®35 145 4 rols 0Ideallysuitedtoplasmacutting Argoplas®20 144 4 rols Ideallysuitedtoplasmaweldingand Argoplas®5 143 Goodweldappearance C1 M24 SG-C M21(1) SG-ACO-7/1.5 SG-AHeC-25/10 Argoshield52 Wideoperatingrange Highweldappeal; Excellentfinishwithminimalclean-up M24 Idealforfluxcored Goodpenetration; SG-ACO-16/2.75 Argoshield®100 M23 IndustrialCarbonDioxide Argoshield®54 SG-ACO-5/3.1 Goodappearance 070 081 cleanappearance Fast, 095 minimalspatter Lowdistortion; 071 Argoshield®Heavy Argoshield®Universal Argoshield®Light 064 065 060 8 nutilCro ixd Somewiresdesignedforuse IndustrialCarbonDioxide Lowprofilebeadshape 081 Argoshield®40 068 hce aeil ieba hp GHA2 I3(3) SG-HeA-25 widebeadshape thicker material, eppntain atwligsedS-C2 M21 SG-AC-25 fastweldingspeed Deep penetration, xeln r tblt,fs pe GAe-528M12(2) SG-AHeC-35/2.8 fastspeed Excellent arc stability, o eetlvl ntikmtra GAO1/ M24 SG-ACO-18/2 Low defectlevelsonthickmaterial xdto ihotmlcnorS-C-./ M11 SG-ACH-2.8/1 oxidation withoptimalcontour maximum corrosion resistance fsanessel n lmnu GA-5R2 SG-AH-35 of stainlesssteelsandaluminium lsactigo tils tesS-H5R1 SG-AH-5 plasma cuttingofstainlesssteels li edpo,ecletfso GA- M22 SG-AO-5 excellentfusion Fluid weldpool, odpntainS-C2 M21 SG-AC-25 Good penetration atwl pe GH-7I3(1) SGAHe-27 fast weldspeed fsanessel GA-0R2 SG-AH-20 of stainlesssteels under CO sipratS-HO3/. M13(2) SG-AHeO-35/0.9 is important 2 nyS- C1 SG-C only 031997 2003 TECHNICAL AND TRADE INFORMATIONTECHNICAL AND TRADE SHIELDING GAS INFORMATION

Mild and Medium Tensile Steels - Gas Metal Arc and Flux Cored Arc Welding

Shielding Gas Filler Metals GMAW Comments Filler Metals FCAW Comments Argoshield 40 Autocraft Autocraft Clean, smooth finish Metal-Cor XP* LW1 LW1-6 Argoshield Autocraft Autocraft Clean, dip & spray Metal-Cor XP* Light LW1 LW1-6 transfer Metal-Cor 5* Argoshield Autocraft Autocraft Higher penetration Metal-Cor XP Optimum shielding for Universal LW1 LW1-6 Metal-Cor 5 penetration and travel speeds Satin-Cor XP (1.6mm) Smooth even transfer Verti-Cor XP spatter and fine levels. Verti-Cor 3XP Adequate penetration. Verti-Cor 3XP H4 Supre-Cor 5 Supre-Cor XP Tensi-Cor 110TXP H4 Argoshield 52 Autocraft Autocraft Higher CO2 level, Satin-Cor XP (1.6mm) Optimum shielding giving LW1 LW1-6 excellent dip Verti-Cor XP excellent edge fusion and and spray Verti-Cor 3XP penetration, low spatter Verticor 3XP H4 and fume levels. Supre-Cor 5 Supre-Cor XP Tensi-Cor 110TXP H4 Metal-Cor XP Higher CO2 content with Metal-Cor 5 slightly increased spatter levels. Argoshield 54 Autocraft Autocraft High quality, triple Metal-Cor XP* LW1 LW1-6 mixture Verti-Cor XP* Argoshield 100 Autocraft Autocraft Helium addition for Supre-Cor 5 Improved arc transfer, LW1 LW1-6 higher travel speeds better fillet shapes & lower spatter levels Welding CO2 Autocraft Autocraft High penetration, Satin-Cor XP Optimum shielding for LW1 LW1-6 low cost Verti-Cor XP economy and weld Verti-Cor ULTRA metal quality. Supre-Cor 5 Low cost shielding giving Supre-Cor XP deep penetration Tensi-Cor 110TXP H4 characteristics.

* These shielding gases are not normally recommended due to higher Mn and Si recovery in the weld metal. For single pass fillet welds the results may be acceptable.

www.cigweld.com.au 283 SHIELDING GAS INFORMATION

Alloy Steels - Gas Metal Arc and Flux Cored Arc Welding Shielding Gas Filler Metals GMAW Comments Filler Metals FCAW Comments Argoshield 52 Autocraft Super Steel Excellent penetration Supre-Cor 5 For alloy steels where Autocraft Mn-Mo and usability for dip Supre-Cor XP H4 full joint efficiency is not Autocraft CrMo1 and spray transfer. Most required Autocraft NiCrMo suitable for dip transfer. Verti-Cor 81Ni 1 For alloy steels where Verti-Cor 81Ni 1 H4 higher joint strength Verti-Cor 91 K2 is required Verti-Cor 91 K2 H4 Verti-Cor 111 K3 Tensi-Cor 110 TXP H4 Stainshield Autocraft Super Steel Optimum choice for Autocraft Mn-Mo smooth transfer in Autocraft CrMo1 spray mode, N.R. Autocraft NiCrMo higher alloy recovery Argoshield 100 Autocraft Super Steel Helium addition Supre-Cor 5 Improved arc transfer, Autocraft Mn-Mo for high travel Supre-Cor XP H4 better fillet shapes Autocraft CrMo1 speeds & lower spatter levels. Autocraft NiCrMo For alloy steels where full joint efficiency is not TECHNICAL AND TRADE INFORMATION required

Stainless Steels - Gas Metal Arc and Gas Tungsten Arc Welding Shielding Gas Filler Metals GMAW Comments Filler Wires GTAW Comments Stainshield Autocraft 307Si Smooth, even Autocraft 308LSi transfer, excellent N.R. Autocraft 309LSi fillet shape, ideal Autocraft 316LSi for spray transfer Autocraft 2209 Stainshield Autocraft 307Si Excellent dip Heavy Autocraft 308LSi transfer, can also N.R. Autocraft 309LSi be used for spray Autocraft 316LSi For welding heavier Autocraft 2209 section (>9mm) stainless steels. Welding Argon N.R. Comweld 308L Low cost shielding for Comweld 309L all general purpose Comweld 316L applications. Also used as Comweld 2209 purge gas on pipe welding.

284 www.cigweld.com.au TECHNICAL AND TRADE INFORMATION 285 applications mechanised applications. Higher travel speeds. N.R. Comweld AL5356 Comweld AL5356 travel speeds. requirements. Higher sections. Comweld AL5356 applications. Autocraft Silicon Bronze applications Autocraft AL4043Autocraft AL5356 general purpose applications Comweld AL4043 Comweld AL4047 manual applications Autocraft AL5356 penetration. Comweld AL4047 Autocraft AL5356Autocraft penetration for heavyAL4047 Comweld and mechanised LightAL4043 Autocraft broader & deeper AL4043 Comweld penetration is required. Heavy Autocraft AL4043 broadest, deepest Comweld AL4043 sections (>6mm) Copper Autocraft Silicon Bronze characteristics Alushield Autocraft Deox. Copper Hotter arc, reduces Comweld Si. Bronze Hotter arc for Alushield AL1188 Autocraft Hotter arc to give AL1188 Comweld Hotter arc where more Alushield AL1188 Autocraft arc, Hottest high speed AL1188 Comweld Hottest arc for heavier Specshield Autocraft Deox. Copper improved For Shielding Gas Metals GMAW Filler CommentsWires GTAW Filler Comments Shielding Gas Metals GMAW Filler CommentsWires GTAW Filler Comments Welding Argon Welding Autocraft Deox. Copper general purpose For Si. Comweld Bronze general purpose For Welding Argon Welding AL1188 Autocraft shielding for Excellent AL1188 Comweld Excellent shielding for Alushield Heavy Autocraft Silicon Bronze preheat temp. Copper Alloys - Gas Metal Arc and Gas Tungsten Arc Welding Arc Tungsten Arc and Gas Alloys - Gas Metal Copper Aluminium Alloys - Gas Metal Arc and Gas Tungsten Arc Welding Arc Tungsten Gas and Arc Metal Alloys - Gas Aluminium SHIELDING GAS INFORMATION GAS SHIELDING www.cigweld.com.au 286 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Factors influencingweldability: pleaserefer tothe Welding Technology Instituteof “weldability ofsteels” Australia (WTIA) Technical Note1. For acomprehensivetreatmentofthe under theappropriatesteelstandardspecificationorproprietarytradenames. The followinginformationisforguidanceindeterminingtheweldabilityofvarious gradesofsteelwhichhavebeenlisted 3) Welding Energy orHeatInput: 2) DeterminationofCombinedJoint Thickness: 1) The effectofCarbononSteel: WELDING OFSTEEL where Welding energy inputisbasedonthefollowingformula: Determination ofcarbonequivalentandgroup numberofthesteel: V I E Q and thewelddeposit. minimises theriskofhighhardnessinHeat Affected Zone(HAZ)ofthebasemetal thebestpracticeistoadoptaweldingprocedurewhich From aweldingpointofview, when thematerialissubjecttothermaltreatment. carbon contentofaparticularsteelresultsincorrespondingincreasehardenability increasingthe Carbon isamajoralloyingelementinthevarious gradesofsteel; =IxEx 60 x Q =IxE and automaticwelding. semi-automatic specific arcweldingprocessesadoptedincludingmanualmetalarc, arcvoltageandweldingspeedforthe inparticularweldingcurrent, variables used, Welding energyorheatinputcalculationsaredependentuponthepracticalwelding T joint configurations. PleaserefertoDiagram1forCJT’s forarange of are basedonthefollowingformula. cooling rateofadjoiningsections-calculationsfordeterminingcombinedthickness The conceptofcombinedjointthickness(CJT)isrequiredtoaddresstheexpected CE =C+MnCrMo V +NiCu weldability referencenumbersdetailedin Table 1. Refer totheCarbonEquivalent (CE)tableandrespective its relativeweldability. important alloyingelementsincalculatinganumberwhichgradesthesteeltermsof The followingformulaforCarbonequivalent (CE)takes accountofthe manganese. inparticularcarbonand given tothecombinedeffectofalloyingelements, considerationmustbe In determiningtheweldabilityofaparticulargradesteel, CJT = Welding speedortravelrate(mm/min) = Welding current(Amperes) = Arc voltage(volts) KJ/mm) = Welding energyorheatinput(Kilojoulespermillimetre, = t V 1000 V 1 6 5 15 + t 2 + t 3 + t 4 TECHNICAL AND TRADE INFORMATION 287 is to be used, 2; refer to Figure is to be used, 3. refer to Figure hydrogen controlled welding consumable controlled hydrogen Hydrogen controlled welding consumables: controlled Hydrogen as those consumable/process Hydrogen controlled types are defined 15 mls of diffusible hydrogen per 100 gms combinations which produce less than of deposited weld metal.arc include hydrogen controlled manual These electrodes of the EXX16, EXX18, 1 and AS/NZS 1553 Parts EXX28 and EXX48 types to 2.AS 2203.1 and and flux-cored welding wires to Many gas shielded metal-cored AS/NZS 2717.1 satisfy the hydrogen all steel gas metal-arc welding wires to used with the correct shielding gas. controlled requirement provided they are welding consumables, all hydrogen controlled For in must be taken precautions status is not compromised. storage and handling to ensure the hydrogen on the correct storage and handling of CIGWELD welding further information For “Care consumables, Note 3 Tech WTIA publication refer to this handbook or please Consumables”. Welding and Conditioning of Non-hydrogen controlled welding consumables: controlled Non-hydrogen group includes cellulose,This iron powder type electrodes to mild steel and AS/NZS 1553.1 classifications EXX10,Australian Standard EXX11, EXX12, EXX13,and EXX24. EXX14 to care should be taken these non-hydrogen controlled electrodes For adverse atmospheric conditions (ie avoid moisture pick-up from exposure to excessive heat, humidity etc) specific joint being welded. the two numbers from 1 & 2 above (ie the weldability reference number and the CJT number). 3* to calculate the appropriate preheat temperature. 2* or ( in KJ/mm ) on Figure non-hydrogen controlled welding consumable controlled non-hydrogen *Note: if a 3. 1, Using Figure determine the joint weldability index from the intersection point of 4. index, Cross reference the joint weldability with the expected welding energy input Where a particular grade of steel is not listed, calculate the CE from the formulae given n section 1. 1 cross reference the CE calculation to determine the Table Using appropriate weldability reference number. 2. Using Diagram 1 as a guide, (CJT) for the determine the combined joint thickness ▲ ▲ When determining the weldability of steel,When determining the be given to careful consideration must selection. welding consumable the purpose of preheat determination,For the welding consumable/process types. be broadly grouped into two major combination used can are which Those and those which are not hydrogen controlled: hydrogen controlled if a 1. weldability reference number for the particular grade of steel. Select the corresponding General Procedure in Determining Weldability and Preheat Requirements. and Preheat Weldability in Determining Procedure General 4) Hydrogen Controlled Consumables and Welding Process Selection: Process Welding and Consumables Controlled 4) Hydrogen WELDING OF STEEL OF WELDING www.cigweld.com.au 288 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Weldability Reference Numbers: The NeedforPreheating oftheSteelJoint: WELDING OFSTEEL .0t eo .5608 n bv 12 Reference 11 7 10 9 0.80andabove 0.75tobelow0.80 0.70tobelow0.75 0.55tobelow0.60 0.65tobelow0.70 Weldability (CE) 6 5 4 1 3 Reference CarbonEquivalent 0.50 tobelow0.55 Weldability 0.45 tobelow0.50 0.40 tobelow0.45 0.35 tobelow0.40 ≤ below 0.30 (CE) Carbon Equivalent .0t eo .5206 oblw06 8 0.60tobelow0.65 2 0.30 tobelow0.35 TackProcedure: Welding Table 1 The beneficialeffectsofpreheating inimproving theweldabilityofsteeljointare: oe edblt eeec ubr bv 2(e 2,1B 12C&13)arenot 12B, 12A, Weldability ReferenceNumbersabove12(ie. Note: shown in Table 1below: The Weldability ReferenceNumbersusedinthisguiderelatetothecarbonequivalent (CE)ranges operation regardlessofthefactthattackweldswillbecomepartweldment. Best practicerequiresthatthespecifiedpreheatisusedpriortoanytackwelding .Peetn sit ntermvlo ifsbehdoe rmtewl oei.the Preheatingassistsintheremoval ofdiffusiblehydrogenfromtheweldzoneie. 4. Preheattemperaturesshouldbedeterminedinaccordancewiththerequirements 3. Preheatingisusedtooffsetthethermalconductivityofsteelsectionsand 2. Preheatingretardsthecoolingrateinjointandisbeneficialpreventing 1. weld beadandHAZ. subsequent weldpasses. of Figure 2or3withthepreheattemperaturebeingmaintainedbetween beneficial inreducingthelevelofresidualstressjointafterwelding. (HAZ) ofthebasemetalandinweldhighalloysteeldeposits. undesirable metallurgicalmicrostructuresfromoccurringintheheataffectedzone Number related toCE. Number TECHNICAL AND TRADE INFORMATION 289 Figure 1 - Determination of joint weldability index using combined joint thickness Figure number. and weldability reference Diagram 1 - Combined Joint Thickness (CJT) calculations for welds shown in black. 1 - Combined Joint Diagram Preheat Determination: Preheat The information on this page is reprinted with the kind permission of The Welding Technology Institute of Australia (WTIA). Institute of Technology Welding The information on this page is reprinted with the kind permission of The WELDING OF STEEL OF WELDING www.cigweld.com.au 290 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au WELDING OFSTEEL The informationonthispageisreprintedwiththekindpermissionof The Welding Technology Instituteof Australia (WTIA). Preheat Determination: than hydrogen controlled consumables Figure 3-Determinationofpreheat requirements forManualmetal-Arc Welding withother EXX28&EXX48)semi-automaticandautomaticweldingprocess. EXX18, (EXX16, Figure 2-Determinationofpreheat requirements forhydrogen controlled electrodes . TECHNICAL AND TRADE INFORMATION 291 Reference Number Reference Number Chemical Analysis % Chemical Analysis % Chemical Analysis % Chemical Analysis % . 11441214 0.40/0.48 0.15 Max 1.35/0.65 0.80/1.20 0.08-0.13 0.25-0.35 11A 3A 10101020103010401050 0.08/0.131060 0.18/0.231070 0.28/0.34 0.30/0.60 0.37/0.44 0.30/0.60 0.48/0.55 0.60/0.90 0.55/0.65 0.10/0.35 0.60/0.90 0.65/0.75 0.10/0.35 0.60/0.90 0.10/0.35 0.60/0.90 0.10/0.35 0.60/0.90 0.10/0.35 0.10/0.35 0.10/0.35 1 2 5 8 10 11 12 1006 0.08 0.25/0.50 0.10/0.35 1 12L14 Max 0.15 0.80/1.20 0.25-0.35 0.15-0.35 3A X1112X1147 0.08/0.15 0.40/0.47 1.10/1.40 0.60/1.90 0.20-0.30 0.10-0.35 2A 11A K1070S 0.65-0.75 0.60-0.90 0.10-0.35 12A XK5160SXK9261S 0.55-0.65 0.55-0.65 0.70-1.0 0.70-1.0 0.10-0.35 1.8-2.20 0.70-0.90 12A 12A XK5155S 0.50-0.60 0.70-1.0 0.10-0.35 0.70-0.90 12A C350-C350LO*C450-C450LO* 0.20 0.20 1.60 1.60 0.05 0.35 3 3 C250-C250LO* 0.12 0.50 0.05 1 Steel Designation C Mn S Pb Weldability Steel Designation C Mn Si Cr Weldability Steel Designation C Mn Si Reference Number Weldability Steel Designation C Mn Si Reference Number Weldability Steel Specifications: WELDING OF STEEL OF WELDING AS 1447 (1991) Hot Rolled Spring Steels. * Nb + V + Ti = 0.15 Ti V + * Nb + Free Machine Steels Free AS 1442 (1992)AS 1443 (1993)Finished Product. Hot Rolled Bar and Semi Carbon Steel. Cold Finished Bars AS 1663 (1991) Steel Hollow Sections. Structural www.cigweld.com.au 292 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Carbon ManganeseSteels. S20 19)Wrought Alloy Steels. FullyKilled Alloy Steels. AS 2506(1990) AS 1444(1986) Steel Specifications: WELDING OFSTEEL K32E3A .001 .506 .003 .-.507-. 6 0.70-1.0 3.0-3.75 0.10-0.35 0.35-0.60 0.10-0.16 XK3312(EN36A) Designation te einto nWeldability ReferenceNumber Mn C Steel Designation K9003-.404-.001-.52328 .008 .506 12 12 10 0.45-0.65 0.45-0.65 12 0.15-0.30 0.50-0.80 12 0.50-0.80 2.3-2.80 1.0-1.40 0.10-0.20 2.30-2.80 0.10-0.35 3.90-4.30 0.20-0.35 0.40-0.80 0.10-0.35 1.10-0.35 0.45-0.70 0.65-0.95 0.45-0.70 0.25-0.50 0.36-0.44 1.55-2.0 0.27-0.35 0.12-0.18 0.10-0.35 XK9940 0.10-0.40 XK9931 XK9315 0.55-0.90 1.0-1.40 0.37-0.44 0.47-0.55 XK4340 XK4150 1003-.307-.007-.011 6 12 6 9 0.70-0.90 0.20-0.30 0.15-0.25 0.15-0.25 0.15-0.25 0.80-1.10 0.40-0.60 0.80-1.10 0.40-0.70 0.60-0.90 0.10-0.35 1.65-2.0 0.90-1.20 0.10-0.35 0.70-0.90 0.70-0.90 0.45-0.55 0.45-0.65 0.18-0.23 0.38-0.43 0.17-0.23 9050 0.75-1.0 8620 0.40-0.60 5140 0.30-0.43 4620 0.28-0.33 4140 4130 te nS iC oWeldability Mo Cr Ni Si Mn Steel C 14 .304 .017 11 10 6 5 5 1.40-1.70 1.40-1.70 1.40-1.70 1.40-1.70 1.40-1.70 0.43-0.48 0.38-0.43 0.23-0.28 0.18-0.23 0.12-0.18 X1345 X1340 X1325 X1320 X1315 Chemical Analysis % Chemical Analysis Chemical Analysis % Chemical Analysis Reference Number 11 TECHNICAL AND TRADE INFORMATION 293 4 5 5 3 4 5 3 3 4 5 Number Reference Reference Number Chemical Analysis % Chemical Analysis % Steels Non-alloy and Alloy Steels with Elevated Temperature Properties Temperature Alloy Steels with Elevated Non-alloy and Mo 0.15 0.50 0.50 0.50 7B MoMo 0.12 0.12 0.50 0.50 1.10 5.00 0.50 0.60 7B 12B 2 2 2 / / / 1 1 1 Cr-1Mo 0.12 0.50 2.30 1.00 12B 4 Cr- / Mn-Mo 0.20 1.40 - 0.45 7B 2 1 / 1Cr- 5Cr- 2 1 Steel C Mn Si Cr Ni Mo S P Weldability En 25En 26 0.27-0.35 0.36-0.44 0.10-0.35 0.10-0.35 0.50-0.70 0.50-0.70 2.30-2.50 2.30-2.80 0.50-0.80 0.50-0.80 0.40-0.70 0.40-0.70 0.050 0.050 0.050 0.050 12 12 En 39BEn 40B 0.12-0.18 0.10-0.35 0.20-0.30 0.10-0.35 0.50 0.40-0.65 3.80-4.50 0.40 1.00-1.40 0.15-0.35 2.90-3.50 0.050 0.40-0.70 0.050 0.050 0.050 10 12 En 36AEn 40A 0.15 0.10-0.20 0.10-0.35 0.10-0.35 0.30-0.60 0.40-0.65 3.00-3.75 0.40 0.60-1.10 2.90-3.50 0.40-0.70 0.050 0.050 0.050 0.050 10 6 Steel Designation C Mn Si Pb Weldability Grade 360Grade 400Grade 430 0.17 0.22 0.25 0.40 - 1.20 0.50 - 130 0.60 - 1.40 Designation Grade Fe 360 Grade Fe 430 Grade Fe 430Grade Fe 1.60 Grade P355GH 0.10 - 0.22 1.00 - 1.70 Grade P265GHGrade P295GH 0.08 - 0.20 0.20 0.90 - 1.50 0.50 - 1.40 Grade P235GH 0.16 0.40 - 1.20 Steel Specifications: WELDING OF STEEL OF WELDING BS EN 10025 (1980) Steels Alloy Structural of Non Hot Rolled Products BS 1501 (1980)Vessels Pressure and Unfired Steels for Fired BS970/PD970 Specification BS970/PD970 Specification BS EN 10028-2 (1993) Purposes, Steels for Pressure Ferritic Creep Resistant Steels Creep Ferritic BS STEEL SPECIFICATION. www.cigweld.com.au 294 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au ae B05 .000 .501 12C 12C 0.18 0.40 13.0 0.65 1.0 0.08 1.65 0.1 0.30 0.50 0.35 0.50 0.80 420 MFQ Maxel HB CSM20.30 ASSAB ASSAB COMMONWEALTH STEEL STEELMARK EAGLE &GLOBE BOHLER STEEL COMMONWEALTH STEEL STEELMARK EAGLE &GLOBE BOHLER STEEL ae odr05 .003 .501 12C 0.18 0.65 0.30 1.30 0.50 Maxel Holder Steel Specifications: WELDING OFSTEEL Designation Supreme Supreme R 0 .807 . 622 0912C V0.9 2.25 .6 1.0 0.75 0.38 QRO 90 amx060803 . . 212C V02 0.5 4.5 0.35 0.8 0.6 Calmax C505 .51216 .5V.512C V0.15 0.35 1.65 1.2 0.85 0.55 NCM5 5005 .502 . . .5V.012C V0.10 0.55 1.7 1.1 0.25 0.75 0.55 W500 3203 .011 .014 09 12C V0.50 V0.95 2.8 1.40 2.90 5.20 0.30 1.10 0.35 0.40 0.39 0.39 W321 W302 2803 .003 . .002 12C 12C 0.070 0.20 0.20 13.5 1.10 2.0 1.90 0.30 0.40 1.50 1.50 0.43 0.38 0.40 M310 M238 M200 Block DC03 . . .0V.512C V0.35 1.40 5.2 1.0 0.39 ADIC 4703 .0105313V. 12C V0.9 12C V0.9 1.3 1.40 5.3 5.2 1.0 0.40 1.0 0.40 0.39 8407 0.39 8407 te nS rN oSOhrWeldability Other S Mo Ni Cr Si Mn Steel C 1 .004 . . .0V.012C V1.10 1.30 5.0 1.0 0.40 0.40 H13 1 .507 .006 .003 12C 0.35 1.40 0.65 0.30 0.70 0.55 R15 2 .007 .017 .012C 0.40 1.70 0.60 0.75 0.30 P20 Plastic MouldSteels Hot Work ToolSteel Chemical Analysis % Chemical Analysis o.012C Co2.90 Reference Number 12C 12C TECHNICAL AND TRADE INFORMATION 295 12C Number Reference V0.1 4 3 4 Chemical Analysis % Cold Work Tool Steel Tool Cold Work Chemical Analysis % Chemical Analysis % Steel Designation C Mn Si Reference Number Weldability Steel Designation C Mn Si Number Reference Weldability Grade 50kg or 60kg 0.66-0.82 0.70-1.00 0.15-0.50 12 SRS 0.60 0.80 1.60 0.35 0.40 V0.15 12C DF2 0.95 1.1 0.6 W0.6 12C Steel C Mn Si Cr Ni Mo S Other Weldability XW5 2.05 0.80 0.30 12.5 W1.3 12C SC23SC25 2.0 1.50 0.20 0.45 0.30 0.25 12.0 18.0 1.0 V0.35 12C K190K600K660 2.3 0.45 0.70 0.40 0.40 2.0 0.40 0.25 0.30 12.50 1.30 1.0 4.0 1.10 0.25 1.35 0.15 V4.0 12C 12C 12C NSS6 0.70 1.90 0.30 1.0 1.35 12C Grade 250R Plain Bars* 0.25 XW10XW41 1.0 1.55 0.60 0.4 0.30 0.3 5.3 11.8 1.1 0.8 V0.20 V0.8 12C 12C Grade Grade 31kg or 41kg 0.53-0.69 0.60-0.95 0.15-0.35 12 Grade 250S Deformed Bars* 0.25 Designation Grade 400Y Deformed Bars* 0.22 Steel Specifications: WELDING OF STEEL OF WELDING STEELMARK EAGLE & GLOBE STEELMARK EAGLE BOHLER STEEL ASSAB *Grain refining and micro alloying elements = 0.15% AS1085.1 Rail Steels AS1302 (1991) Concrete For Bars Steel Reinforcing www.cigweld.com.au 296 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Steels toShippingClassificationSocietyRules FloorPlatesandSlabs Structural SteelsHotRolledPlates, AS3678 (1990) rd 5,4002 .005 4 6 1 1 3 5A - - - - 0.15-0.50 - 0.35-1.05 - - - - 0.55 ------0.55 0.55 0.25 1.70 0.55 1.70 0.55 1.70 0.60 0.14 1.70 0.22 1.70 0.22 0.15 0.22 L0 Grade WR350 400L15 Grade 350L15, 0.22 400 Grade 350, 350L15 Grade 250L15, 300 Grade 250, Grade 200 Steel Specifications: WELDING OFSTEEL Designation te einto nWeldability ReferenceNumber Mn C Steel Designation te nS iC oWeldability Mo Cr Ni Si Mn Steel C rd V .106 i.4A 0.60min. 0.21 Grade NVD rd V .3-3A - 0.23 Grade NVA rd V .807 i.4A 0.70min. 0.18 Grade NVE ls S01 .013 3A 1.00-1.35 0.16 Class DS ls S01 .013 3A 1.00-1.35 0.16 Class CS rd .106-.04A 0.60-1.40 0.21 4A Grade D 0.60min. 0.21 Grade D rd 3A - - 3A Grade A - 0.23 Grade A rd .108-.04A 0.80-1.40 0.21 3A Grade B 0.80min. 0.21 Grade B rd .807-.04A 0.70-1.50 0.18 4A Grade E 0.70min. 0.18 Grade E ls .107-.54A 0.70-1.35 0.21 Class D ls .3-3A 4A - 0.80-1.10 0.21 0.23 Class B Class A ls .807-.54A 0.70-1.35 0.18 Class E Chemical Analysis % Chemical Analysis American Bureau ofShipping Det Norske Veritas Chemical Analysis % Chemical Analysis Bureau Veritas Reference Number TECHNICAL AND TRADE INFORMATION 297 Number Reference Chemical Analysis % Chemical Analysis % Chemical Analysis % Grade B 0.26 1.15 4 Grade B 0.27 1.15 5 Grade A 0.21 0.90 3 Grade A 0.22 0.90 3 Grade X42Grade X65Grade X70Grade X80 0.28 0.26 1.25 0.23 0.18 1.40 1.60 1.80 5 5 5 5 Grade X42 0.29 1.25 5 Steel Designation C Mn Number Reference Weldability Steel Designation C Mn Reference Number Weldability Grades X56, X60 0.26 1.35 5 Grades X56, X60 0.26 1.35 5 Grade A25 CI I,Grade CI II 0.21 0.30 - 0.60 2 Grade A25 CI I,Grade CI II 0.21 0.30 - 0.60 2 Non-expanded -Grades X46, X52 0.30 1.35 5 Non-expanded -Grades X46, X52 0.31 1.35 5 Cold-expanded -Grades X46, X52 0.28 1.25 5 Cold-expanded -Grades X46, X52 0.29 1.25 5 Steel C Mn Si Ni Cr Mo Cu Weldability Designation 5-490 N or A5-490 N or 0.24 0.90-1.70 .60 .30* .25* .10* .20* 5 Steel Specifications: WELDING OF STEEL OF WELDING 7-430 R,N,A,T7-460 R,N,A,T 0.20 0.20 0.50-1.60 0.90-1.70 .50 .60 .30* .30* .25* .25* .10* .10* .20* .30* 5 5 7-490 R,N,A,T 0.24 0.90-1.70 .60 .30* .25* .10* .30* 6 *Total Ni + Cr + Mo + Cu = .70% max. Ni + Cr *Total PIPE LINE STEELS API 5L (1992) Specification for Seamless Line Pipe API 5L (1992) Line Pipe Welded Specification for AS 1548 (1989)Vessels and Pressure Steel Plates for Boilers www.cigweld.com.au 298 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au ASTM SPECIFICATION STEELS SM24 19)Low andIntermediate Tensile Strength Carbon-SiliconSteelPlates ASTM 284M(1990) SM25 19)Pesr eslPae,CarbonSteel Pressure Vessel Plates, ASTM 285M(1990) SM22 19)HighStrength Low Alloy Structural Steel ASTM 242M(1991) SM23 19)LowandIntermediate Tensile Strength CarbonSteelPlates ASTM 283M(1992) SMA6 19)Structural SteelPlates ASTM A36M (1991) Steel Specifications: WELDING OFSTEEL vr20t 0m,icuig03 .06 5 0.90 0.90 0.36 0.33 including Over 200to300mm, including Over 100to200mm, vr10t 0m,icuig03 .05 0.90 0.33 including Over 100to200mm, vr5 o10m nldn .909 4 4 0.90 0.29 0.90 including Over 50to100mm, 0.29 including Over 50to100mm, vr6 o10micuig02 .5-12 5 0.85-1.20 0.27 Over 65to100mmincluding vr2 o5 m nldn .709 4 4 0.90 0.27 0.90 including Over 25to50mm, 0.27 including Over 25to50mm, vr4 o6m nldn .608 .04 4 0.80-1.20 0.80-1.20 0.26 0.25 Over 40to65mmincluding Over 20to40mmincluding o2m nldn 0.25 To 20mmincluding 5madudr02 .03 3 0.90 0.24 0.90 0.24 25mm andunder 25mm andunder te einto nWeldability ReferenceNumber Mn C Steel Designation vr10m02 .5-12 5 0.85-1.20 0.29 Over 100mm Grade D: Grade C: rd .709 4 0.90 0.27 Grade D rd .409 4 0.90 0.24 Grade C rd .809 4 0.90 0.28 Grade C rd .709 2 0.90 0.17 Grade A rd .409 2 0.90 0.14 Grade A rd .709 3 0.90 0.17 Grade B rd .209 3 0.90 0.22 Grade B ye101 .05 1.00 0.15 Type 1 Chemical Analysis % Chemical Analysis 4 TECHNICAL AND TRADE INFORMATION 299 Chemical Analysis % Over 200 0.29 0.85 - 1.20 5 Over 200 0.27 0.85 - 1.20 5 Grade 345Grade 415 0.23 0.26 1.35 1.35 5 6 Grade 290 0.21 1.35 5 Grade 485 Grade Grade 450 Grade Grade 415 Grade Over 40mm 0.24 1.00 - 1.60 6 Grade 450: Grade Over 200mm 0.31 0.85 - 1.20 6 Steel Designation C Mn Reference Number Weldability 13mm and under 0.26 1.35 6 40mm and under 0.24 0.70 - 1.35 5 12.5mm and under 0.27 0.85 - 1.20 5 12.5mm and under 0.2112.5mm and under 0.60 - 0.90 0.24 0.85 - 1.20 3 4 Commercial quality 0.15 0.60 1 over 13mm to 32mm 0.23 1.65 6 Over 50 to 100mm including 0.28Over 50 to 100mm including 0.85 - 1.20 0.30 0.85 - 1.20 5 6 Over 50 to 100mm including 0.25 0.85 - 1.20 5 Over 12.5 to 50mm including 0.28 0.85 - 1.20 5 Over 12.5 to 50mm including 0.23Over 12.5 to 50mm including 0.85 - 1.20 0.26 0.85 - 1.20 4 5 Over 100 to 200mm including 0.29Over 100 to 200mm including 0.85 - 1.20 0.31 0.85 - 1.20 5 6 Over 100 to 200mm including 0.27 0.85 - 1.20 5 Steel Specifications: WELDING OF STEEL OF WELDING ASTM A516M (1990) Pressure Vessel Plates,Vessel A516M (1990) Pressure ASTM Steel Carbon ASTM A537M (1991) Vessel Plates,Pressure Heat Treated, Carbon-Manganese-Silicon Steel ASTM A572M (1992) High Strength Low Alloy Niobium Vanadium Steels Vanadium Alloy Niobium Low A572M (1992) High Strength ASTM ASTM A569M (1991) Carbon Steel (0.15% max) Hot-Rolled Sheet and Strip A569M (1991) Carbon Steel (0.15% max) Hot-Rolled ASTM ASTM SPECIFICATION STEELS. ASTM SPECIFICATION www.cigweld.com.au 300 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au ASTM SPECIFICATION STEELS. SMA6M(90 rsueVse lts CarbonManganeseSteelforModerate andLower ASTM TemperatureA662M (1990)Pressure Vessel Service Plates, SMA0 19)te he n ti,Hg tegh o lo,HotRolledandCold Low Alloy, HighStrength, SheetandStrip, ASTM A607 (1992)Steel SMA3M(97 rsueVse lts HighStrength Low ASTM Alloy Steels A737M (1987)Pressure Vessel Plates, Steel Specifications: WELDING OFSTEEL ls ,Gae 0 501 .04 1.50 0.15 65 Grades60, Class 2, ls ,Gae 05 .513 3 1.35 0.15 Grades50,55 Class 2, ls ,Gae7 .616 6 6 6 5 5 4 1.65 1.50 1.50 1.35 1.35 1.35 0.26 0.26 0.26 0.25 0.23 0.22 Grade70 Class 1, Grade65 Class 1, Grade60 Class 1, Grade55 Class 1, Grade50 Class 1, Grade45 Class 1, ls ,Gae7 .516 4 1.65 0.15 Grade70 Class 2, te einto nWeldability ReferenceNumber Mn C Steel Designation Grade 415: rd .211 .05 5 1.15-1.50 1.00-1.60 0.22 0.20 Grade C Grade C rd .409 .53 0.90-1.35 0.14 Grade A rd .011 .05 4 1.15-1.50 0.85-1.50 0.20 0.19 Grade B Grade B Chemical Analysis % Chemical Analysis TECHNICAL AND TRADE INFORMATION 301 Number Reference V: 0.04 V: 0.04 V: 0.04 V: 0.04 V: 0.03 V: 0.04 Ti: 0.04 Ti: 0.02 Ti: 0.03 Cu: 0.30 Cu: 0.28 Cu: 0.35 Cu: 0.25 Cu: 0.35 Cu: 0.28 Typical Chemical Analysis* (%) Analysis* Chemical Typical Designation PropertiesC Steel Mn Si Cr Ni Mo S Other Weldability 550MPa690MPa690MPa HY80 HY100 USST1 0.14 0.16 0.30 0.85 0.25 0.30 1.60 0.57 2.8 0.90 0.40 0.50 B: 0.004 13 13 500MPa600MPa Bisalloy 60 Bisalloy 70 0.16-0.18 1.10-1.40 0.20 0.20-0.90 --- 0.20 0.003 B: 0.001 13 690MPa450MPa690MPa A USST1 Type 0.18 60 Welten 80C Welten 0.90 0.11 0.10 0.30 1.22 0.55 0.85 0.45 0.22 0.17 0.80 0.20 --- B: 0.001 0.45 13 B: 0.001 V: 0.04 13 13 690MPa 80E Welten 0.18 0.90 0.23 0.40 B: 0.001 13 Hardness: 320HB minAR 320 Welten 0.18 1.10 0.25 0.70 0.35 B: 0.002 13 360HB minAR 360C Welten 0.18 1.10 0.25 0.90 0.35 B: 0.002 13 477HB minAR 500 Welten 0.30 1.20 0.40 0.60 0.10 B: 0.003 13 400-460HB Bisplate 400 0.28 0.50 0.35 0.96 --- 0.15 --- B: 0.002 13 320-360HB360-400HB Bisplate 320 Bisplate 360 0.18 1.15 0.40 0.85 --- 0.20 --- B: 0.002 13 Steel Specifications: WELDING OF STEEL OF WELDING 620-690MPa Bisalloy 80/80PV IMPORTED Q & T STEELS (JAPAN & USA). T STEELS (JAPAN Q & IMPORTED BISALLOY Q & T STEELS (Australia). Q & BISALLOY Yield Stress: Yield Yield Stress: Yield QUENCHED AND TEMPERED QUENCHED AND TEMPERED STEELS. Resistant Grades. Abrasion and Structural Hardness: * Dependent on plate thickness. www.cigweld.com.au 302 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Filler MetalSelectionGuideforBisalloyQ& T Steels- Table 3. edSrnt aeoyDfntos S- acigSrnt S-LowerStrength LS- MatchingStrength MS- pleaserefertoproductdatainthishandbook. # Useonlyrecommendedshieldinggases, * Weld StrengthCategoryDefinitions: l rds2535455.0 220 4.5 200 3.5 175 2.5 150 All Grades All Grades Abrasion ResistantGrades. High Strength Structural Grades. te rd<1m 3m<2m 2m 0m>50mm >25mm<50mm >13mm<25mm Q & T SteelGrade<13mm Preheat recommendations forQ& T Steels- Table 2 WELDING OFSTEEL Quenched & Tempered Steels: ipae30 6,M RN NR NR NR MS 360, Bisplate 320, 8 P iiu il tes5 0 2 150 150 100 125 125 75 100 100 25 50 50 10 680 MPa minimum Yield Stress 620 MPa minimum Yield Stress 450 MPa minimum Yield Stress einto tegh r edn edn Welding # Welding # Arc Welding Strength Designation ialy7 SAlyrf 1 uorf iroTensi-Cor 110TXP H4 AutocraftNiCrMo Alloycraft110 MS Bisalloy 70 ialy8 SAlyrf 1 uorf iroTensi-Cor 110TXP H4 AutocraftNiCrMo Alloycraft110 MS Bisalloy 80 ialy6 SAlyrf 0AtcatM-oVerti-Cor 91K2H4 AutocraftMn-Mo Alloycraft90 MS Bisalloy 60 0,50L ercat6/71 uorf W- Supre-Cor5/ AutocraftLW1-6 Ferrocraft 61/7016 LS 500 400, te Wl aulMtl a ea r FluxCored Arc GasMetal Arc ManualMetal Weld Steel 0 B101010--- 150 100 150 125 125 150 100 100 100 50 50 500 HB 360 HB 320 HB aeoy MA)(MW (FCAW) (GMAW) (MMAW) Category* oaac30 5 – 650 Cobalarc350, M H RN NR NR NR M H RN NR NR NR M H RN NR NR NR M H SFrorf 1 06AtcatL16/Supre-Cor5/ AutocraftLW1-6 / Ferrocraft 61/7016 LS SFrorf 1 06AtcatM-o/Supre-Cor5/ AutocraftMn-Mo/ Ferrocraft 61/7016 LS SFrorf 1 06AtcatL16Supre-Cor5/ Autocraft LW1-6 Ferrocraft 61/7016 LS MAXIMUM ARC HEAT INPUT(Kj/mm) MAXIMUM INTERPASS TEMPERATURE ( MINIMUM PREHEAT TEMPERATURE ( ( assuminghighjointrestraint) acigHrns R-NotRecommended NR- MatchingHardness M H- . uorf nM Verti-Cor 81Ni1 Autocraft Mn-Mo uorf W- Verti-Cor 81Ni1 Autocraft LW1-6 ° C) ° C) toySprBidu,Stoody 965G/O Stoody SuperBuild-up, Verti-Cor 111K3H4 Verti-Cor 81Ni1 Verti-Cor 81Ni1 TECHNICAL AND TRADE INFORMATION 303 . in this handbook 50mm, practice is the best ≥ to select a hydrogen controlled welding process / consumable combination and a to select a hydrogen controlled welding correspondingly lower preheat temperature. AS/NZS welded using mild steel electrodes of the group of steels are readily This 1553.1: E41XX-2 or E48XX-2 classifications. Also readily weldable with the GMAW “W503” welding wire or other Autocraft LW1-6 process and GMAW welding wires. “W503” Ultra 3 / 3XP or other Verti-Cor used with FCAW process can also be The FCAW wires. deposit analysis and/or mechanical consumable producing near matching weld properties. best practice is to select a hydrogen controlled electrode or welding The the wire of a comparable strength grade to that of the steel being welded and use recommended preheat. and Copper alloy additions must be used.containing Nickel If colour match is not an issue refer to 5. the welding process / consumable combinations is considered more important as of the steel increases. and hardenability carbon equivalent weld deposit strength The level should at least equal that of the grade of steel being welded. steels are These hardenable and the use of correct preheat and interpass temperatures and slow cooling after welding are important for success. avoid hydrogen cracking,To the welding consumable should be used, stored and recommendations.reconditioned in accordance with the manufacturer’s For CIGWELD welding consumables please refer to Recommended Storage, Care and Conditioning of CIGWELD Electrodes,Wires and Rods Welding near matching welding consumables such as Alloycraft 80-B2 electrodes, near matching welding consumables such as rods etc. Autocraft Mn-Mo / CrMo1 GMAW welding wires or Comweld CrMo1 GTAW resistance to is carried out to achieve comparable creep strength and corrosion This the parent steel. Low hydrogen welding conditions are essential as are the correct preheat and interpass temperatures, retarded cooling and a post weld heat treatment. AWS A5.1:AWS classifications (such as Satincraft 13, E60XX or 70XX 12XP, Ferrocraft Ferrocraft Weldcraft).21 or Arc welding or Flux Cored Arc (GMAW or MIG/MAG) Gas Metal Autocraft such as an appropriate CIGWELD welding consumable welding (FCAW) with be carried out with out any precautions.‘series’ wires can Verti-Cor or LW1-6 No required. preheat is normally often lead to hot shortness during welding.or lead content can non critical For applications, best results are achieved using basic coated electrodes such as Ferrocraft 7016, 16TXP 61 or Ferrocraft Ferrocraft on specific welding details including FCAW processes can be used depending equipment availability, welding location, thickness and positional welding material requirements etc. and FCAW product Autocraft LW1-6 Refer to GMAW product data for 3 and 3XP in the front of this handbook. XP / Ultra / Ultra Verti-Cor data for (CJT,Thicknesses Combined Joint 1) of refer Diagram For 3A* & 4A* requirements of the consumable. specific Shipping Society approval Check 5 & 6 low alloy high strength steel, intermediate strength and For select a welding 5A*7, 8 & 9‘weathering’ of the parent steel, achieve matching To a welding consumable prescribed in 5 & 6. the recommendations Follow use a hydrogen controlled The 7B* and Molybdenum type steels are usually welded with Chromium-Molybdenum These A ,*Note covered by the CE formula (eg high S, B & C suffixes indicate constraints or conditions not adequately Pb etc) 1 & 2AS/NZS 1553.1: mild steel electrodes of the Readily weldable with E41XX or E48XX, or 2A* high sulphur welding of these steels is normally not recommended because the 3 & 4 The using mild steel electrodes as per recommendation 1 & 2. Readily welded GMAW or Welding Recommendations: Welding WELDING OF STEEL OF WELDING Weldability Reference No: Reference Weldability www.cigweld.com.au 304 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Weldability ReferenceNo: Welding Recommendations: WELDING OFSTEEL Nt ufxsidct osrit rcniin o dqaeycvrdb h Efrua(ghg ,Pbetc) B&CsuffixesindicateconstraintsorconditionsnotadequatelycoveredbytheCEformula(eghighS, *Note A , 2*The weldingoftoolsteelsintheheattreated(hardenedandtempered) condition 12C* These Chromium-Molybdenum typesteelsareusuallyweldedwithnearmatching 12B* 0&1 Usehydrogencontrolledweldingprocess/consumablecombinationswhichbest 10 &11 1 olwn nfo eomnain2 h edn fhg abn sulphur bearing Following onfromrecommendation2Atheweldingofhighcarbon, 11A 2*For theweldingofhighalloyspringsteelsinhardenedandtemperedcondition: 12A* includingsuch Usehydrogencontrolledweldingprocess/consumablecombinations, 12 slowly coolaspreviouslydescribed. recommendations. Pleaserefertothesteelmanufacturerforspecificwelding to reduceresidualstresses. retardedcoolingandapostweldheattreatment(PWHT) and interpasstemperatures, Weldall electrodesandappropriatepreheat can becarriedoutusing “reconditioned” Minorrepairworkonheattreatedtoolsteels tool steelsintheannealedcondition. electrodes orSupre-Cor5fluxcoredwireshouldonlybeattemptedonmouldand lowhydrogenconsumablessuchasFerrocraft 18-Ni applications usingferriticsteel, Comprehensiverepairandmaintenance should beavoidedwherepossible. retarded coolingandapostweldheattreatment. conditions areessentialasthecorrectpreheatandinterpasstemperatures, Lowhydrogenwelding creep strengthandcorrosionresistancetotheparentsteel. This isdonetoachievecomparable welding wireorComweldCrMo2GTAW rodsetc. AutocraftCrMo2GMAW welding consumablessuchas Alloycraft 90-B3electrodes, odtoigo IWL lcrds Welding Wires andRods Conditioning ofCIGWELDElectrodes, Careand CIGWELD weldingconsumablespleaserefertoRecommendedStorage, For reconditioned inaccordancewiththemanufacturer’s recommendations. storedand theweldingconsumableshouldbeused, To avoidhydrogencracking, match thechemicalcompositionand/orstrengthlevelofparentsteel. (PWHT) isalsoconsideredgoodweldingpractice. Post Weld Heat Treatment asisslowcoolingafterwelding. welding ofthesesteels, The useof ‘dry’ weldingconsumablesisessentialforthesuccessful of thisguide. Preheat temperatureshouldbedeterminedusingtheproceduredescribedonpage289 odtoigo IWL lcrds Welding Wires andRods Conditioning ofCIGWELDElectrodes, Careand pleaserefertoRecommendedStorage, immediately priortouse, Welding consumablesmustbedry controlled process/consumablecombinations. Usehydrogen steel isnotrecommendedexceptfornoncriticalapplications. odto.Preheatsteelsectionstobejoined250-300 condition. Ferrocraft 7016orSupre-Cor5inathoroughlydry consumables asFerrocraft 61, Use hydrogencontrolledprocess/consumablecombinationsincludingsuch particular heattreatmentrecommendations. in optimum resultspleaserefertothesteelsupplierforspecifictechnicalinformation, To achieve postweldcoolingandPWHT. interpasstemperature, control ofpreheat, normally suppliedinthehardenedandtemperedconditionwhichrequiresstrict These steelsare strength levelswilldependonthespecificsofapplication. The choiceofhigherorlowerconsumable cored wireforhigherstrengthjoints. wire forlowerstrengthweldingand Alloycraft 110electrodeor Tensi-Cor 110 TXP flux consumables asFerrocraft 61andFerrocraft 7016electrodesorSuprecor5fluxcored with approximately100 use Weldall electrodes Alternatively wherepreheatmustbereducedtotheminimum, lime orwrapinathermalblanket. temperature of250-300 ° ° C lesspreheatandinterpasstemperature(ie150-200 hogotwlig Afterweldingslowlycoolthejointin C throughoutwelding. ° C andmaintainaninterpass in thishandbook in thishandbook ° C) and . . TECHNICAL AND TRADE INFORMATION 305 . in this handbook welded and the specific service requirements of the weldment. welded and the specific matching) weld metal mechanical properties. 302 for CIGWELD 3 on Page Table See welding consumable recommendations. alloy content.lower weld metal tensile properties and 302 for on Page 3 Table See CIGWELD welding consumable recommendations. 2 on Table in T steel grades are detailed & for structural and abrasion resistant Q 302.Page to closely the strength or integrity of the joint If they are not adhered may be compromised. of their very high tensile properties.T steels because Q & butt welds subject to For surface abrasion, consumable of a capping pass deposited with a welding sometimes used. matching hardness to the base steel is the welding consumable has been used,the welding consumable stored and re-conditioned in accordance instructions.with the manufacturer’s Storage, Refer to Recommended Care and Electrodes,Conditioning of CIGWELD Wires and Rods Welding 2. being on the particular grade of steel consumable selection is dependant Welding 3. of matching ( or near full strength weld joints select a welding consumable For 4. welding consumables having lower strength welds select hydrogen controlled For 5. input data Recommended preheat and interpass temperatures and maximum heat 6. used to join abrasion resistant Lower strength welding consumables are invariably Welding Quenched and Tempered ( Q & T ) steels: ( Q & Tempered Quenched and Welding 1. combination, hydrogen controlled welding process / consumable Use only where 13 Welding Recommendations: Welding WELDING OF STEEL OF WELDING Weldability Reference No: Reference Weldability www.cigweld.com.au 306 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au * Seeapplicablesteeltypesonnextpage. osmbe rqaiidt SNS15.:1995 Consumables Prequalified to AS/NZS 1554.1: WELDING OFSTEEL a ea lxCrdACA/Z tnadLSDVApplicable LRS/DNV AS/NZS Standard Gas Metal&FluxCored ARC Welding Consumables: Welding Consumables: aulMtlAc SNSSadr R/N Applicable LRS/DNV AS/NZSStandard Manual Metal Arc et-o lr 4EPGpW0A CM1H ETP-GCp-W502A. Verti-Cor UltraH4 et-o X 4EPGpW0A CM2H ETP-GMp-W503A. Verti-Cor 3XPH4 ercat1TPE4816-2H Ferrocraft 16TXP uorf W- S-CMW0A Y “ 3YS ES6-GC/M-W503AH Autocraft LWI-6 ercat1X 41- Y“ 2Y E4112-0 Ferrocraft 12XP ercat71 E4816-3H Ferrocraft 7016 ier 00 41- “ 3 E4110-2 PipeArc 6010P et-o lr T-C-52.CM1H ETP-GCp-W502A. Verti-Cor Ultra uorf W S-CMW0A YSAll Types 3YMS ES4-GC/M-W503AH Autocraft LW1 ercat5UE4816-2H Ferrocraft 55U et-o X T-M-53.CM1H ETP-GMp-W503A. Verti-Cor 3XP ea-o PEDGnpW0A CM1H ETD-GMn/p-W503A. Metal-Cor XP ercat1 41- ,4 5&6 4, “ 3, 3 2 E4111-2 E4113-0 Ferrocraft 11 Satincraft 13 ercat6 E4818-3H Ferrocraft 61 ercat2 42- Y“ 7A&7B 6, 5, 4, 3, 2Y 3 E4824-0 E4814-2 Ferrocraft 22 Ferrocraft 21 ai-o PEDGpW0A CM1H ETD-GCp-W502A. Satin-Cor XP et-o PEDGpW0A CM1H ETD-GMp-W502A. Verti-Cor XP ur-o T-M-55.CM1H ETP-GMn-W505A. Supre-Cor 5 edrf 41- “ 3 E4113-2 Weldcraft GP6012 E4112-0 2 1 &2 1 2 E4112-0 GP6012 10 10 10 10 10 10 10 10 5 5 5 5 prvlSteel Types* Approval prvlSteel Types* Approval YHAllTypes 3YSH YH“ 3YSH YH“ 2YSH YH“ “ 3YSH 3YSH YH1 2&4 1, 2YSH YH1 2&4 1, 2YSH YH“ 2YSH Y “ 3YH Y “ 3YH Y “ 3YH Y “ 3YH TECHNICAL AND TRADE INFORMATION 307 L 350 L0 300 L0 250 L0 430C Fe WR350/2 L0 350 L15 WR350/2 L15 510D Fe 250 L15300 L15 250 L15 300 L15 430D Fe 400 L15 350 L15 AS 3679.2 C7A-2 XF400 A1006 A1010 A1016 Hd200Hd250 Hd300 XK1016 HW350 C4-2 400 350 Hd300/1 7-460L0 7-430L40 7-430L50 7-460L20 7-460L40 7-460L50 5-490L40 5-490L50 7-490L20 7-490L40 7-490L50 C250 Hd3 C7A-1 300 H250 Hd4 A1006 H350 7-490 Hd400 C4-1 WR350/1 WR350/2 510B Fe G300 H200 7-460 Hd2 C3 250 300 APPLICABLE STEEL TYPES - PREQUALIFIED TO AS/NZS 1554.1: TO TYPES - PREQUALIFIED 1995 STEEL APPLICABLE 1 C250 G250 C200 7-430 Hd1 All grades C2 200 250 430A Fe 2 C250 L03 7-430L0 7-430L20 4 C350 G350 C350 5-490 Hd350 C1 350 WR350/1 510A Fe 6 5-490L20 5 C350 L0 7-490L0 XF300 WR350/1 L0 WR350/1 L0 510C Fe 7B C450L0 7A C450 G450 C450 type Steel AS 1163 AS 1397 AS 1450 AS 1548 AS 1594 AS 1595 AS 2074 AS 3678/ AS 3679.1 NZS 3415 WELDING OF STEEL OF WELDING www.cigweld.com.au 308 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au ASTM A335-P22 Alloycraft 90-B3 Comweld CrMo2 Comweld Alloycraft90 ComweldCrMo1 AutocraftCrMo1 90-B3 Alloycraft Alloycraft80-B2 (P) These productsareprequalifiedto AS/NZS 1554.1forweldingthesteelslisted. AS2074 GradeL6 Bisalloy60 ASTM A852 eg. 65 ASTM A572 Grades60, ASTM A537 C1.2 AS3597 -500 L5F L5D, AS2074 GradesL5C, ASTM A387-G22 ASTM A335-P22 ASTM A217-WC9 L5F L5D, AS2074 GradesL5B, 12 ASTM A387-G11, ASTM A335-P11 ASTM A2170-WC6 S06E3 locat8-1AtcatM-oVerti-Cor 81Ni1 AutocraftMn-Mo Supre-Cor5 Alloycraft80-C1 ComweldSupersteel AutocraftLW1-6 Verti-Cor 3XP(P) 80-50 Ferrocraft 7016 A14880-40, ComweldSupersteel AutocraftLW1 AutocraftLW1(P) Satin-CorXP(P) ASTM Grades: FluxCored Arc AS2056 EN33 ComweldHigh Test (P) Ferrocraft 61 FerrocraftAS2074 GradeL3A 22(P) K9 K5, AS1442 S5, AutocraftLW1 (P) ASTM A333 Grades3&7 Gas Tungsten Arc AS1548 L40 ASTM A106 All Grades L1B Ferrocraft 21(P) L1A, C7, C6, C5, GasMetal Weldcraft (P) Arc AS2074 GradesC4, and L20Grades 5-490 AS 1548Grades7-460R, ManualMetal Arc and LO&L15Grades 400 AS3678 (AS1204)Grades350, Ferrocraft 11(P) AS 1548Grad7-430R and LO&L15Grades 300 250, AS3678 (AS1204)Grades200, Applicable SteelGrades osmbe o edn tutrl StainlessandEngineeringSteels: Consumables for Welding Structural, WELDING OFSTEEL A437 Class2 A420 WPL9 C &D A302B, ercat6 P uorf W- P Metal-CorXP(P) AutocraftLW1-6 (P) Ferrocraft 61(P) uorf W- P Verti-Cor Ultra(P) Autocraft LW1-6 (P) ur-o P()M-Cor5(P) Supre-Cor XP(P) Verti-Cor XP(P) Vert-Cor XP(P) Verti-Cor 91K2H4 Verti-Cor 81Ni1H4 Verti-Cor 81Ni1H4 Verti-Cor 81Ni1 Supre-Cor 5 Verti-Cor (P) Metal-Cor XP(P) Satin-Cor HD70 TECHNICAL AND TRADE INFORMATION 309 Verti-Cor 111K-3 H4 111K-3 Verti-Cor 111K-3 H4 Verti-Cor Stoody Super Build Up cont. Consumables for Welding Structural,Welding for Consumables Steels and Engineering Stainless WELDING OF STEEL OF WELDING Applicable Steel GradesApplicable Steel AS 3597-600 & 700 A Type A533 ASTM ASTM A514 A517 Arc Manual Metal Alloycraft 110Arc Gas Metal Arc Tungsten Gas Autocraft NiCrMoArc Flux Cored 110T XP H4 Tensi-Cor eg. Bisalloy,& 70 Welten 80 AS2074 Grade L6A AS2074 Grades H1A, H1B (Hadfield Manganese)(Austenitic Manganese)ASTM A128 All Grades AISI Grades 201, 202301, 301, 304, 304L,AS2074 Grade H5A 305 AISI Grades 316L, 316, 316TIAS2074 Grades H6B, H6C Cobalarc MangcraftAISI Grade 309AS2074 Grades H8A, H8B (build up) Joining 3CR12 & 5CR12. Joining dissimilar Satincrome 308L-17 316L-17 Satincrome Autocraft 309LSisteels eg. stainless steel to structural steel 318-17 Satincrome A288 Grade 5ASTM Autocraft 308LSi Autocraft 316LSiA434 Grades BB,ASTM 309L Comweld BC A513 Grades 4130,ASTM 8630 Hardened to 230-270 HB Satincrome 309Mo-17AS1444 Grade XK4140 Comweld 308L 316L Comweld A288 Grades 6,ASTM 7, 8 Satincrome 309Mo-17A434 Grades BB,ASTM BC, 309LT Verti-Cor BD Autocraft 309LSiA513 Grades 4130,ASTM 8630 Hardened to 330-370HB Austex Cobalarc AS2074 Grade L6C Autocraft 309LSi Alloycraft 110 308LT Verti-Cor 316LT Verti-Cor Comweld 309L 350 Cobalarc Comweld 309L Autocraft NiCrMo 309LT Verti-Cor 309LT Verti-Cor 110T XP H4 Tensi-Cor www.cigweld.com.au 310 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au available today. This sectionisdesignedtoprovidethereaderwithatechnicaloverviewforweldingmajortypes ofstainlesssteels WELDING TECHNIQUE Types ofStainlessSteels: Introduction. WELDING OFSTAINLESS STEEL The maintypesofweldablestainlesssteelsavailable include: highstrengthand/oreaseofcleaningandsterilising. temperature properties, low aestheticappeal, heatresistance, applications basedontheircorrosionresistance, Stainless steelsareanimportantgradeofstructuralmaterialusedworldwideforamultitude NOTES ON TECHNIQUE: greater thanthatofmildsteel. thermal conductivityofthesealloysteelsislessandthecoefficientexpansionconsiderably This procedureisnecessaryasthe closer togetherthanistheusualpracticeformildsteel. shouldbeplacedmuch particularlyonthinsheets, Tack welds, 2.5 mm(1/16into3/32in)thick. welding sheetsthinnerthan3mm(1/8in)whilecoolingblocksarehelpfulwith1.6mmto Clampsandjigsareadvisablewhen The edgesofthepreparationshouldbefreefromscale. andevenlessforplateofdissimilarcomposition. electrodes oflike composition, not widerthantwicethediameterofelectrodeforbasematerialand Weaving shouldbe Usuallythelowestconvenientcurrentshouldbeused. weaving techniquesaretobediscouraged. speedoftravelortheusewide Any techniqueswhichaimatincreasingthepenetration, allstainlesssteelforhigh-classworkshouldbeweldedwithashortarc. principle, In extraprecautionsandattentiontodetailatallstagesoffabricationisdesirable. usually involved, andexactingconditionsofserviceare butasthe material beinghandledisveryexpensive, steel, The techniqueofweldingstainlesssteelsdoesnotdiffergreatlyfromthatthemild .Miti hr r uigwlig toavoidlossofalloyingmaterialsduring Maintainashortarcduring welding, atabouthalfthepitchusedformildsteel. 4. Tack atregularintervals, 3. Usetheedgepreparationshownin Table 1overthepage. 2. Ensurethatthesurfaceofmaterialinweldareaiscleanandfreefrom 1. ▲ ▲ ▲ ▲ austenitic stainlesssteels. and usedforcorrosionresistantapplicationsasanalternativeto300series Duplex stainlesssteels(UNSS30000series)whichareweldablewithprecautions to weldandcommonlyusedforwearresistantapplications. Martensitic stainlesssteels( AISI 400series/UNSS40000)whicharedifficult particularly inthinsectionsandcommonlyusedforelevated temperatureapplications. Ferritic stainlesssteels( AISI 400series/UNSS40000)whichareweldable over 70%ofthestainlesssteelsoldaroundworld. series) whichareeasytoweldandbyfarthemostpopulartype-accountingfor Austenitic stainlesssteels(AISI200and300series/UNSS20000S30000 transfer acrossthearc. foreign matter. TECHNICAL AND TRADE INFORMATION 311 not gap. 3 mm (1/8”) gap. Square butt joint - Square butt joint - 1.5mm (1/16”) max. 1.5 mm (1/16 “) gap. 1.5 mm (1/16 3 mm (1/8”) landing, 3 mm (1/8”) landing, Single V preparation - V preparation Single Single U preparation - Double V preparation - Double Double U preparation - 1.5 mm (1/16 “) landing, 1.5 mm (1/16 gap equal to half thickness. landing, 1.5 mm (1/16”) gap. 1.5 mm (1/16”) to 3mm (1/8”) gap. minimise distortion. for mild steel. previously been used those used for mild steel. somewhat lower than 5. rather than wide weaves. Use stringer passes 6. minimise distortion, To 7. welding. back step or block sequences when employ passes. remove slag from welds between Thoroughly 8. U joints,V or double When welding on each side, balance the welding to 9.polishing stainless if they have emery wheels or buffs for grinding or Never use 10. current. Do not use excessive welding electrical resistance and Because of the high low thermal conductivity, are currents used with stainless steel electrodes the (mm) Edge Preparation Notes (3/4”) (1/16”) Over 20 1.5 - 5.0 Up to 1.5 Thickness 5.0 - 13.0 13.0 - 20.0 (1/2” - 3/4“) (3/16” - 1/2”) NOTES ON TECHNIQUE cont.: ON NOTES (1/16” - 3/16”) WELDING OF STAINLESS STEEL STAINLESS OF WELDING TABLE 1.TABLE FORWELDING: ARC EDGE PREPARATION METAL MANUAL www.cigweld.com.au WELDING OF STAINLESS STEEL

Austenitic Stainless Steels Austenitic stainless steels are easily welded with all standard arc welding processes, without preheat and using matching or near matching welding consumables. Because of their high thermal expansion and low thermal conductivity compared to carbon steel they will distort more during and after welding. This can be minimised by more frequent tacking prior to welding, balanced and back step welding methods and the use of lower welding current and heat input parameters. Low carbon austenitic stainless steels are commonly used because they are less susceptible to sensitisation ( or carbide precipitation ) during welding or high temperature service which can result in intergranular corrosion in a caustic environment. Matching low carbon welding consumables ( designated with an “L” ) are also commonly used to de- sensitise the weld deposit, in the same way as the parent metal, and eliminate the risk of intergranular corrosion of the welded joint. The common welding consumable types used for welding the many austenitic stainless steel grades are shown in the following table. Austenitic Stainless Steel Grades - Welding Consumable Selection Guide.

Stainless Steel Grade Welding consumable type AISI UNS Werkstoffe 1st Choice 2nd Choice 3rd Choice No: No: No: 201 S20100 --- 308 / 308L 316L 347 202 S20200 1.4371 308 / 308L 316L 347 205 S20500 --- 308 / 308L 316L 347 TECHNICAL AND TRADE INFORMATION 209 S20910 1.4565 308 / 308L 316L 347 301 S30100 1.4310 308 / 308L 316L 347 302 S30200 --- 308 / 308L 316L 347 303 S30300 1.4305 312 (Weldall) 309L / 309Mo 308 / 308L 303Se S30323 312 (Weldall) 309L / 309Mo 308 / 308L 304 S30400 1.4301 308 / 308L 316L 347 304L S30403 1.4306 308 / 308L 316L 347 304H S30409 1.4948 308H 308L 316L 304N S30451 --- 308L / 308 316L 347 304LN S30453 1.4311 308L / 308 316L 347 305 S30500 1.4303 308 / 308L 316L 347 308 S30800 --- 308 / 308L 316L 347 309 S30900 1.4828 309 / 309L / 309Mo 312 (Weldall) --- 309S S30908 1.4833 309L / 309Mo 312 (Weldall) --- 310 S31000 1.4841 310 --- 310S S31008 1.4845 310 --- 314 S31400 --- 310 318 309L / 309Mo 316 S31600 1.4401 316 / 316L 318 309L / 309Mo 316L S31603 1.4404 316L / 316 318L 309L / 309Mo 316H S31609 1.4919 316H 316L / 318 309L / 309Mo 316N S31651 --- 316L / 316 318 309L / 309Mo 316LN S31653 1.4406 316L / 316 318 309L / 309Mo 317 S31700 1.4429 317 / 317L 318 316L 317L S31703 1.4438 317L 318 316L 321 S32100 1.4541 347 318 308 / 308L 321H S32109 1.4941 347 318 308 / 308L 347 S34700 1.4550 347 318 308 / 308L 347H S34709 --- 347 318 308 / 308L 348 S34800 --- 347 318 308 / 308L 384 S38400 --- 309L / 309Mo 312 (Weldall) ---

312 www.cigweld.com.au TECHNICAL AND TRADE INFORMATION 313 100- C for 30- ° ≈ C ). is done to ensure This ° 130 -150 ≈ C are commonly recommended to avoid cracking. Interpass temperature ° C and minimise the heat input during welding.C and minimise the modify carbides in the Heat dissolve or To Stainless Steel Grade consumable type Welding ° also plays an important role in reducing the risk of cracking. In multipass welding, an interpass ) will minimise temperature between the martensite start and finish temperatures (Ms and Mf crack sensitivity by allowing each subsequent weld pass to be tempered. Weld-Heat Post (PWHT) is also carried out to improve mechanical properties and reduce welding Treatment stresses. complicated joint configurations PWHT is commenced once the fully welded joint For has cooled to just under the martensite start temperature ( the complete transformation of austenite to martensite before PWHT. Martensitic stainless steels are difficult to weld successfully due to the formation of hard and Martensitic stainless steels are difficult to weld successfully due to the formation (HAZ) of the joint.Affected Zone brittle martensite in the Heat reduce the affects of martensite To formation, control over pre-heat, adequate interpass temperatures and heat input are essential. Depending on the carbon content of the particular martensitic steel, preheat temperatures of between 100 - 300 Ferritic stainless steels can be welded under strict precautions using all standard arc welding strict precautions using all standard stainless steels can be welded under Ferritic processes. match the base consumables which match or near can be joined with welding They welding consumables,metal or with austenitic for example Satincrome 308L-17 & 316L-17 Autocraft 308LSi & 316LSi GMAW wires.electrodes or During welding, steel grades ferritic stainless ductility due to grain growth,can suffer a loss of and carbide precipitation. martensite formation good welds, achieve To sections, thicker in is often necessary to preheat the work to it Affected Zone (HAZ) and reduce welding stresses,Affected Zone (HAZ) heat treatment to 750-850 post-weld 120 60 minutes is necessary. improve the ductility, heat treatment will This toughness and corrosion Zone. Affected resistance of the Heat No: No: No: 444446 S44400 S44600 1.4521 1.4762 316L / 308L 308 309L / 309Mo 318 310 309L / 309Mo 405409429430 S40500 S40900 S42900434 S43000 1.4002436 1.4512442 1.4001 S43400 1.4016 S43500 309L / 309Mo S44200 430 1.4113 430 312 (Weldall) --- 430 --- 309L / 309Mo 430 308 / 308L --- 308 / 308L 430 316L 308 309Mo 309L / 308 / 308L 309L / 309Mo 308 / 308L 309Mo 309L / 318 309L / 309Mo 309L / 309Mo AISI UNS Werkstoffe Choice 1st 2nd Choice 3rd Choice 430F S43020 1.4104 430 308 / 308L/ 309Mo 309L 3Cr12 ------309L / 309Mo 316L 308L 430FSe S43023 --- 430 308 / 308L 309L / 309Mo Martensitic Stainless Steels: Ferritic Stainless Steel Grades - Welding Consumable Selection Guide. Consumable Selection Welding - Stainless Steel Grades Ferritic Ferritic Stainless Steels: Stainless Ferritic WELDING OF STAINLESS STEEL STAINLESS OF WELDING www.cigweld.com.au 314 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Heat Input: Duplex StainlessSteels: Martensitic StainlessSteelGrades - Welding ConsumableSelectionGuide. WELDING OFSTAINLESS STEEL 1S 463--4039 0M 310 309L/309Mo 410 --- S41623 416Se 4AS40 - 1 Wlal 0L/39o--- 309L/309Mo 312(Weldall) --- S44002 440A 4CS40 - 1 Wlal 0L/39o--- 309L/309Mo 312(Weldall) --- S44004 440C 4BS40 - 1 Wlal 0L/39o--- 309L/309Mo 312(Weldall) --- S44003 440B IIUSWrsof s hie2dCoc 3rdChoice 2ndChoice 1stChoice Werkstoffe UNS AISI 3 410145 3 0L/38309 310 310 310 310 308L/308 309L/309Mo 310 309L/309Mo 310 309L/309Mo 309L/309Mo 410 430 309L/309Mo 410 309L/309Mo 410 410 1.4057 --- 410 410 --- S43100 1.4313 S42000 --- 1.4006 S41600 431 1.4000 S41500 420 S41400 S41000 416 S40300 415 414 410 403 o o No: No: No: Heat Affected Zone(HAZ). the formationofanevendistributionferriteandaustenite ( Ifthecorrectheatinputisusedresultantcoolingratewillpromote to austeniteuponcooling. theweldmetalconsistsof100%ferritewhichbeginstotransform When theweldpoolsolidifies, toughnessandcorrosionresistancewillbeachievedintheweldedjoint. combination ofstrength, If thebasemetalandweldferritelevelsarecontrolledto25-50%(FN30-70)thenagood austenite intheweldandsurroundingheataffectedzone(HAZ)ofbasematerial. be giventoheatinputandinterpasstemperaturepromotethedesiredbalanceofferrite carefulattentionmustalso Inadditiontoweldingconsumableselection, weld depositmicrostructure. whichhelpstoachievethecorrectbalanceofaustenite andferriteinthe an alloyingelement, Welding ConsumablesforduplexstainlesssteelscontainNitrogen(astrongaustenitestabiliser)as can beclassifiedintotwo(2)maingroups: These alloys The maingradesofduplexstainlesssteelsusedinindustrytodayarelistedbelow. joint toughnessandcorrosionresistance. whichcanreduce the formationofexcessiveferritelevelsinbothbasemetalandweld, Carefulattentionmustbegiventoheatinputandconsumableselectionprevent processes. Duplex stainlesssteelsarereadilyweldedwithprecautionsusingallcommonarcwelding approximately 50%ferriteandaustenite. Atypicalduplexmicrostructureconsistsof referred toasFerritic-Austenitic stainlesssteels. ferriteandaustenitearealso Duplex stainlesssteelsconsistoftwomicrostructurephases, tils te rd Welding consumabletype Stainless SteelGrade ue ulxSanesSel 353 S39275(2507)andS39276(Zeron100). Super DuplexStainlessSteels=S39553, S39205(2205)andS39230(2304) Duplex StainlessSteels=S32900(329), ≈ 50:50) inthewelddepositand TECHNICAL AND TRADE INFORMATION 315 C maximum ° C is helpful in reducing the ° A789, A790, A815 C. ° Travel Speed (mm/min) x 1000 Travel C should be used. S39205 S39230 S39553 S39275 S39276 ° 50 ≈ Duplex stainless steel grade C preheat of ° 329 S32900 1.4460 A240, A789, A790 329 2304 S32304* 1.4362 A789, A790 2209 2205 S31803* 1.4462 A182, A240, A276, 2209 2507 S32750* 1.4410 A789, A790 2507 Name UNS Werkstoffe ASTM Specification Welding or No: No: No: No:Type Consumable 2RE60 S31500 1.4841 A789, A790, A815 2209 may be required to reduce the cooling rate and increase austenite in the weld and the HAZ. reduce the cooling rate and increase austenite may be required to 60 Amps x x Volts ) = Heat Input ( kJ/mm Always use the correct welding electrode, use the Always wire or rod (refer to the welding consumable selection guide shown below). without a filler rod unless using the (TIG) welding do not weld GTAW For correct nitrogen content shielding gas. use an inert (nitrogen containing) backing gas Always when completing root runs. Consult your local gas supplier for detailed information. Interpass temperature should be limited to between 75-150 Interpass temperature should be limited is required.On thicknesses below 6mm no preheat heavier sections or for welds under high For the risk of weld cracking.restraint preheat may be used to minimise When a welding process with less than 0.6kJ/mm heat input is used, preheating to between 50-200 Generally heat input should be limited to between 0.6 - 2.6 kJ/mm. limited to between heat input should be Generally a welding process with When heat input is used (as in automatic GMAW),less than 0.6kJ/mm up to 150 preheating cooling rate and increasing austenite in the weld and the HAZ.cooling rate and increasing austenite in is below If the air temperature 15 Zeron# 100 S32760* 1.4501 A182, A276, A790, A815 2507 Bohler A903 Ferralium# 255Ferralium# S32550* 1.4507 A240, A789, A790 2507 Duplex Stainless Steel Grades - Welding Consumable Selection Guide. Welding - Duplex Stainless Steel Grades Correct Welding Consumables and Shielding Gas: Consumables Welding Correct Interpass Temperature Control: Interpass Temperature Preheat: Duplex Stainless Steels cont.: Stainless Steels Duplex WELDING OF STAINLESS STEEL STAINLESS OF WELDING # - Ferralium is a trademark of Langley Alloys Ltd. is a trademark of Langley # - Ferralium Material Services Ltd. Weir Zeron is a trademark of * - old UNS number, replaced by the number beneath in bold. www.cigweld.com.au 316 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Schaeffler andDeLongDiagrams: Duplex StainlessSteelscont.: WELDING OFSTAINLESS STEEL 85Pp itns weldedandseamless Pipefittings, weldedandseamless Pipe, weldedandseamlessforgeneralwork Tubing, Barsandextrudedshapes stripandsheetforpressurevesselsequipment Plate, Flangesandotheritemsforhightemperatureservice Valves, Fittings, A815 A790 DescriptionofProduct Types: A789 A276 A240 A182 ASTM SpecificationNo: By explanation: 316 austeniticstainlesssteelusingSatincrome309Mo-17isshowninDiagram1. theresultantwelddepositmicrostructurefromjoiningmildsteelto For example, AWM deposit. giventhechemicalanalysesofbothbasemetalsandwelding consumable of dissimilarmetals, The Schaefflerdiagramiscommonlyusedtopredictwelddepositmicrostructuresforthejoining Seetheshadedregionson Schaefflerdiagramfordetails. cracking andbrittlegraincoarsening. martensitic sigmaphaseembrittlement, guide topotentialjointproblemssuchashotcracking, predicting themicrostructuralphasespresentinwelddepositSchaefflerdiagramisalsoa In calculatedfromtypical AWM chemicalanalysis. electrode isshownasPoint DinDiagram1, austenite-ferritemicrostructureofCIGWELDSatincrome309Mo-17manualarc crack free, The or DeLongdiagramstodeterminethemicrostructuralphasespresentinwelddeposit. Once theChromiumandNickel Equivalents arecalculatedtheycanbeplottedontheSchaeffler diagram alsoclassifiesferritecontentasaFerrite Number(FN)ratherthanasapercentage. The DeLong where gasshieldingcansignificantlyinfluencenitrogenpickupinthewelddeposit. for thegasshieldedweldingprocessessuchasGasMetal Arc andGas Tungsten Arc Welding it incorporatesnitrogeninthecalculationofNickel Equivalent whichisparticularlyimportant however The DeLongdiagramworksinasimilarway totheSchaefflerdiagram, Schaeffler diagram. The DeLongDiagramshownin2isalaterdevelopmentofthecentralpart weld depositswhichhavebeenheattreatedafterwelding. diagram isnotapplicabletotheHeataffectedZone(HAZ)ofweldedjointnoritusablefor ItshouldbenotedthattheSchaeffler used toestimatethemicrostructuralphasespresent. Once theChromiumandNickel equivalent havebeencalculatedtheSchaefflerdiagramcanbe - Nickel Equivalent=%Ni+30x%C0.5%Mn - Chromium andNickel Equivalents fortheSchaefflerdiagramarecalculatedasfollows: deposit sasafunctionofChromiumandNickel Equivalents. Diagram 1whichpredictsthemicrostructureoffreelycooled All Weld Metal(AWM)stainlesssteel The resultsofthisresearcharesummarisedintheSchaefflerdiagramshown steel weldmetals. out adetailedstudyoftherelationshipbetweencompositionandmicrostructurestainless AntonSchaefflerwas thefirstpersontocarry significant influenceontheresultantmicrostructure. The alloyingelementsusedinstainlesssteelbasemetalsandweldingconsumableshavea Chromium Equivalent=%Cr+%Mo1.5x%Si 0.5x%Nb Point ContheSchaefflerdiagram Point BontheSchaefflerdiagram Point A ontheSchaefflerdiagram Point DonSchaefflerdiagram Point EonSchaefflerdiagram welddepositmicrostructureforjoiningmildsteel = microstructureof316stainlesssteelbasemetal. = microstructureofmildsteelbasemetal. = microstructureof AWM depositwith = microstructureofwelddepositassuming30% = to 316stainlesssteelwithout Satincrome 309Mo-17. dilution usingthemanualmetalarcweldingprocess. a fillermetal. TECHNICAL AND TRADE INFORMATION 317 depending on composition and phase balance. WELDING OF STAINLESS STEEL STAINLESS OF WELDING Diagram 1.Diagram Schaeffler Diagram. of potential weld problems regions Showing approximate www.cigweld.com.au 318 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au iga .DeLongDiagram. Diagram 2. WELDING OFSTAINLESS STEEL TECHNICAL AND TRADE INFORMATION 319 , parent metal 2 parent 20-40 = Percentage nickel in the weld metal nickel = Percentage = Percentage nickel in the parent metal in the parent nickel = Percentage = Percentage nickel in the filler metal nickel = Percentage = Percentage Dilution (%) = Percentage , + 15% contribution from x F W P parent metal 1 parent x 100 = 0.3 x 100 = 30% dilution x 100 F - P 13 - 12 x = W F - x = 13 - 12.7 Welding Process Used Process Welding Manual metal arc weldingGas Metal Arc Welding & Arc Welding Gas Tungsten Submerged-arc welding Dilution % 20-30 30-40 Dilution can be calculated using the following formula. the purpose of this example Nickel For from the filler metal to the weld metal is virtually 100%. content will be used since the transfer of nickel Figure 1.Figure process in a stainless steel butt weld using the GMAW Example of 30% dilution 316LSi welding wire. Autocraft with Dilution can be approximately calculated using a geometric approach involving the calculated using a geometric Dilution can be approximately cross-section of the weld. Dilution is the degree to which the base metal(s) contributes to the resultant weld deposit. to which the base metal(s) contributes Dilution is the degree It is in the total weld metal. as the percentage of melted parent metal normally expressed i.e. of weld deposit. 30 parts of base material per 100 parts 30% dilution = parent metals be the same irrespective of the any given process will always dilution for The influenced by preheating.involved but may be metals each It is often assumed that the parent in the resultant weld. contribute equal parts i.e. = 15% contribution from 30% dilution see Figure 1 below. see Figure Therefore, if for example F = 13%, W = 12.7% and P = 12% The following values are a guide to typical dilution levels expected in a butt weld: are a guide to typical dilution levels expected following values The Calculating Dilution: Definition of Dilution: Definition WELDING OF STAINLESS STEEL STAINLESS OF WELDING www.cigweld.com.au 320 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au General: Terms: Affecton 1) Weld“Atmospheric Quality: Conditions” WELDING OF ALUMINIUM Base Metal or AluminiumWelding WireMetal TemperatureBase - Air Temperature- Dew Point - Relative Humidity- Moisture(H Many fabricatorsexperienceweldingproblemsatdifferenttimesoftheyear. erlu ae ovn.Allsurfaces mustbethoroughlydriedaftercleaning. petroleum basedsolvent. Welders shouldwipejointedgeswithacleanclothdippedinvolatile during welding. recommends mildalkalinesolutionsandcommercialdegreasersthatdonotevolvetoxicfumes CIGWELD should becleanedandbrushedwithacleanstainlesssteelbrushpriortowelding. The basemetal opened intheweldingareafor24hoursafterentryfromacoolerstoragearea. The aluminiumweldingwireshouldnotbe be allowedtostabilisetheweldareatemperature. Aluminiumweldingwires andthebasemetalshould especially whentherelativehumidityishigh. theuniformityofairandmetaltemperaturesisimportant In analuminiumweldingshop, content (-57 Shieldinggassuppliesarecontrolledtoverylowmoisture that causeporosityinweldmetal. water breaksdownreleasinghydrogenatoms Atarctemperatures, prime sourceofhydrogen. or thebasemetalcancausetwoproblemsduringwelding: Moisturefromcondensationpresentoneither theweldingwire hydrated oxide(AlOH)coating. Aluminium whichisallowedtorepeatedlycomeintocontactwithwater willeventuallyforma wire orbasemetal. need tobecontrolledpreventmoisturecondensationfromformingonthealuminiumwelding ° e on rlwr.Lkws,theatmosphericconditionsinafabricatingfacility Likewise, C dewpointorlower). ▲ ▲ metal. intheweld presentonthemetalsurfaces, Entrapment oftheactualoxide(AlOH), breakdown ofhydratedoxide(AlOH)presentonthemetalsurfaces. Porosity causedbyhydrogengeneratedfromthebreakdownofwater orfromthe The temperatureoftheweldingwireorbasemetalatanygiventime. The temperatureoftheairinweldingareaatanygiventime. corresponding dewpoint. thereisa For eachrelativehumiditypercentage, below thedewpoint. Moisture willcondenseonmetalsurfaceswhentheirtemperatureisequaltoor The temperatureatwhichcondensationofwater vapour intheairtakes place. affectrelativehumidity. etc. cleaningstations, Diptanks, welding area. humidity isexpressedasapercentagenumberandneedstobemonitoredinthe Relative quantity whichwouldsaturatetheairatexistingtemperature. The ratioofthequantitywater vapour presentintheatmosphere tothe 2 O) isa TECHNICAL AND TRADE INFORMATION 321 RH F. ° C and ° F) % ° ° F) while the melting ° metal) T air - C (1200 T ° C( ° C below the air temperature to prevent C below the air temperature ° F). oxide is not melted during the Aluminium ° C (3700 ° RH ( F) % ° welding wire must be no colder than 5 welding wire must be moisture condensation. ° - Temperature of the air minus the temperature of the metal shown in temperature of the of the air minus the Temperature - If the relative humidity in the weld area is 70%,If the relative humidity the base metal and aluminium ° metal) T metal) T air - T ( air - T temperature of aluminium oxides is 2040 The chart below shows the relative humidity at which detrimental water condensation will form condensation detrimental water shows the relative humidity at which chart below The differential temperatures. for a number of given * Example - One of the most frequently asked questions in the process of welding aluminium is “Should the of welding aluminium is questions in the process One of the most frequently asked base metal be cleaned before welding?” answer this question correctly, To one must first determine the finished welded product requirements. If consistent, porosity free,high quality welds are desired, high strength, using a properly then the base metal must be thoroughly cleaned designed and executed procedure. wire quality is a subject of constant concern among Welding designers, engineers, and welders, however, base metal preparation and cleanliness if of equal or even greater importance and is often ignored. Producers of aluminium sheet, plate, rod, bar,products with a protective coating of oil or other hydrocarbon to protect the surface.shapes generally ship their and other fabricated Depending on storage conditions and storage time, aluminium products are covered with oil, ink, grease,moisture, dirt, of hydrated oxide. layer and a variable contaminants contain hydrogen and are These down by the arc during welding,broken by the releasing atomic hydrogen which is absorbed molten aluminium in the weld puddle. During solidification, this hydrogen comes out of solution and coalesces into bubbles in the aluminium which we see as porosity. of aluminium alloys is around 650 general melting temperature The ( welding process and if it is present to an excessive degree, and it can easily cause lack of fusion oxide inclusion type defects. C( 012346 (0)7 (1.8)8 (3.6)9 (5.4) (7.2) (10.8) (12.6) (14.4) 100 93 (16.2) 87 81 75 66 61 57 12 13 53 14 15 16 20 22 (21.6) 24 (23.4) 26 (25.2) (27.0) (28.8) (36.0) (39.6) 44 (43.2) 41 (46.8) 38 36 34 26 23 21 18 1011 (18.0) (19.8) 50 48 28 30 (50.4) (54.0) 16 14 5* (9.0*) 70* 18 (32.4) 30 ° 2) Aluminium Storage & Preparation for Welding: for & Preparation Aluminium Storage 2) Dew Point Conditions Versus Relative Humidity (RH): Humidity Relative Versus Conditions Dew Point WELDING OF ALUMINIUM OF WELDING www.cigweld.com.au 322 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Aluminium Welding Wires: Mechanical Machining: andGouging: Bevelling, Plasma Arc Cutting, abnAcCtig eeln,andGouging: Bevelling, Carbon Arc Cutting, Oxy-fuel GasCutting: Base Metal: Joint Preparation: Storage andHandling: WELDING OF ALUMINIUM rprto,cenn,andweldingofaluminiumbeadheredto: cleaning, preparation, joint CIGWELDsuggestthefollowingguidelinesforproperstorage, With thisinmind, harmful eutecticmeltingandheavyoxidefilms. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ Not recommendedforaluminiumbecauseitleavesalargeheataffectedzonewith Use dustcoversonallweldingequipment. Store unpacked materialinaheatedcabinet. unpacking toallowitstemperatureequalisewiththatofthesurroundingarea. Hold the Aluminium Welding Wire in theweldingareafor24hoursbefore humidity controlaswell. with ifpossible, Store inaheatedroomwithuniformtemperaturecontroland, ifitcanbeachieved. Humiditycontrolisalsodesirable, possible. preferablyinaheatedroomwithasconstanttemperature Store inside, minimise condensationcontactpoints. Position basemetalverticallyandspaceaparttoprovideforaircirculation avoid metalsmearing. Lubricantsorcoolantsmustnotbeusedandtoolsshouldsharpto orrouter-type cuttingproduce thebestsurfacefor welding. milling, filing, gouging, Drilling, and5XXXalloysarenotascrackpronecan generally beweldedascutbythisprocess. 3XXX, Series1XXX, welding. alloys andwillrequire3mmormoreofmechanicalsurfaceremoval before and7XXXseries 6XXX, affected zoneswillbecrackproneparticularlyfor2XXX, Heat the useofasmallorificetogainhighvelocityandconcentratedheat. itrequiresthepower sourcetobesetonDCENalongwith Ifitisused, controlled. This processiscommerciallyusedbuthassomelimitationsandmustbecarefully itrequiresheavymechanicalsurfaceremoval beforewelding. used, Ifitis Not widelyrecommendedorusedforthesamereasonsasgascutting. TECHNICAL AND TRADE INFORMATION 323 F) and remember that oxy-fuel flames produce water as a by-product of F) and remember that oxy-fuel flames produce water ° C (150 ° combustion. Before oxides can be removed from aluminium, the base metal must be degreased. is best done with a solvent. This is the best general solvent for this purpose. Toluene Acetone is a poor solvent for oils and greases and is less effective than toluene. Chlorinated solvents are also good degreasers but are not recommended for this application because they present environmental problems can decompose into toxic or poisonous gases in the presence and their vapours of heat. with solvent prior to assembly and wiped joints should be washed Weld dry using clean cloth such as cheese cloth. Shop rags should not be used since and they contain soaps and other organic compounds from the washing conditioning processes used to treat them. Do not use compressed air to blow off or dry solvent cleaned areas since it often contains moisture and oil. Lubricants or coolants must not be used and band saw surfaces should be Lubricants or coolants must not be used removed by filing prior to welding. it smears the surface of aluminium and Wheel grinding is not recommended since during grinding. can deposit organic binders from the wheel Disc grinding can be used with grit size, 30 to 50 preferred, and speeds of 4,000 to 6,000 fpm. used and grinding pressures should be Only flexible discs should be smearing of the aluminium.moderate to prevent surface heating or Lubricants or coolants must not be used. Minute traces of moisture on aluminium can produce severe weld porosity. Both 24 the welding wire and the base metal should be brought into the welding area to allow all material temperatures to equalise.hours in advance A dew point test should be done prior to welding. If pre-heating must be used, that heat no higher 65 Blade speed: steel (8,000 fpm) - Circular high-speed fpm) - Circular carbide (12,000 - Band saw (5,000 fpm) shape and spacing: Tooth - Circular (std. Spacing, angle) high rake - Band (3 to 4 teeth per inch) ▲ ▲ ▲ ▲ ▲ ▲ ▲ Base Metal Cleaning: Joint Preparation cont.: Preparation Joint WELDING OF ALUMINIUM OF WELDING Lubricants: Moisture: Sawing: Grinding: www.cigweld.com.au 324 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Oxides: Hints onFeedability: WELDING OF ALUMINIUM 3) Feedability of AluminiumWeldingFeedability Wire: 3) Base MetalCleaningcont.: recommended equipmentforaluminiumGMA Welding. eachofwhichisCIGWELD's’ Shownbelowareimportantaccessorycomponents, markedly. Correctingthesedeficienciesoftenimprovesweldingwirefeedability preventive maintenance. poorcareorlackof Such deficiencies canbeattributedtoimpropercombinationsofaccessories, Arcingorburn-backsareoftentheresultofdeficienciesinaccessoryequipment. feedability. Performance ofGMAWequipmentusedforweldingaluminiumsignificantlyaffectswire c) a) e) ) lasueweepsil,nln conduitsand inletandoutletguides. nylon, always usewherepossible, b) orforheavycurrentworkuseatipsize always usethecorrectsizecontacttip, a) ▲ ▲ ▲ Clean brassinletandoutletguidesare2ndchoice. longer contacttipsforbettercurrentpickup. Wherepossibleuse diameterofthewire1.2mm=1.3mmtip. eg. 10-15% larger. This surfaceshouldbemilledorwirebrushedpriortowelding. oxides thatabsorbmoistureduringstoragefasterthananas-fabricatedmillsurface. theprocessleavesaporoussurfacecontaininghydrated However, hydrocarbons. sawnorsmearedsurfacesand roughmachined, removes heavyoxides, Iteffectively This processusesahotsodiumhydroxideetchandnitricacidrinse. Etch Cleaning: brushed priortowelding. base metalmustbethoroughlyrinsedanddriedshouldmilledorwire the Iftheyareused, acids andcanpresentproblemsinhandlingdisposal. These cleanerscontain Chemical cleaningdeoxidisesandetchesthealuminium. Chemical Cleaning: base metal. not forward towards thebrushwherecompressedaircancontaminate Compressedairpowerbrushesshouldexhausttheirtotherear, surface metal. keep rpm’s andpressureslowtoavoidheatingsmearingthe If power isused, Wirebrushingcanbedonebyhandorwithapowerbrush. as thebasemetal. Wirebrushesmustbefrequentlycleanedwiththesamesolvent steel wirebrush. Oxide removal mustbedoneafterdegreasingandisbestwithastainless Wire Brushing: b) d) b) TECHNICAL AND TRADE INFORMATION 325 istorts or straight barrelled conductor tube. or straight barrelled conductor ° Using dust covers and periodically cleaning the dust and dirt Using dust covers and periodically cleaning from the liner increases service life. Proper storage is also important in reducing contamination. CIGWELD recommends in a controlled that aluminium welding wires be stored humidity (30%RH), atmosphere below thirty percent relative controlled cabinet. preferably a temperature and humidity welding wire should never be containing aluminium Packages overnight welding wire should never be left on equipment welding unless protective means are added to the machine, such as fully enclosed temperature controlled wire feeders (resistance heater inside the feeder), temperature and humidity controlled workshops, etc. Always use U-Groove drive rolls.Always types distort or shave Other backs.wire causing more burn that the U-groove drive Ensure roll edges are chamfered, white coloured not sharp...The picture shows the correct drive roll type. Centre line, distort the welding wire misaligned drive rolls will and cause serious feedability problems. Check your wire feeder for drive roll alignment after each size change of feed rolls. for most of the CIGWELD can supply U-groove rollers TRANSMIG range. : c) tube (goose neck). use a copper jump liner in the conductor d) drive rolls. use U-Groove always e) where possible use 45 f) g) type wire feeders. as possible (3 metre) when using push MIG guns as short keep & equipment when welding over longer distances. use push pull MIG guns left outdoors or stored in unheated buildings. Aluminium pressure has been backed off. pressure has been backed welding wire starts to feed through the entire length of the MIG gun. b) wind the pressure roller down until the pull the trigger of the MIG gun and slowly c) once the welding wire has passed through the contact tip,down another 1 - 2 turns. wind the pressure roller a) wire, lower the pressure roller down onto the aluminium making sure that all The correct drive pressure can normally be obtained by following these steps; correct drive pressure can normally The 3) Wire Feedability cont.: Welding of Aluminium WELDING OF ALUMINIUM OF WELDING In addition to proper U-type drive roll contours, correct drive roll pressure must be maintained. d Excessive drive roll pressure the welding wire increasing frictional drag through the liner and contact tip. Proper Alignment of Drive Rolls Proper Dust Covers and Wire Storage: Wire and Dust Covers Hints on Feedability: Drive Rolls: Drive Roll Pressure: www.cigweld.com.au 326 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Conduits (liners): Proper nozzle&contacttiprelationship: Inlet andoutletguides: Contact Tips: 3) Feedability of AluminiumWeldingcont.: Feedability Wire 3) WELDING OF ALUMINIUM also improvesoverallperformance. pulsingorspirallingoftheweldingwire, feeding isnotedeg. reduce thetipsworkinglife. soften thetipandcausepoorcurrentpickupseverely Where possibleuselongercontacttipsforbettercurrentpickup. diameterofthewire1.2mm=1.3mm. eg. 10-15% larger. orforheavycurrentworkuseatipsize size contacttip, ▲ ▲ unsteady feed. increases dragforcesandproducesburn-backsdueto surfaceofthetipwhich build upofparticlesontheI.D. Continuousarcingcausesa arcingwilloccur. the contacttip, there istoomuchclearancebetweentheweldingwireand If ofthecontacttipisparamountimportance. Correct I.D. burn back. Cleartotallengthoftheconduitaftera connection fittings. Smoothfeedingisalsoassuredbynon-metallic wire. through longdistancesbyavoidingabrasionofthewelding liners improvesthefeedingofaluminiumweldingwire orplastic Properly sizedflexibleconduitswithnylon, and voltagesettingsupto5mmforhighersettings. shielding nozzlebyapproximately1.6mmforloweramperage The contacttipshouldberecessedfromtheedgeofgas aluminium wiresbutare2ndchoice. cleanbrassinletandoutletguidesmaybeusedon New, nyloninletandoutletguides. Where possibleuse, ee erl h ..ofagenuine Tweco tipasthiswill Never redrilltheI.D. damagedorcrimpedcontacttips. Do notusebent, ▲ Changing contacttipswhenunsteady ▲ Always usethecorrect TECHNICAL AND TRADE INFORMATION 327 conductor ° or Straight barrelled conductor tubes.or Straight barrelled The ° tubes are not recommended. to use a copper It is advisable the length of the conductor tube, jump liner throughout pick up.which will aid in current copper jump liner The between the end of the replaces the nylon liner diffuser. handle and the gas inert gas leaks as these can be a major and Check for water cause of porosity. and inert gas Do not interchange water lines. Never use old oxy / acetylene hoses for inlet gas lines. Conductor Tubes (goose necks) are a critical component for (goose necks) are a critical Tubes Conductor welding.successful aluminium the CIGWELD recommends use of either 45 straighter the tube the better the wire feed.straighter the tube the 60 1. of surface oxides (hydrated oxides). removal The 2. vapour. or water water absence of any The 3. of hydrogen-containing compounds (hydrocarbons). removal The Although welding equipment is sturdy, regular the abuses of day-to-day work makes maintenance a necessity. equipment can result in or improperly maintained welding Faulty poor welding work. Nevertheless, of welding parameters, with proper selection correct equipment and accessories, of preventive maintenance and the purchase an effective program of CIGWELD aluminium welding wires, welds are attainable. high quality Weld porosity results from the entrapment of hydrogen gas.Weld gas entrapment results in lower This and by acting as weld strength and ductility by reducing the cross sectional area of sound metal stress risers which cause premature failure. can produce gas porosity, Several variables one of which is the surface condition of the aluminium filler wire. qualities relating to the surface The characteristics of the filler wire include: Of these three surface conditions, the most common cause of weld porosity is the presence of hydrocarbons. Examples of these compounds include residual wire drawing lubricants, mill dirt or even fingerprints. One relatively quick and inexpensive method of testing aluminium welding wire Test”. “Smoke for freedom from residual hydrocarbons is by means of a The “Smoke Test” “Smoke test performed by heating a sample of wire using an electrical is a qualitative The resistance heating machine. While conducting the test, the wire is visually examined for the presence of smoke, caused by the burning of any surface contamination. Minute amounts of contamination,fingerprint, even a will result in smoke. 4) Smoke Testing Aluminium Welding Wire Wire for Aluminium Welding Surface 4) Testing Contamination: Smoke 3) Wire Feedability cont.: Welding of Aluminium WELDING OF ALUMINIUM OF WELDING What is a Smoke Test? is a Smoke What What Contributes to Weld Porosity? Weld Contributes to What Conductor Tubes: Conductor Achieving High Quality Welds: Achieving High Quality Water and Inert Gas Leaks: Water www.cigweld.com.au 328 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au What CanIInterpret From theSmoke Test? Suggested Amperage Settings By Alloy Series Smoke Testing Apparatus: Donottouchthewire aftertestingsinceitbecomesextremely hot. CAUTION: WELDING OF ALUMINIUM 4) SmokeContamination: Testing4) Surface AluminiumWeldingfor Wire m)21 A356& A357 2319 (mm) ie XX4X,C5 5XXX C355 4XXX, 1XXX Sizes . 2 2 225 70 120 60 50 40 225 120 90 60 50 40 225 140 90 60 50 45 2.4 1.6 1.2 1.0 0.9 0.8 in 3to5seconds. The amperageshouldbesufficientto meltthesample time todetectthepresenceofanysmoke. The amperageischosentocontrolthemeltrateofsampleandallowadequate listed below. Typical amperagessettingsbaseduponthealloyanddiameterofsampletobetestedare iede o oei otc ihaycnaiain includinghumanhands. wire doesnotcomeincontactwithanycontamination, Caremustbetaken inselectingandplacingthesamplevicegripssothat test isperformed. Alightwithadarkviewingbackgroundisrecommendedtoaidinobservinganysmoke asthe The wiresamplecompletesthe circuit. The weldcablesareconnectedtotwohobbyvices. source willsuffice. Justaboutanycommercialweldingpower The schematicshowsatypicalsmoke testermachine. wire shouldbefurtherexaminedbeforecontinuingproduction welding. Alargeamountofsmoke willindicateseverecontaminationandthefiller generated bycontamination. Asmallamountofsmoke willindicatesomeevidenceofweldporosity minimal weldporosity. Zerosmoke shouldindicate A directcorrelationexistsbetweensmoke testresultsandweldporosity. Power Supply. Welding Cables. bolts onthevices. Countersinkandinsulate heat resistance. (Baker-Light) for Dielectric PhenolicBoard, Hobby Vices. Usecleanpliersatends only. with hands. donottouchthewiresample IMPORTANT: paintedblackinside. Wooden Cabinet, Viewing lightwithshade. TECHNICAL AND TRADE INFORMATION 329 Lower Amperage Higher Arc Voltage Lower Arc VoltageHigher Amperage- - - Longer Arc shorter arc lengths are required for desired penetration. for desired required lengths are shorter arc Note: 4XXX series alloys, Because 5XXX series alloys conduct heat significantly less than The visual characteristics and mechanical properties of aluminium welds are controlled by weld of aluminium welds are controlled by weld and mechanical properties visual characteristics The shape.bead penetration and of the weld bead affect the end properties A number of variables by the welder.and they can be controlled and of those variables Presented here is a description to achieve the desired end results. how they can be used CharacteristicsPenetration WidthWeld HeightWeld SurfaceMolten Pool SpatterArc Noise - SurfacePorosity CharacteristicsPenetration Short ArcSurfaceSmut (soot) Depressed Deep - RootPorosity NarrowRecommendations HighRoot Pass More PassFinish 5XXX Alloys Crackling Less High Heat Deep4XXX Alloys Long Arc Less More Flat Smooth Wide Shallow Arc Shorter - Flatter Shorter Arc Less Low Heat Humming More Shallow Less Rippled More - - Arc Longer 5) Arc Length & Heat (volts x amps) the Affect on Weld Bead Characteristics: Weld on Affect x amps) the & Heat (volts Length Arc 5) WELDING OF ALUMINIUM OF WELDING www.cigweld.com.au 330 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au WELDING OF ALUMINIUM 5) Arc Length&Heat(voltsxamps)the Affect on Weld BeadCharacteristics cont. oe:1 eebr hncagn r egh arcvoltageischangedwhich alsorequiresa whenchangingarclength, Remember, 1) Notes: )Freape thethermalconductivityof5083is32%lessthan6061because For example, 2) ihrmgeimcnet This requiresmoreheatinput intothe6061alloy. higher magnesiumcontent. amps Watts (heat)=voltsx change inarcamperageifconstantheatistobemaintained. estvt ocakpoaainDecreasearclength Increaseheat sensitivity tocrackpropagation Reduced weldstrengthandincreased Increaseweldingheat Incomplete penetration Change torchpositionto Severe reductioninfatiguestrength Overlap Reduced mechanicalproperties Undercut eue ehnclpoete Reducecoolingrate Reduced mechanicalproperties Insufficient Throa eue ehnclpoete Changetorchangle Increasetorchangle Reduced mechanicalproperties Insufficient Throat orLeg Reduced fatiguestrength rbe Solution R(max) 2.4mm T upto10mm Excessive Convexity Problem SPECIFICATION (USAonly) CONVEXITY CONTROL OVXT OTO C(max) plus1.5mm .07 xfacewidth, SPECIFICATION (USAonly) CONVEXITY CONTROL t Decrease traversespeed - Dissimilarthermalconductivity - Dissimilarsectionsizes compensate for: Decrease arclength Decrease travelspeed Increase wirefeedspeed Decrease torchforehandangle Decrease traversespeed Change torchposition Decrease arclength Increase arclength 0mt 0m3.2mm 10mm to20mm 0m+5.0mm 20mm + 1 1 1 1 2 TECHNICAL AND TRADE INFORMATION 331 C dew point. ° speed. Preheat base metal. of the “Aluminium Alloy Selection Chart”. “Aluminium of the and 1.0 to 3.0% magnesium. Avoid MgSi eutectic problems (5xxx welded with 4xxx). speed. Narrow heat zone by increased traverse Produce Convex rather than Concave bead. Minimise super heated molten metal, control to grain size. Proper weld size - not too small. Preheat base metal. reduce current surge and arcing in contact tip. metal droplets. oil and oxide immediately Clean base metal of prior to welding. and reduce arc voltage on CV power supply. slippage. shielding gas or inadequate flow. of weld pool. cooling rate Fast Increase flow rate. Shield from air currents. current and/or a slower Use higher welding Improper choice of aluminium Select welding wires with lower melting and welding wire or rod.Critical chemistry range.Inadequate edge preparation or spacing.Incorrect weld technique. solidification temperatures,“W” refer to category Avoid weld pool chemistry of 0.5 to 2.0% silicon Reduce base metal dilution of weld through Clamp to minimise stress. increased bevel angle and spacing. Turbulence of weld poolTurbulence Hydrogen from hydrated wire,oxide film or oil on base metal, drive rolls & liner. or contaminated Wet of Increase welding current to stabilise transfer constant temperature. wire covered. Keep Store wire in a low humidity chamber at a Reject bottles above -57 Fast run-in wire feed.Fast Insufficient wire feed.Electrode too soft, or not kinked level layer wound.Flexible conduit too long or kinked. or dirty liner or conduit.Worn to Slow run-in wire feed for CV power supply Spatter on end of or eroded THERMADYNE to your local CIGWELD or Talk interior of the Gas Nozzle. Cut down or Replace. Aluminium fillings in liner or wire feed for CC dropper power supply Increase conductor tube and contact tip,resulting in arcing Replace. TipArcing in the Contact Replace gas nozzle. Branch Office. rolls with the outlet guide, Align drive rolls,“U” use align the centerline of the drive grooved feed Match contact tip size to wire (or 10-15% above). rollers,prevent use only enough feed pressure to ProblemPorosity Causes Corrections or irregular Burn-back feed wire Cracking 6) Aluminium Welding Welding 6) Aluminium Problems, Causes and Corrections: WELDING OF ALUMINIUM OF WELDING Weld www.cigweld.com.au 332 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au 6) Aluminium Welding Problems, Causes and Corrections: and Causes Problems, 6) AluminiumWelding WELDING OF ALUMINIUM Unstable arc Corrections Dirty welds Causes starting Poor arc Problem r lw Donotweldinareaofstrongmagneticfield. paints cuttingcompounds, grease, Removealloil, steelbrushingoretch. Checkelectricalconnections. Arc blow. varsol ormineralspirits, Degreasewithtoluene, Keep heavystainless aluminiumwirecoveredwhenspoolis Cleanjointareawithdiscsander, Dirt injointarea. Poor electricalconnections. on parentmaterial. Heavy oxidefilmorwater stain Changepolarity. Dirty parentmaterial. Pre-purgegasshield. Removeanodiccoating. Increasegasflow. Dirty fillerwire. Reconnectground(earth). Inadequate gascoverage. Wrong polarity. No shieldinggas. Anodic coating. Improper grounding. Arrange groundclamptoneutralisemagneticfield. and caulkingfromjointareas. matter fromjointarea. Stainless steelbrushtoremoveotherforeign toremoveoilorgreasefromjointarea. etc. mounted onmachine. Check gunandleadsforairorwater leaks. Decrease gunangle. Centre contacttipingasnozzle. Replace damagedgasnozzle. Hold gasnozzleclosertowork. Shield arcfromdrafts. TECHNICAL AND TRADE INFORMATIONTECHNICAL AND TRADE WELDING OF ALUMINIUM

6) Aluminium Welding Problems, Causes and Corrections: Cont. Problem Causes Corrections Weld bead Welding current too high. Arc Change welding parameters. excessively travel speed too low. wide Too long an arc. Inadequate Insufficient welding current. Increase weld current. penetration Arc travel speed too high. Reduce arc travel speed. and Too long an arc. Decrease arc length through increased wire feed speed. incomplete Dirty parent metal. Degrease with toluene, varsol or mineral spirits, fusion in etc to remove oil or grease from joint area. welds Stainless steel brush to remove other foreign matter from joint area. Inadequate joint spacing or Redesign joint. edge preparation. Oxide on base metal. Clean joint area with disc sander, heavy stainless steel brushing or etch. Insufficient depth or improper Increase depth of back gouge, U-type preferred shape of the back-gouge. over V-type. Fillet or vee grooves - torch Weld with straight stringer passes without torch oscillation with CV power supply. manipulation. Switch to CC dropper power supply. Mismatch Improper alloy selection. Match colour selection in “Aluminium Alloy Selection Chart”. of colour after Avoid 4xxx and 6xxx match; use 5xxx filler wire anodising with 5xxx and 6xxx base alloys.

www.cigweld.com.au 333 334 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au ALUMINIUM ALLOY SELECTIONCHART 3.,55 ABABB- ABABB- ABABB- AABB-B ADCC CCAA-B ABAB-A BABB-A AABB-B ABCC CAAA-A BAAB-A BABB-A BABB-A CCAA-A BBAB-A BABB-A ADCC BABB-A CCAA-A BBAB-A BABB-A BABB-A ADCC CAAA-A BAAB-A BABB-A ABCC - - AAAA ------BABB-A ADCAA - CAAA-A BAAB-A ABDBA BABB-A BABB-A ABCC ABCAA CAAA-A BAAB-A BCDBA BABB-A ADCAA ABCC 5556 BCDBA 5554 ADCAA 5356 AADBA 5183 ABCAA 4043 AABAA 535.0, BBAAA 514.0, AABAA 513.0, BBAAA 512.0, 511.0, AADBA AACAA AADBA AACAA 4145 4043 6063, 6005, 4444 BC BC AA BC DC DC BC ADCCA ABCCA ADCCA ADCCA ABCCA AAAAA - ABCCA ABCCA 4043 5454 31 56BB- A-A--BB- A-ABB- A-ABABC-B BAB--A BAB--A BAB--A BAB--A - - BAB--A BAB--A 5556 6351, 0310 BAABAA BBAAAA - AABAA CCAAAA BAAAA - BAAAA BBAAAA - BBAAAA AABAA AABAA - CCAAAA 1100 DBAAAA DBAAAA 4043 - ALCLAD 3003 3003 1100 - DBAAAA 3004 DBAAAA 1100 ALCLAD 3004 30 18CCAAAA BBAAAB 1188 1100 1350, 1060, 1.,430 03AAA AAABAA BAAAAA AAAAAA AAAABAAAA - AAAAAA AAAAAA AABAAA - AABBA BBAAAA AAAAAA AABAAA BAAAAA BBAAAA AAAAAA AABAA AABAAA BAAAAA AAAAAA BBAAAA AABAA AABAAA BBAAAA BBAAAA ABCBAA BBAAAA AABBA CCBCAA - ABCBAA AAAAAA CCBCAA A357.0 AABBA AABAAA AAAAAA BAAAAA AABAAA BAAAAA - 4145 A356.0 4043 359.0 A357.0, A356.0, 4145 356.0, 444.0, 4043 443.0, 413.0, 2319 380.0 C355.0, 355.0, 354.0, 333.0, 319.0, Characteristics Base Alloys 00 0044 AABAA 4043 1080 1070, - AABA-A ABCB AABA-A ACCB AABA-A BCAA-A AABA-A CAAA-B ACCB AABA-A CCAA-B ABCB CCAA-B AAAA CAAA-B - - - - AABA-A ABCB AABA-A - ABCB CAAA-B CAAA-B 5183 4043 5654 5056 5086, 5254 5154, 5654 6951 11 36BA- A-A--BA- B-ABA- A-ABBAC-A BABC-B BAA--A BAB--A BBA--A BAB--A BBA--A BAB--A BAA--A BAB--A - - - - BAA--A BAB--A BAA--A BAB--A 5554 5356 5183 6201, 6151, 6101, 05 10CAA BAA--CAA -AA- B-AAAA - - AABC-B ABDAA BAB--A - ABCAA BAB--A - CCAAAA ABCAA ADCBA BAB--A AABA-A ABCB ABCAA ABCAA BAB--A AABA-A - ACCB BBAAA ACCAA AABA-A BBAAA ABCAA AABA-A ACCB - - AACAA AABA-A ABCAA ABCB CBAAAA AACAA AAAAA CBAAAA - AAAA AAAAA - BAB--A 4043 ABCAA 1100 BAB--A - ABCAA - AABA-A ABCB 5183 5050 5005, 4043 AABA-A ABCB 5183 5652 5052, 4043 5456 5083, ABAA-A BAAA-A AABA-A BBAA-A BABA-A BBAA-A BABA-A BDCBA BAAA-A BABA-A ABCBA - BABA-A ADCBA AABAA - ADCBA ABAA - ABCAA - BBAAA BAAA-A - - BBAAA BAAA-A BABA-A AACAA BABA-A - 5356 AACAA 5183 4145 4043 7110.0 710.0, 7146, 7046, 7039, 7021, 7005, 2921 AAAAAA - AAAAAA BAAAAA - - 2319 2219 1010 BAABAA------CAAAAA - - BCBCA BBAAA - BAAAA BBAAAA BAAAA - 1100 4043 2319 1100 2036 2214, 0044 AB AB AA AA AB CB CB BB - ADCAA ABDBA ABCAA BCDBA ADCAA BCDBA ADCAA AADBA ABCAA AABAA BBAAA AABAA BBAAA AADBA -ACAA AADBA AACAA 4145 4043 6070 6061, 4643* 56BB- ABA--BB- ABABB- ABAAABB-A ABAB-A BABB-A AAAB-A CCAAAA BAAB-A BABB-A BABB-A CAAAAA BBAB-A BABB-A CCAAAA BABB-A BBAB-A BABB-A CCAAAA BABB-A CAAAAA BAAB-A BABB-A ------BABB-A - CAAAAA BAAB-A BABB-A BABB-A CAAAAA BAAB-A BABB-A 5556 5554 5356 5183 36CB- A-B--CB- BCA------BBBC-A BACC-A - CABC-A C-BC-A - - BBBC-A - - BACC-A - BBBC-A ABDAA - BACC-A BBDBA CABC-A ABCAA - CABC-A AABAA - ADDAA BBAAA - AABAA - CAB--B ADDAA BBAAA - CAB--B BBDBA BADBA CAB--B ABCAA AACAA CAB--B AABAA BADBA - BBAAA AACAA 5 - AADAA 5356 CABC-B BBAAA 5183 CABC-B 4145 BADBA CABC-B 4043 AACAA CABC-B BADBA AACAA 5 5356 5183 4145 4043 54-----CAA CAACAA BCAAAA CAAAAA AABA-A CCAAAA BABA-A CCAAAA BABA-A BABA-A BABA-A - - - - - BABA-A BABA-A - 5556 5554 56CB- A-B--CB- ACA------BACC-A C-BC-A - BACC-A - - BACC-A BAC--B CABC-A BABB-A - BAB--A - CAB--B CABC-B CAB--B 4 - - 5556 CABC-B CABC-B - 5556 CAB--B CAB--B 5556 5 5 5 5 5 5 5 Filler Alloys 15ABAABAACA-- - - ABCBA ABCBA AABAA ABCBA AABAA AABAA 5 AABAA 4145 4145 4 03BAABAABBABBA- BCBCA BCBCA BAAAA BAAAA 4043 36AA- AAA--AA- BAAAA- AAAABAA-A AAAA-A ABAA-A ABAA-A AAAA-A - - AAAA-A AAAA-A 5 5356 56AB- AAA--AB- AAAAB- AAAAABA-A AABA-A AABA-A AABA-A AABA-A - - AABA-A AABA-A 5556 36CB- A-B--CB- A-ABA- A-B- - BAB--B BAC--B BAAB-A BABB-A BAA--A ABAC-A BAB--A CABC-B CABC-B BAA--A BBA--A - BAA--A - ABAA-A BBDBA BAA--A AAAA-A AABAA - ABAA-A - AABAA CAB--B ABAA-A - CAB--B BADBA AAAA-A CAB--B CAB--B BADBA - 5356 - 5183 BAA--A 4145 BAA--A - 5 AAAA-A 5356 AAAA-A 5 5356 56BB- A-A--BB- A-ABB- A-AAABC-B BAB--A BAB--A BAB--A AABA-A BAB--A AABA-A AABA-A AABA-A - AABA-A - - BAB--A BAB--A - AABA-A 5556 AABA-A 5556 36BA- A-A--BA- B-ABA- A-ABBAC-A BABC-B BAA--A BAB--A BBA--A BAB--A BBA--A BAB--A BAA--A BAB--A - - - - BAA--A BAB--A BAA--A BAB--A 5 5356 5183 4643* 56BB- A-A--BB- A-ABB- A-ABABC-B BAB--A BAB--A BAB--A BAB--A - - BAB--A BAB--A 5556 5 5 1 6 6 6 6 6 6 3 3 0 5 5 5 5 5 5 4 5 5 5 5 5 5 5 5 4 5 5 5 5 4----- 4----- 5A 4------B 4------B 4------B 4------4------4----- 6------B 6------3A 4------4------4------4------00 0630 0455 5652 5050 3004 5052, 5005, ALCLAD 3003 WSDCTM 3004 WSDCTM ALCLAD WSDCTM WSDCTM 2219 WSDCTM 2036 WSDCTM 2014, WSDCTM WSDCTM 1100 WSDCTM 1350 1060, 1080 1070, ------A A C B A B AA AA ------A A C B A B AA A------A B A AA A B A AA 3303, A C B A------CBA------CCABAA - CCABAA CCABAA ------CABCA- AAABCAA-A CAAA-A CCAA-B CCAA-B ------BCAB-B CCAB-A CCAB-A CCAA-A CCABAB CCAAAB CCAA-A CCABAB ABB-A CAB-A CAA-B CAA-B TECHNICAL AND TRADE INFORMATION 335 A A A A A ABBBAA C). ° A A A B F (65.5 A ° AAAAAA - AAAAAA - AA LEGEND A A B A AA A A--- A A B B A C SymbolWcracking). Ease of welding (relative freedom from weld Scondition). particularly to fillet (Rating applies Strength of welded joint (“as welded” welds. All rods and electrodes rated will develop presently specified minimum strengths for butt Characteristic welds.) Delongation of the weld.) Ductility. the free bend (Rating is based upon Calternate immersion in fresh or salt water. resistance in continuous or Corrosion Ttemperatures above 150 Recommended for service at sustained M and D are relative ratings in decreasing *A,B,C Colour match after anodising. order of merit. ratings have relative meaning The only within a given block. NOTE: Combinations having no rating are not usually recommended. Ratings do not apply to these alloys when heat-treated after welding. AA A AA A---- A A A B B B A C C ADCBA ADCBA BDCBA - - AABBA AABBA AABBA AABBAB - 511.0, 512.05154, 5254 6005, 6063, 6951 7005, 7021, 413.0, 443.0 319.0, 333.0 711.0 A356.0, A357.0 ------A------A------A A B B A A ----A ----A 5083,50565456 5086, 535.0 513.0, 514.0 5454 6101, 6151, 6201, 6061, 6351, 6070 7039, 7046, 444.0,356.0 7146, 710.0, 354.0, 359.0 355.0 C355.0,380.0 ------B ----A ------WSDCTM WSDCTM WSDCTM WSDCTM WSDCTM WSDCTM WSDCTM WSDCTM WSDCTM ------4------6A 4------4------4------3A 3------5------5------3------3------5 5 5 5 5 8 4 4 4 4 4 5 5 6 6 5 1 0 1 1 0 0 5183535655545556 AABA-A ABAA-A BCAA-A AABA-A AABA-A ABAA-A BCAA-A BABC-B AABA-A BBAC-A CCAB-B BABC-A BABC-B BBAC-A CCAAAA BAAC-A BABC-B BAAC-A CBABBA BAAC-A BAAC-A BBAC-A CBABBB - BAAC-B ------53565 5 A-AA-A 5 5 5654 - - BCAA-B BCAB-B - - - - - 5654 -5654 - BCAA-B BCAA-A BCAA-B BCAA-A CCAB-A BCAA-A CCAB-B BCAA-A CBAB-B BCAA-A CBAB-B - - - - - Filler Alloys Filler 5356 AAAA-A AAAA-A AAAB-A AAAB-A4643* - -4643* AAAA-B - - 53565 5556 ABAA-A AABA-A ABAA-A AABA-A ------5183535655545556 AABB-A ABAB-A BCAA-A AABB-A AABB-A ABAB-A BCAA-A AABB-A AABB-A ABAB-A BCAA-A AABB-A AABB-A ABAB-A BCAAAA - AABB-A ------55545556 - AABA-A AABA-A AABA-A - BCAA-A AABA-A BCAAAA BCAAAA AABA-A BCAAAA AABA-A BCAAAA AABA-A - - - - 6 5 3 4 0 4 3 4 4 4 6 4 5 8 7 6 5 8 4 0 0 0 4 0 6101615162016351 5183 5356 5554 5556 AABA-A AAAA-A BAAA-A AABA-A AABA-A AAAA-A BAAA-A BABC-A AABA-A BAAC-A CAAB-A BABC-A BABC-A BAAC-A CAAAAA BAAC-A BABC-A BAAC-A CBABBA - - BAAC-A ------5 5 511.0 4043 512.0513.0514.0535.0 5183 5356 5554 5556 AABA-A ABAA-A BCAA-A AABA-A AABA-A ABAA-A BCAA-A AABB-B AABA-A ABAB-A BCAA-B - AABB-B ------7005, 7021, 4043 6061,6 404360056 ADCA ADCA 4043 ADCA ABCA ADCBA ACBAA ABCA ACBAA ABCA - ABCBA ACBAA ------5056 5183 AABA-A AABA-A ------69515 5654 BAAA-B5154, BAAA-B 52545 CAAB-B 5654 CAAB-B CBAB-B BCAA-B - BCAA-B BCAA-A ------Base Alloys Characteristics 319.0, 333.0,C355.0, 380.0 2319 4149 413.0, 443.0,444.0, 356.0, 4043 4145 ABBA-A ABBA-A ABBA-A ABBAAA ABAAAA ABAAAA ABBAAA ABAAAA - 7146, 710.07110.0 5183 5356 AABA-A AABA-A ABAA-A AABA-A ABAA-A AABA-A ABAA-A AABA-A ABAA-A AABA-A ABAA-A AABA-A ABAA-A - ABAA-A - - - 7039, 7046, 4145 354.0, 355.0, 4043 AAAA-A AAAA-A AAAA-A AAAAAA BBAAAA BBAAAA BBAAAA BBAAAA - A356.0, A357.0, A356.0 359.0 A357.0 ALUMINIUM ALLOY SELECTION CHART CONT. CHART SELECTION ALLOY ALUMINIUM *4643 gives higher strength in thick 6xxx series welds after post weld solution heat treatment and aging. 4047 can be used in lieu of 4043 for thin section sheet due to the lower melting point of 4047. ALUMINIUM ALLOY SELECTION CHART ALLOY ALUMINIUM How to Use: 1. Select base alloys to be joined (one from the side column,2. the other from the top row). the block where the column and row intersect. Find 3. or D) representative of the alloy directly across from block contains horizontal rows of letters (A,B,C This them in the filler alloy box at the end of each row.A-to-D rating of the give the letters in each line The characteristics listed at the top of each column - W, S, D. C, T and M (see Legend at right for explanation of each letter). 4. by each filler alloy. Analyse the weld characteristics afforded ‘trade off’ one will find that you can You needs. characteristic for another until you find the filler that best meets your Example: When joining base alloys 3003 and 1100, find the intersecting block. Now,excellent ductility (D), note that filler alloy 1100 provides corrosion resistance (C), temperatures (T) and colour match after at elevated performance anodising (M), with good ease of welding (W) and strength (S). However,UTMOST in importance, if ease of welding and shear strength are match can be sacrificed slightly, and ductility and colour filler alloy 4043 can be used advantageously. www.cigweld.com.au 336 TECHNICAL AND TRADE INFORMATION 337 1000300040005000 99% Pure Manganese Magnesium Silicon *2000*6000*7000 Copper Magnesium & Silicon Zinc SERIES No. ELEMENTS ALLOY MAJOR Group B - Wrought Alloy System Wrought Group B - and superior machinability. corrosion resistance. 200/2000 Series: contain copper as a major alloying element. - limited corrosion resistance, a high strength to weight ratio - very poor weldability. - uses: forgings, heavy duty structural work. 300 Series: containing copper and silicon have almost replaced the original 200/2000 series due to better casting characteristics, the other features are the same. 3000 Series contains manganese which provides approximately 20% more strength than the 100/1000 series. has good ductility and retains workability. series This - good weldability. - uses: cooking utensils, which are used on storage tanks. sheets and panels 100/1000 Series: (iron and silicon are the major AL or greater contain 99% impurities). - excellent surface finish, high thermal and electrical conductivity and excellent weldability. - excellent - uses: electrical conductors, architectural items and containers. Group A - Cast Alloys A - Cast Group Alloys Wrought Group B - ▲ ▲ ▲ ▲ 100400500800 99% Pure Magnesium Silicon Tin *200*300*600*700 Copper & Silicon Copper & Silicon Magnesium Zinc * NB: alloys are heat-treatable. These Cast aluminium alloys generally contain a higher percentage of alloying elements than wrought alloys. Cast aluminium alloys generally contain higher additions of alloys greatly improve casting qualities,The machining and working but make more difficult. Aluminium Alloys can be broken up in to the following groups: up in to the Alloys can be broken Aluminium SERIES No. ELEMENTS ALLOY MAJOR The Different Groups (Features) Groups The Different 1) Aluminium Base Metals Aluminium 1) WELDING OF ALUMINIUM OF WELDING Group A - Cast Alloy System Alloy A - Cast Group www.cigweld.com.au 338 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au GTAW Welding Consumables for Aluminium and AluminiumAlloys: GTAWfor Aluminium Consumables Welding The Different Groups (Features) cont. WELDING OF ALUMINIUM The CIGWELD/Comweldrange h ru r ieyue u oterecletmcaia rpris high the grouparewidelyusedduetotheirexcellentmechanicalproperties, seeproductinformationinthefrontofthisPocket Guideorthe - * Comweld AL5356 * Comweld AL4047 * Comweld AL4043 * Comweld AL1100 ▲ ▲ ▲ ▲ ▲ poorweldability. - resistance tocorrosionbyengineoils. These alloyshaveahigh improve anti-frictioncharacteristicsinbearingalloys. itschiefpurposebeingto tinistheprincipalalloyingroup, 800 Series: aircraftstructuresandmobileequipment. uses: - notrecommendedforwelding. - highstrengthandexcellentductility. resistance, containszincwhichhelpstogivethesealloysverygoodimpact 700/7000 Series: bridgesetc. engineeringstructures, transportationequipment, uses: - goodweldability. plushighstrength. - highresistancetocorrosionandeaseofmachining, - heat treatmentafterforming. whichallowsthemechanicalpropertiestobeimprovedconsiderablyby treatable, containsiliconandmagnesiummakingthesealloysheat 600/6000 Series: widelyusedintheshippingandmarineindustries, anglesetc, plate, sheet, uses: and alsoingeneralfabrication. - goodtoexcellentweldability. - 500seriesaredifficulttocast. - corrosion resistanceandexcellentanodisingcharacteristics. The alloysin containsmagnesiumasthemajoralloyingelement. 500/5000 Series: decorativegatecastings andsheet. castings, weldingwires, uses: - goodtoexcellentweldability. - melting pointandmakes the400alloysoneofbestforcasting. The siliconlowersthe metals fluidityandimprovesstrengthmachinability. containssiliconasthemajoralloyingelementwhichaidsin 400/4000 Series: CIGWELD Welding Consumables Technical ReferenceManual. TECHNICAL AND TRADE INFORMATION 339 3203 R1100 R1100 Comweld AL1100 (Pure Aluminium) 525154547005 R5356 R5356 R5356 R5356 R5356 R5356AL5356 (Aluminium 5% Magnesium) Comweld AL5356 (Aluminium 5% Magnesium) Comweld AL5356 (Aluminium 5% Magnesium) Comweld 5154A R5356 R5356AL5356 (Aluminium 5% Magnesium) Comweld Pure, Zirconiated,A.C. and Ceriated are the recommended tungsten welding electrodes for use in welding. welding electrodes are generally reserved for D.C. Thoriated welding of products such as low alloy steels and stainless steels. tungsten will handle a higher current than pure Thoriated tungsten,A.C. although it does not retain the balled shape required for welding of aluminium. A.C. or used for welding electrodes are not often recommended Tungsten Pure welding on aluminium and magnesium alloys as Zirconiated, and Ceriated electrodes have gained popularity in recent years. contain a minimum of 99.5% tungsten, electrodes Tungsten Pure with no alloying elements intentionally added. By using high purity tungsten, current carrying capability is diminished, although it maintains a clean, good arc stability. balled end which provides CAST WROUGHT AS1167.2 AWSA5.10 CIGWELD PRODUCT BP401 R4047 R4047 10% Silicon) AL4047 (Aluminium Comweld BP601 5050A R4043 R4043AL4043 (Aluminium 5% Silicon) Comweld CP401AS303 R4047 R4047 R4047 R4047 10% Silicon) AL4047 (Aluminium Comweld AL4047 (Aluminium 10% Silicon) Comweld CP601AS601 6061 6063 R4043 R4043 R4043 R4043AL4043 (Aluminium 5% Silicon) Comweld AL4043 (Aluminium 5% Silicon) Comweld AP303AP309 R4047 R4047 R4047 R4047 10% Silicon) AL4047 (Aluminium Comweld AL4047 (Aluminium 10% Silicon) Comweld AP603AP501AP701AP703 6351 5052 5083 5086 R4043 R5356 R5356 R5356 R4043 R5356 R5356 R5356 Silicon) AL4043 (Aluminium 5% Comweld AL5356 (Aluminium 5% Magnesium) Comweld AL5356 (Aluminium 5% Magnesium) Comweld AL5356 (Aluminium 5% Magnesium) Comweld AP150AP170AP185 1100 1200AP403 3003AP601 R1100 3004 R1100 5005 R1100 R1100 R4043 R1100 R4043 R1100 R4043 R4043 Comweld AL1100 (Pure Aluminium) Comweld AL1100 (Pure Aluminium) Comweld AL1100 (Pure Aluminium) Silicon) AL4043 (Aluminium 5% Comweld Silicon) AL4043 (Aluminium 5% Comweld ALUMINIUM ALLOYS CONSUMABLE (Filler Rod) TYPE Rod) CONSUMABLE (Filler ALLOYS ALUMINIUM 2) Tungsten Electrodes 2) Tungsten Filler Metals to AS 1167.2/AWS A5.10 1167.2/AWS AS to Filler Metals WELDING OF ALUMINIUM OF WELDING Pure Tungsten Electrodes: Pure Tungsten AWS A5.10-92 Specification for Bare Aluminium and Aluminium Welding Electrodes and Rods. Welding Aluminium Aluminium and A5.10-92 Specification for Bare AWS www.cigweld.com.au 340 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au ss designedforhighqualitycleanweldingof Aluminium andMagnesiumalloys. Uses: Zirconiated TungstenElectrodes: Ceriated TungstenElectrodes: WELDING OF ALUMINIUM 2) Tungsten Electrodes cont. Advantages: directional capabilities. very importantin AC-HF weldingasitallowsthe AC currenttoobtainarcstabilityandits This balledendis the radiusendheatsupandbecomesslightlymoltenformingaballedend. When currentflowsthroughaZirconiatedelectrodetheendtipwhichhasbeenpreparedwith Zirconiated electrodesmustbepre-groundtoformataperedtipwithradiusendbeforeuse. Current (AC-HF) andarealloyedwithvarying percentagesofzirconium. These electrodeshavebeendesignedprimarilyforusewithHighFrequency stabilised Alternating tungstens. than puretungstenandbetterforradiographic-qualityweldingapplicationsthoriated Itismoreresistanttocontamination welding electrodeprovidesagoodbalanceofproperties. This tungsten besidesthehighercurrentcarryingcapabilityfoundinthoriatedtungsten. Zirconiated tungstenweldingelectrodeshavearcstabilitycharacteristicsthataresimilartopure This electrodecanreplaceboth Thoriated andZirconiatedelectrodesinmostinstances. mode. aluminium inbalancedwave machines(A.C.)andonsteelintheD.C. These characteristicsallowthisweldingelectrodetoperformwellon tungsten “spitting”. electrode willreactmuchlike puretungstenbyprovidingastablearcandreducingtheamountof theceriatedwelding Inperformance, which helpstoreduceweldingelectrodeburn-off. Ceriated tungstenweldingelectrodeshaveanadditionofapproximately2%ceriumoxide(CeO been designedtofunctiononboth AC andDCcurrents. These electrodescontainvarying percentagesofceriumandhave “The bestofbothworlds”. ▲ ▲ ▲ resultant weldmetalqualityisofhighradiographicstandard. high resistancetocontaminationfromaluminiumoxides(selfcleaningaction). high currentcarryingcapacity. 2 ) TECHNICAL AND TRADE INFORMATION 341 cause tungsten particles to drop off the tip during welding. will result in tungsten inclusions,This a weld defect. “arc wander”. Welding polarity being used (AC-HF or DC) polarity being used (AC-HF Welding Metal being welded. type of Parent The electrodes,Tungsten When grinding sure to make it is very important the electrodes axis. the grinding lines run longitudinally to If the grinding lines run around the circumference of the electrode, they may cause the following problems: - ridges will be formed around the circumference which can - these ridges will reduce the stability of the arc and cause reduces the number and types of electrodes required to complete different jobs. and types of electrodes required to complete reduces the number zirconiated types. contamination than the thoriated and higher resistance to capacity. higher current carrying life. a longer electrode tip non-radioactive material. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ Grinding lines will run with the length of the electrode Preparation is dependent upon two factors: Preparation before welding is dependent upon the current used. dependent upon the before welding is Preparation Uses: general purpose work on most metals. designed for quality and 3) Preparing Tungsten Electrodes: Tungsten 3) Preparing 2) Tungsten Electrodes cont. Electrodes Tungsten 2) WELDING OF ALUMINIUM OF WELDING The Correct Grinding Technique: Correct Grinding The Tungsten electrodes are pre-ground before commencement of welding to allow efficient performance during welding. electrodes are pre-ground before commencement of welding Tungsten Advantages: www.cigweld.com.au 342 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Current CarryingCapacitiesof Tungsten Electrodes: High Frequency (HF): WELDING OF ALUMINIUM 4) Gas Tungsten and “Power Source Arc Terminology”Welding - “Process Explanation” Preparing Zirconiated &Ceriated Tungstens for AC-HF Welding: LCRD IMTRTOITDZROITDCERIATED ZIRCONIATED THORIATED ELECTRODE DIAMETER iewv.Trepstoseito otGA ahnse.TRANSTIG200 AC/DC: Three positionsexistonmostGTAW machineseg. sine wave. The highfrequencymodewillinitiateandmaintainthearcduringzerocrossingof A.C. Discussed below areseveralimportantitemsthatmustbeaddressedinordertoproducehighqualitywelds. andweldertechnique. typeofpowersource, andtungstenelectrodequality, filler wire, GTAW weldqualityisprimarilycontrolledbyworkpiece, is envelopedbyastreamofinertgas. The arc maintained betweentheworkpieceandanonconsumabletungstenweldingelectrode. The Gas Tungsten Arc Welding (GTAW) processutilisesheatgeneratedbyanelectricarc .m 0-0 5-0 210-600 130-450 80-320 60-230 5-60 7-95 20-130 150-400 90-300 50-225 45-160 35-75 15-55 5-35 200-500 120-370 80-250 50-190 20-120 10-90 5-50 5.0mm 4.0mm 3.2mm 2.4mm 1.6mm 1.0mm 0.5mm .Continuous-thisalsohelps initiatethearcandcontinuesthroughoutprocess 2. Start- This modehelpsarcinitiationwithoutmakingactual contacttotheworkwith 1. automatically when AC current forGTA weldingisselected. This andoccurs typeof mode isoftenabuiltinfeatureonmostCIGWELDGTAW machines, welding. This modeismostoftenusedin A.C. point ofthesinewave. to maintainthearcduringperiodswhencurrent(amperage) isatthezerocrossing h ugtnwligeetoe h Sat oei ototnue nDC welding. modeismostoftenusedinD.C. The “Start” the tungstenweldingelectrode. TECHNICAL AND TRADE INFORMATION 343 this mode. surface must occur the tungsten electrode and work Contact between initiated.before the arc can be Scratch Start Practice” Start or “Touch A to initiate in the GTAW of the the tungsten electrode the arc can cause contamination process.“Off” The where TIG or stick welding (MMAW) for DC- mode is often used initiate the arc. scratch starting will 3. any part of the process in frequency system does not engage during high The Off - 4) Gas Tungsten Arc Welding Welding Arc - “Process 4) Explanation”Gas Tungsten and “Power Terminology”Source cont. WELDING OF ALUMINIUM OF WELDING www.cigweld.com.au 344 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Starting the Arc: Pulsed GTAW (TIG) Welding: WELDING OF ALUMINIUM 5) GTAW (TIG) Techniques cont. Source Terminology” “Power and Gas TungstenExplanation” 4) “Process - Arc Welding following stepsarerecommended; foot controlstartsuchasthe TRANSTIG 150the For powersourcesthatdonothaveabuttonor path fortheweldingcurrenttofollow. workpiece orstartingblockandthusestablishesa bridges thegapbetweenelectrodeand The superimposedhighfrequencycurrent workpiece orstartingblocktoeffectarcignition. theelectrodedoesnothavetotouch the After gasflowisestablishedandprovidingHFused, In PulsedGas Tungsten “seebelow” Arc Welding thecurrentconsistsoftwoparts, ) thetorchshouldfirstbepositioned a) thelowbackgroundcurrentwhichmaintainsarcandallowsweldto cool. 2) thehighpulsewhichmeltsmetal, 1) as it provides less risk of contamination). as itprovideslessriskof recommended forastartingblock starting block(apieceofcopperis 50mm abovetheworkpieceor in anearhorizontalpositionabout and c)improvedtolerancetojointfitup, d)userfriendlyoperation. b) reducedheatbuildup, a) reduceddistortion, TIG weldingoffersthefollowingadvantages; Pulsed The rateofpulsecurrentisusuallyintherange1-10pulsespersecond. TECHNICAL AND TRADE INFORMATION 345 angle from the ° horizontal position. filler rod The is added ahead of the weld pool 10 to 25 degrees from the plane of the weld bead. rod or filler The be placed wire should always within the inert gas shield and at the leading edge of the weld pool. large a rod or wire disturbs Too and often freezes the pool, while a rod too small in size forces the welder to feed too fast for steady operation. within approx 3mm of the workpiece or starting block as within approx 3mm page.shown on the previous then be initiated. arc will The the so that the arc will not mark or damage in a rather rapid manner weld surface or workpiece. Some care will be necessary, particularly the arc. and in pipe preparation when breaking with high quality work is advisable to run off,In some instances it to a tab or up the side of on when completing a pass. the pipe preparation the joint evenly. of the torch by the fingers alone, Movement usually results in incorrect torch angles and a poor weld. to hold the wire steady.should be as close as possible to the arc wire should The move in conjunction with the torch movement. When adding wire, move the wire with the thumb through the fingers. end of the wire should extend 150mm to The 200mm from the hand. wire results in a wobbly much extension of the filler Too allowing the filler wire to become wire end making the puddle uneven and contaminated. steadiness and concentration Adding wire to the puddle requires the right place,to place the right amount of material at at exactly the right time. torch is usually pointed in the direction of travel with a 45-90 b) electrode is until the downwards the torch is then moved quickly c) to stop an arc, be returned to the horizontal position the torch should - hand should be placed lightly on a surface, The can move across so that the hand - When adding filler wire, the wire should be gripped in the fingers. hand The - only slightly depending on the welding position. angles vary Torch The Torch Angles: Torch a good weld. proper manipulation of the welding torch is very important in making The When welding in the flat position, 5) GTAW (TIG) Techniques cont. Techniques (TIG) 5) GTAW WELDING OF ALUMINIUM OF WELDING www.cigweld.com.au 346 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au oc nls forDifferent WeldingTorch Positions: Angles, WELDING OF ALUMINIUM 5) GTAW (TIG) Techniques cont. Fillet Welds relationship. Overhead jointtorchandfiller rod relationship. Vertical jointtorchandfiller Overhead Welding Vertical Welds Corner to Weld (OutsideCorner) relationship. joint torch Corner tocorner TECHNICAL AND TRADE INFORMATION 347 35-50 45-70 70-95 Tungsten Rod Filler Lap/Fillet Lap/Fillet Lap/Fillet Lap/FilletLap/Fillet 3.2mmLap/Fillet 4.0mm 4.0mm 130-160 190-240 250-320 Aluminium GTAW (TIG) Welding - Alternating Current - High Frequency (AC-HF) Alternating Current - High Frequency - Welding (TIG) Aluminium GTAW Metal Electrode Diameter Gas 1.0mm Butt/Corner 1.0mm 1.6mm 30-45 Argon 5-7 1.2mm Butt/Corner 1.0mm 1.6mm 40-60 Argon 5-7 1.6mm Butt/Corner 1.6mm 1.6mm 60-85 Argon 7 3.2mm5.0mm Butt/Corner6.0mm Butt/Corner 2.4mm Butt/Corner 3.2mm 2.4mm 4.8mm 3.2mm 125-150 4.8mm 180-225 Argon 240-280 Argon 10 Argon 10 13 ThicknessType Joint Diameter (if required) Amperage Type Flow L/min* 6) Joint Types and Parameters in GTAW in and Parameters Types 6) Joint WELDING OF ALUMINIUM OF WELDING Joints types applicable to the following parameter table: Parameter Table for GTAW (TIG) Welding of Aluminium: of Welding (TIG) table: following parameter applicable to the Joints types for GTAW Table Parameter *Flow rates are for argon only, see manufacturers’ recommendations for mixtures. Size and shape of gas nozzle has an effect on the flow required for an effective gas cover. www.cigweld.com.au 348 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Cast ironscangenerallybedividedintothefollowinggroups: Types ofCastIron Introduction WELDING OFCASTIRON technical guidetotheweldingofanumberdifferenttypescastiron. itprovidesthereaderwithathorough Nonetheless, This guideisnotanexhaustivereference. .WieCs rn “hle”Iron) WhiteCastIrons(“Chilled” 4. AusteniticCastIrons 3. DuctileCastIron) SG-SpheroidalGraphiteCastIrons(NodularIron, 2. GreyCastIrons 1. (eitrdtaeako nentoa ehnt ea o Ltd.) *(registered trademarkofInternationalMeehaniteMetalCo. properties superiortothatofgreycastiron. The silicideadditiongivesuniformhardnessaswellphysical white castiron. “Meehanite”* isahightensilewhitecastironmadebyaddingcalciumsilicideto They areoftenusedinthemanufactureofcrushingrolls. strength. are quiteunmachinableandverybrittlewithhighhardnesslowtensile They whitecastironsarevirtuallyfreeofgraphite. Unlike thegreyandSGcastirons, resistance. Ni-ResistforcorrosionresistanceandNicrosilalheat abrasion resistance, Ni-Hardisusedfor Ni-Resist andNicrosilalgrades. up therangeofNi-Hard, chromium andmolybdenummake Austenitic whitecastironscontainingnickel, Austenitic (SG)castironisapproximatelytwiceasstrongaustenitic(grey)iron. producing goodwearandgallingresistanceaswellmachinability. Austeniticcastironsarestrongerandtougherthangreyiron, service. cavitation resistanceandexhibittohightemperature erosion resistance, austeniticcastironsexhibitcorrosionresistance, Due tothenickel addition, SGandwhitecastirons. Austenitic castironsarenickel alloysofgrey, weldability whencomparedtogreycastiron The advantages oftheseproductsaretheirrelativelygoodtoughnessand pumps. valves and pressurepipesaswellfittings, sewers, Applications includeculverts, them machinable. SGcastironscontaingraphitemaking well asgreycastironinmanyapplications. inmany casesreplacingsteelcastingsandforgingsas greater thangreycastiron, SG castironshavemechanicalpropertiessimilartothoseofmildsteelandfar and non-pressureapplications. flangesandfittingsforbothpressure valves, asarevarious typesofpipes, cast iron, moulds andmeltingpotsthatoperateatelevated temperaturesaremadeofgrey ingotandglass Furnaceparts, clutchplatesandcamshafts. including brake drums, Ithasusesinthemachineryandautomotiveindustries, low tensilestrength. Greycastironishoweverquitebrittleandhas for dampingmechanicalvibration. helps inthelubricationofslidingsurfacesandisthereforegoodforbearings greycastironiseasilymachined, Due tothepresenceofgraphiteinitsstructure, normally beexpected. process equipmentandwhereseverethermalmechanicalshockwouldnot lightlystressed including thoseunderconditionsofstaticcompressiveload, Usedformanyapplications, Nominally contain2.5-4.0%carbonandhighsilicon. TECHNICAL AND TRADE INFORMATION 349 Grey and SG cast iron have a dirty, dark grey appearance due to the presence of graphite in the structure.fracture in White cast irons will have a whitish colour in a the casting. and austenitic cast irons have a cleaner appearance than Malleable grey or nodular. If possible, check with the supplier of the cast iron. Quite often the item will be an old item in need of repair, so its origins may be difficult to discern. are the best tests for identification. These a) Spark test test.An easy and useful method is the spark metal is touched against a high The observed against a black background.speed emery wheel and the sparks are The sparks should then be compared against the chart below. SG cast irons can be identified in the same manner as malleable cast irons. Meehanite cast irons can be identified in the same manner as grey cast irons. Malleable cast irons,Malleable and black heart irons, the white heart which include are time. for a set period of heating white iron formed by cast irons have a Malleable bend or cast iron and will ductility than grey strength and better higher tensile grey cast iron. as well as standing shock better than deform before breaking flanges,Applications include parts. and valve pipe fittings parts include Automotive steering components, compressor crank shafts and hubs, transmission and differential parts, universal joints. connecting rods and 1. observation Visual 2. Source of supply 3. Mechanical tests 5. Malleable Cast Irons There are a number of ways of identifying the type of cast iron that is to be welded. of identifying the type of cast are a number of ways There Identifying the type of cast iron: Identifying the WELDING OF CAST IRON CAST OF WELDING www.cigweld.com.au 350 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Preparation General relevant CIGWELDconsumable. The table belowisaprocessselectionguidelistingthe Powder SprayingandSolderingprocesses. WELDING OFCASTIRON Preparation priortowelding Welding CastIrons ry12354 ,57 5 4, 5 4, 5 4, 5 4, 3,5 2 2 1 1 1 Nicrosilal 1 Ni-Resist Ni-Hard White Austenitic Ductile) SG (Nodular/ Grey Cast Iron ehnt 1 Meehanite alal ,54 5 4, 5 4, 2 1 Malleable prior towelding. The mostimportantaspectofweldingcastironistohavethesurfacecleanandfreedefects cast ironismorelikely toabsorbweldingstressesthangreycastiron. For exampleSG depend onthetypeofcastingheattreatmentandweldingprocedure. The degreeofbrittlenessandlikelihood ofcrackingtheweldedmaterialwill applications. been manysuccessfulcastironrepairweldsperformedinmaintenanceandcastingreclamation There have althoughtoafarlesserdegreethancarbonsteel. Cast ironisconsideredweldable, ngnrlcs rn a ewle sn h MW CW a n rz edn,Brazing, GasandBraze Welding, FCAW, In generalcastironscanbeweldedusingtheMMAW, rcs MWFA a rz rzn Soldering GasBrazeBrazing FCAW MMAW Process 6=Comweld 965SilverSolder ComcoatNickel Bronze 5=Comcoat N, ComweldManganeseBronze 4=Comweld ComcoatC, 3=Comweld GeneralPurposeCastIron 2=Nicore 55 Castcraft100 1=Castcraft 55, c) Spectrographic analysis Chiseltest b) qualified laboratorytoensureaccurateresults. Howeveritneedstobeundertaken bya This testisthemostaccurateofall. of thepiece. whereaschipsfrommalleablecastironwillcurlthecorner chips breakeasily, Greycastiron Can beusedfortheseparationofgreycastironandmalleableiron. Considered unweldable edn Welding Welding Considered unweldable Considered unweldable TECHNICAL AND TRADE INFORMATION 351 C for 2-3 hours ° C for 15 minutes will give fairly complete C for 15 minutes will give fairly complete ° 1.not so important when welding SG iron due to its good ductility) of cracking due to stresses set up by welding. Low ductility with a danger is (This 2. the molten metal to form a white cast iron structure in the weld area and makes of a hard brittle zone in the weld area. Formation is caused by rapid cooling of This weld unsuitable for service where fairly high stresses are met. 3.metal. of a hard, Formation with weld metals which do not form hard carbides does not occur This pick-up of carbon from the base brittle weld bead due to alloys.such as Monel and high nickel are are used where machinable welds These desired. followed by wire brushing. overcome porosity and poor welds. will help This “Gassy” castings can a dull red for a short time before welding.be treated by heating the weld area to small For components, treatment in a furnace at 650 All sand, to be welded by area of the casting be removed from the and scale must slag means such as grinding,mechanical machining, or rotary burrs. chipping Physical defects such as blowholes, sand inclusions, need to be removed. sponginess and shrinkage cracks Cracks should full length and depth. to their be excavated spongy areas and pinholes. Excavate Quite often a to expose a large cavity hidden underneath.pinhole will open up grinding During preparation smeared on the finished surface impregnated with carbon which can be wheels can become of the surface. because of the high carbon content making joining difficult Because of this the final 1-2mm should be prepared by chipping, file to clean the surface. rotary burrs or a coarse surface graphite. flame can be used to burn off any An oxidising oxy-acetylene a also provides This is advantageous. light preheat which Arc-air gouging is not usually recommended. However, it can be used to remove the bulk of metal providing the last 1-2mm is removed by grinding. in oil due to their environment eg.Often castings are soaked gear boxes. may appear clean They after mechanical cleaning, in the pores of the casting. however oil will still be present The by heating the casting to 200-300 elimination of the residual can be achieved Factors to consider are the same whatever the type of cast iron. Factors degasification. porous metal is face is welded and the resultant On heavier castings the relevant a clean surface is obtained. removed and the surface rewelded until to weld and can be identified by a glassy and shiny Castings high in phosphorous are difficult appearance. to repair these castings. Often brazing is the best way castings, repair cracked To drill a hole at each end of the crack to prevent it spreading further and grind out to the bottom. of the crack, Begin welding at the drilled end is greatest where restraint the free end. and move towards joint assisted by Castings which have to transmit fairly heavy working loads often have the weld mechanical means, such as bolted straps, or hoops which are shrunk on. teeth of large Broken cast iron gears are sometimes repaired by studding. Holes are drilled and tapped in the face of the fracture and mild steel studs screwed in. are then covered with weld metal and built up These to the required dimensions. to shape. or ground are machined afterwards They Precautions when welding cast irons Precautions WELDING OF CAST IRON CAST OF WELDING Oxy-acetylene Arc-air gouging castings Oil soaked Grinding & machining Grinding & www.cigweld.com.au 352 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Peening Postweld Heating Preheating WELDING OFCASTIRON the temperatureraisedto900 heat at900 per houruntilthecastinghascooledtoabout370 then cooledto705 otherwise causecrackingintheweld. The weldcanreadilyyieldduringcoolingandrelievewelding stressesthatmight temperature. canbeusedwiththebasemetalatorslightlyaboveroom suchasCastcraft100, strength, Aconsumablethatdepositsrelativelylow metal haslowductilitynearroomtemperature. Highpreheatis neededwhenusingacastironconsumablebecausetheweld input requirements. In generalallcastironsneedtobepreheatedwhenoxy-acetyleneweldingreducetheheat be minimisedbysuitablepreheating. may especiallycomplicatedshapes, due totherigidityorlackofductilitycastings, cracking Although alargeamountofsatisfactoryweldingisdonewithoutpreheating, oln ae lc.(Castcraft100issoftandallowspeening). cooling takes place. Good practiceistodepositshortweldruns(50mmatatime) andthenpeenbeforetoomuch This spreadstheweldmetal and counteractstheeffectofcontraction. welding. soft metalandpeeningtheweldwithablunttool(suchas aballhammer)immediatelyafter Satisfactory weldsmaybemadeoncastironwithoutpreheating byusingelectrodesdepositing case itisnormaltoheatthecastingatemperatureof595-620 Inthis sometimes thepracticetopost-heatweldedjointsrelievestressesandsoftenhardareas. Itis remaining inthepreheatingfurnaceorcoolingunderablanket ofinsulatingpowderorsand. theparteither theslowestcoolingratepossibleshouldbeallowed, close machiningtolerances, especiallyweldsintendedforuseinsevereserviceorsubjectto After anyweldingoncastiron, o h etrslswt Gcs rn thecastingshouldbeplacedinafurnace(595-650 For thebestresultswithSGcastiron, heat treatmentshouldbecarriedoutimmediatelyfollowingwelding. The coolingrateshouldnotexceed10 at thistemperatureforonehourper25mmofthickness. omtmeaue Malleablecastironmaybereheat-treatedafterwelding. room temperature. ° C followedbyslowcoolingto540 500 especiallythosevarying in Itinvolvescompletepreheatingto Completepreheatingisusedforintricatecastings, section thicknessessuchascylinderblocks. 3. spokes etc. Suchatechniqueissuitableforopenframes, and minimisecontractionstresses. This isdonesothattheywillcontractwiththe weld in additiontolocalpreheating. .Localpreheatingoccurswherepartsnotheldinrestraintmaybepreheatedto about 500 1. .Indirectpreheatinginvolvesapreheatof200 2. casting whichiswhylocalpreheatingshouldalways begradual. of complexcastingsorwhenthepreheatingisconfinedtoasmallarealarge Crackingfromunequalexpansioncantake placeduringthepreheating completed. and preheatsthejobevenly. Anothermaybefilledwithcharcoalwhichburnsslowly into whichgasjetsproject. Asimplepreheatingfurnacemaybemadeofbricks be maintainedduringwelding. ° ° olwdb lwcoigatrwlig The preheatingtemperatureshould C followedbyslowcoolingafterwelding. ,hl hr o or,thencooledto590 heldtherefor5hours, C, ° nteae ftewl,withslowcoolingafterweldingis C intheareaofweld, ° .Tecsigsol ehl ttmeauefr24hus Itis The castingshouldbeheldattemperaturefor2-4hours. C. ° C orlower.) theabove To obtainoptimumductility, ° .(For maximumsofteningandstressrelief, C. ° ° C forothercriticalpartsofthejob ° C inthefurnaceandfinallyto .The castingshouldbeheld C. ° C) and ° C TECHNICAL AND TRADE INFORMATION 353 In general, irons. are applicable for cast for carbon steels joint design used Below are some and double-vee preparations. suggested single-vee - particularly for grey iron,be as narrow as is practical for access should Welds welds build as wide narrow ones.up more stress than vee. uses only half the weld metal of a single A double vee For are not accessible from both sides,thick materials that is a good a U-preparation compromise. joints designs: for various See diagrams below welded using the backstep,Longer joints can be block, cascade, staggered chain intermittent and intermittent methods Joint Design Joint WELDING OF CAST IRON CAST OF WELDING www.cigweld.com.au 354 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Grey CastIron MMAW weldingofcastirons WELDING OFCASTIRON castings usingthecorrectparametersandCastcraft55. lugsandevenwearplatescanbeattachedto Brackets, recommended forweldingcastiron. includinghydrogen controlledtypesaregenerallynot Ferrous basedelectrodes, preferred. butCastcraft55is Joining ofcastirontosteelcanbeperformedwitheitherCastcraft55or100, Peening isamust forgreycastirons. electrodes whenweldingcastingshighinphosphorous. towards contaminantssuchassulphurandphosphorousaresuperiortoCastcraft 100 Castcraft55weldsaremoretolerant however theydohaveincreasedstrengthandductility. Single-layeredweldsofCastcraft55arenotasmachinable100, highly machinable. Castcraft 100ismoresuitableforsinglelayersandfillingsmalldefectsasthedepositremains Castcraft55). Castcraft 100)and55%nickel /45% iron(AWS A5.15 ENiFe-CI, The mostsuitableelectrodesforMMAWofcastironsarepurenickel (AWS A5.15 ENi-CI, TECHNICAL AND TRADE INFORMATION 355 C). A neutral or slightly reducing flame should be used with welding tips of ° medium or high flame velocity. welding. temperature should be maintained during The As with large castings.MMAW preparation it is necessary to use a furnace to ensure even heating of It is should be important that the casting be protected from draughts during welding and provision made to ensure that the required preheat is maintained. It is important to avoid sudden chilling of brittle.the casting otherwise white cast iron may be produced which is very hard and may This subsequent machining impossible. cause cracking or make A5.15 RCI (Comweld General Purpose Cast AWS Oxy welding is suitable for grey cast irons with an Iron - Super Silicon), RCI-A type electrode and should be used with a suitable flux such as Comweld Cast Iron Flux. Bronze & Comweld Comcoat N) type can also be used with AWS RBCuZn-D (Comweld Nickel An Comweld Bronze Flux. AWS RCI-B type consumable. SG cast irons can only be oxy welded with an Braze welding should only be used to repair old castings because of the poor colour match Braze welding should only be used to repair old castings because of the poor achieved with newer castings. Braze welding is suitable for grey, SG and malleable cast irons, to fusion welds are only possible with grey cast iron.however joint strength equivalent A neutral or slightly oxidising flame should be used. For successful oxy fusion welding,For it is essential that the part be preheated to a dull, red heat (approximately 650 Flux cored welding of cast irons is carried out using higher current than that for MMAW.Flux cored welding of cast irons is carried is offset by This welding.faster travel speeds as for normal FCAW Both grey, SG and malleable cast irons can be welded using the FCAW process. Preparation and heat treatment are much the same as for MMAW. 55. Nicore like equivalent AWS ENiFe-CI most suitable consumable that can be used is an The These are usually welded with Castcraft 55.These Austenitic castings can be welded with Although for applications where corrosion/heat resistance qualities Castcraft 55 the weld may be unsuitable do not match the parent metal. using the GMAW process. Cast irons are generally considered unweldable Grey iron can be repaired with either Castcraft 55 or 100 whereas SG cast iron can only really be cast iron can only or 100 whereas SG either Castcraft 55 can be repaired with Grey iron and better ductility. 55 due to its higher tensile strength repaired using Castcraft When welding SG cast irons, from the sides joints or cavities should be built up penetration should be low and wide the centre.towards used. beads or narrow weaves should be Stringer Deposit short beads and temperature.allow to cool to preheat grey but not as critical as when welding is advisable Peening cast iron. Braze Welding of cast irons Welding Braze FCAW welding of cast irons FCAW Oxy-acetylene welding of cast irons Austenitic cast irons Austenitic cast of cast irons welding GMAW SG Cast Iron SG Cast WELDING OF CAST IRON CAST OF WELDING www.cigweld.com.au 356 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Soldering ofcastirons Powder Spraying ofcastirons Brazing ofcastirons WELDING OFCASTIRON Consumables arebasedonanickel-silicon-boron mixture. fused alloyandthenjoiningthecoatingstogetherwithasuitablenickel MMAWelectrode. Poor qualityordifficultironscanbejoinedbycoatingbothpartsseparatelywith1-2mmofspray- Spraying andfusingshouldbeasperthenormalpowdersprayingprocess. they maygointosolutioninthemoltenmetalcausinghardspots. edgesandprotrudingpointsmustberemovedorradiusedas Sharpcorners, overhanging edges. Cavitiesandporous areasmustbegroundouttoasaucerorcupshapewithno contaminants. thebasemetalmustbeextremelycleanandfreefrom As withotherweldingprocesses, Porous metalscanbesurfacedbeforearcwelding. are usuallynoundercutmarks. shallowcavitiesandthinsectionsasthere corners, Powder sprayingisparticularlysuitedtoedges, Consumables suitableforbrazingcarbonsteelcanbeusedcastirons. operations shouldbesimilartothatofstandardbrazingprocesses. Pre-andpost-braze Any brazingprocessessuitableforsteelareapplicabletocastirons. This allowslowerpreheat(320-400 temperature thanthecastiron. Braze weldinghasadvantages overoxyweldinginthattheconsumablemeltsatalower A suitableconsumableisComweld965Solder. The castingmustbethoroughlycleaned. from leakageofliquidsorgases. oftensealingareas Soldering ofcastironsisusuallylimitedtotherepairsmallsurfacedefects, Comcoat C)typesand AWS RBCuZn-D(ComweldNickel Bronze&ComweldComcoatN)types. The applicableconsumablestouseare AWS RBCuZn-C(ComweldManganeseBronze&Comweld deposit. welding thesurfacemustbeproperlycleanedsothatcarbondoesn’tcontaminateweld ° ) Aswithotherformsof C). TECHNICAL AND TRADE INFORMATION 357 residual oxygen content of oxygen-bearing copper may cause porosity and other residual oxygen content of oxygen-bearing discontinuities when these coppers are welded or brazed. made to improve machining. grades are considered to be unweldable due These to a very high susceptibility to cracking. machining coppers are joined by Free brazing and soldering. or zirconium can be added to copper and then given a precipitation hardening heat treatment to increase mechanical properties. or brazing of these Welding the exposed area resulting in degradation of mechanical alloys will over-age properties. iii - 99.3% minimum Copper content. Copper iii 5% alloying elements. High copper alloys - up to alloys (Brass). iv Copper-Zinc alloys (Phosphor Bronze). v Copper-Tin vi alloys (Aluminium Bronze). Copper-Aluminium alloys (silicon bronze). vii Copper-Silicon alloys. Copper-Nickel viii silver). alloys (Nickel Copper-Nickel-Zinc (a) Oxygen free copper. (b) - the impurities and Oxygen-bearing copper (tough pitch and fire-refined grades) (c) Phosphorous deoxidised copper. (a) machining copper - Low alloying additions of sulphur or tellurium can be Free (b) copper alloys - Small additions of beryllium, Precipitation - hardenable chromium Copper alloys in which zinc is the major alloying element are generally called brasses. Copper alloys in which zinc is the major alloying element are generally called in wrought and cast form,Brass is available with the cast product generally not as homogeneous as the wrought products. Additions of zinc to copper decreases the melting temperature, the density, conductivity and the the electrical and thermal modulus of elasticity. additions of zinc will increase the strength, The hardness, ductility and coefficient of thermal expansion. Brasses can be separated into two weldable groups, low zinc (up to 20% zinc) and high zinc (30-40% zinc). main The white - problems encountered with brass is due to zinc volatilisation which results in The eight major groups of copper and copper alloys are: The 1) Types of Copper Alloys: of Copper Types 1) Introduction: WELDING OF COPPER AND COPPER ALLOYS COPPER AND COPPER OF WELDING Copper and Copper alloys remain to this day among the most important engineering materials due to their good electrical important engineering materials due alloys remain to this day among the most Copper and Copper and thermal conductivity, corrosion resistance, distinctive aesthetic appearance. metal-to-metal wear resistance and can be joined by welding,and most copper alloys Copper and soldering. brazing for copper and its alloys include markets major The the building industry,electronic products, electrical and and transportation. industrial machinery and equipment techniques to be used in and gives guidance on processes and the different types of copper alloys section outlines This introducing weld defects. corrosion or mechanical properties or components without impairing their fabricating copper alloy i) Pure Copper: Copper is normally supplied in one of three forms: 99.3% minimum Copper content- ii) High Copper Alloys: ii) High Copper iii) Copper-Zinc Alloys (Brass): iii) Copper-Zinc www.cigweld.com.au 358 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au 1) Types ofCopper Alloys WELDING OFCOPPER AND COPPER ALLOYS viii) CopperNickel Zinc Alloys (Nickel Silvers): vii) CopperNickel Alloys: vi) Copper-Silicon Alloys (SiliconBronzes): v) Copper-Aluminium Alloys (AluminiumBronze): iv) Copper-tin Alloys (PhosphorBronze): plumbing fittingsandpumpcylinders. locks, lampfixtures, Applications includeautomotiveradiatorcoresandtanks, higher zincalloysareusedinapplicationswherestrengthisimportant. The jewellry andcoinageapplicationsasabaseforgoldplateenamel. The lowerzincalloysareusedfor fumes ofzincoxideandweldmetalporosity. stock andhollowware. etching opticalandcameraparts, fasteners, Specific applicationsincludehardware, susceptible tostresscorrosioncracking. althoughsomearesubjecttodezincification andtheycanbe corrosion resistance, makes thesealloyssilverinappearanceandalsoincreasestheirstrength The additionofnickel Contain zincintherange17-27%alongwith8-18%Nickel. condensersandheatexchangers. Commonapplicationsincludeplatesandtubesfor evaporators, tubeandforgings. rod, pipe, These alloyshavegoodhotandcoldformabilityareproducedasflatproducts, nickel whichalsoimprovestheoxidationandcorrosionresistanceofcopper. The cupronickel alloyscontaining10-30%Nihavemoderatestrengthprovidedbythe propeller shafts. for similarapplicationsaswellchemicalprocessequipmentandmarine The highsiliconBronze(3%Si)isused marine andindustrialhardware andfasteners. heatexchangertubes, Low siliconbronze(1.5%Si)isusedforhydraulicpressurelines, rates. hardnessandworkhardening Theaddition ofsilicontocopperincreasestensilestrength, andgoodweldability. excellentcorrosionresistance, due totheirhighstrength, SiliconBronzesareindustriallyimportant Available inbothwroughtandcastforms. environments. otherwater fittingsandbearingsforuseinmarineotheraggressive valves, Commonapplicationsfor Aluminium Bronzealloysincludepumps, manganese. nickel and Contain from3-15percentaluminiumwithsubstantialadditionsofiron, hardware andtextilemachinerycomponents. chemical fasteners, include bridgebearingsandexpansionplatesfittings, Examplesofspecificapplications andslowcoolingrates shouldbeavoided. input, highheat The useofhighpreheattemperatures, cracking inthestressedcondition. These alloysaresusceptibletohot are available inthewroughtandcastforms. These alloys Copper alloyswhichcontainbetween1percentand10tin. cont.: TECHNICAL AND TRADE INFORMATION 359 C. Copper alloys, in o welding of Copper and Copper Alloys. welding of Copper and Copper Figure 1.Figure - Arc and Manual Metal Welding Arc Tungsten for Gas Joint designs The recommended joint designs for welding copper and copper alloys are shown recommended joint designs The 1 & 2.in Figures Due to the high thermal conductivity of copper, the joint designs are adequate fusion and penetration. wider than those used for steel to allow 2) Weldability of Copper and Copper Alloys: Copper Copper and of Weldability 2) WELDING OF COPPER AND COPPER ALLOYS COPPER AND COPPER OF WELDING Welding processes such as Gas Metal Arc Welding and Gas Tungsten Arc Welding are commonly used for welding copper and for welding copper are commonly used Welding Arc Tungsten and Gas Welding Arc such as Gas Metal processes Welding its alloys, conductivity. welding materials with high thermal localised heat input is important when since high Metal Manual the gas is not as good as that obtained with alloys may be used although the quality of Copper and Copper Welding Arc shielded welding processes. copper grades (a) (b) and (c). among the pure weldability of copper varies The high oxygen porosity. the heat affected zone and weld metal copper can lead to embrittlement in content in tough pitch The Phosphorus more weldable,deoxidised copper is (Al, by using filler wires containing deoxidants with porosity being avoided Mn, Si,Ti). P and preheats up to 60 sections require preheat although thicker sections can be welded without Thin contrast to copper, seldom require pre-heating before welding. the different considerably amongst varies weldability The out for each particular alloy to correct welding procedures are carried to ensure the must be taken copper alloys and care defects. reduce the risks of welding 2.1 alloys: joint designs for Joining Copper and Copper Weld www.cigweld.com.au 360 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au 3.1 GMAWofCopper: 2.3 Pre-heating: 2.2 SurfacePreparation: WELDING OFCOPPER AND COPPER ALLOYS 3) GasMetal Arc Welding (GMAW) ofCopperandalloys: 2) Weldability ofCopperand Alloys cont.: h oprscint ewle.Argonisgenerallyusedfor6mmandunder. the coppersectiontobewelded. The gasmixturerequiredwillbelargelydeterminedbythethicknessof copper. Autocraft DeoxidisedCopperisaversatile98%purecopperalloyfortheGMAWof CIGWELD’s ERCu copperelectrodesarerecommendedforGMAWofcopper. of thejointiscompleted. It isalsoimportanttoensurethepreheattemperaturemaintaineduntilwelding too muchofthematerialintoatemperaturerangethatwillcauselossinductility. It isdesirabletolimittheheataslocalisedanareapossibleavoidbringing Aluminiumbronzeandcoppernickel alloysshouldnotbe preheated. weldment. thebasemetalthicknessandtosomeextentoverallmassof welded, thealloybeing considerationmustbegiventotheweldingprocess, application, To select thecorrectpreheatforagiven diffusivity ismuchlowerthanforcopper. donotrequirepre-heatingbecausethethermal even inthicksections, copper alloys, Most conduction ofheatfromtheweldjointintosurroundingbasemetal. The weldingofthickcoppersectionsrequiresahighpreheatduetotherapid removed withawirebrushaftereachweldrunisdeposited. The oxidefilmformedduringweldingshouldalsobe suitable cleaningagent. Wirebrushingwith abronzewirebrushfollowedbydegreasingwith welding. paintandoxidespriorto dirt, grease, The weldareashouldbecleanandfreeofoil, -JointDesignsfor GasMetal Arc Welding ofCopper.Figure 2. TECHNICAL AND TRADE INFORMATION 361 C. ° Welding Voltage Gas Flow Travel # and Copper Alloys. and Copper # or equivalent shielding gases. shielding or equivalent 2 These alloys have a wide solidification range which gives a coarse dendritic grain alloys have a wide solidification range which gives a coarse dendritic These structure, during welding to prevent cracking of the therefore care must be taken weld metal. reduce the stresses developed Hot peening of the weld metal will of cracking.during welding and the likelihood small weld pool should be kept The using stringer beads at high travel speed. Copper sections up to 16.0mm in thickness can be successfully welded using the Copper sections up to 16.0mm in thickness can be successfully welded using process.Welding Arc Tungsten Gas 1. joint designs are shown in Figure Typical The of recommended filler wire is a filler metal whose composition is similar to that - Ar + 25% He or equivalent shielding gases. shielding Ar + 25% He or equivalent - shielding gases. Ar or equivalent - He + 25% ERCuSi-A type welding consumables plus argon shielding and relatively high travel speeds are used with this process. based wire Autocraft Silicon Bronze is a copper Alloys.recommended for GMAW of Copper Silicon It is important to ensure the oxide layer is removed by wire brushing between passes. Preheat is unnecessary and interpass temperature should not exceed 100 The helium-argon mixtures (Alushield Heavy) are used for welding of mixtures (Alushield Heavy) are helium-argon The sections. thicker beads or narrow weave beads should be deposited with stringer filler metal The using spray transfer. on procedures for GMAW 1 below gives general guidance Table of Copper. - Welding - Welding Argon. Grade Ar + >0-3% O - Metal Joint Electrode Preheat 10mm12mm B C 1.6mm 1.6mm 250°C 250°C 250-320 290-350 28-30 29-32 15-20 15-20 300 mm/min 300 mm/min 1.6mm3.0mm6.0mm A6.0mm A B B 0.9mm 1.2mm 1.2mm 1.6mm 75°C 75°C 75°C 100°C 150-200 150-220 180-250 21-26 160-280 22-28 22-28 28-30 10-15 10-15 10-15 10-15 500 mm/min 450 mm/min 400 mm/min 350 mm/min 16mm + C, D 1.6mm 250°C 320-380 29-32 15-25 250 mm/min Thickness Design* Diameter Temperature Current Range(l/min) Rate Speed 4) Gas Tungsten Arc Welding (GTAW) of Copper and Copper Alloys: of Copper and Copper (GTAW) Welding Arc Tungsten 4) Gas 3) Gas Metal Arc Welding (GMAW) of Copper and Copper alloys cont.: and Copper of Copper (GMAW) Welding Arc Metal 3) Gas WELDING OF COPPER AND COPPER ALLOYS COPPER AND COPPER OF WELDING 3.3Alloys (Phosphor Bronze): Tin Copper GMAW of Table 1.Table GMAW of Copper Conditions for Typical - 4.1 Arc Welding of Gas Tungsten Copper: 3.2Alloys: Silicon GMAW of Copper Recommended Shielding Gases for the GMA welding of Copper and Copper Alloys: GMA welding of Copper and Copper Recommended Shielding Gases for the *Refer to Figure 2 *Refer to Figure www.cigweld.com.au 362 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au . ManualMetal Arc Welding ofCopper: 5.1 *Refer toFigure 1 4.3 Gas Tungsten Arc Welding of Silicon-Bronze: GasTungstenof ArcWelding 4.3 Gas Tungsten Arc Welding ofCopper-Aluminium alloys: 4.2 al .- Typical conditionsforGas TungstenTable 2. Arc Welding ofCopper WELDING OFCOPPER AND COPPER ALLOYS hcns m) ein a edn urn imtrTmeaueCurrent Temperature Diameter Welding Current Gas Design* Thickness (mm) 5) ManualMetal Arc Welding (MMAW) ofCopper& Alloys: 4) Gas Tungsten Arc Welding (GTAW) ofCopperand Alloys cont.: .-. ro hrae/C - - 15-60 40-170 ------50 --- 1.6mm 2.4-3.2mm Thoriated/DC- Thoriated/DC- Thoriated/DC- Argon Argon Argon C B A 2.0-5.0 1.0-2.0 0.3-0.8 ea JitSiligTnse ye& edn o Preheat Welding Rod Tungsten Type & Shielding Joint Metal 20DAgnToitdD-32m 250 250 3.2mm 3.2mm 3.2 Thoriated/DC- Thoriated/DC- Argon Thoriated/DC- Argon D Argon E 16.0 F 12.0 10.0 . ro hrae/C . m100 3.2mm Thoriated/DC- Argon C 6.0 using argonshieldinggas. Welding canbeperformedwithDC-usingargonorargon/heliumshielding AC The Aluminium BronzeweldingrodERCuAl-A2mayalsobeused. positions. Comweld SiliconBronzeRod(ERCuSi-A)canbeusedtoweldinall only requiredonthicker sections. Preheatis used inapplicationsrequiringdeeperpenetrationandfastertravelspeed. (DC-) electrodenegativewith Welding Grade Argon or Argon-Helium mixescanbe DirectCurrent cleaning actiontoassistinremovingtheoxidelayerduringwelding. Alternating Current(AC) currentwithargonshieldingcanbeusedtoprovideanarc The ERCuAl-A2fillerrodcanbeusedforGTAW of Aluminium Bronze Alloys. for thefollowing: Bronzecraft AC-DC electrode(ECuSn-C)canbe used copper alloysandbronzes. MMAW isnormallyusedforthemaintenanceandrepairweldingofcopper, copper isshownin Table 2below. Typical conditionsformanualGTAW of stringer beadsornarrowweavebeads. Forehand weldingispreferredforGas Tungsten Arc Welding ofCopperwith stability propertiesof Argon. characteristics ofheliumcombinedwiththeeasyarcstartingandimproved A 75%Helium-25% Argon mixtureiscommonlyusedtogivethegoodpenetration same weldingcurrent. argon/heliummixespermitdeeperpenetrationandhigher travelspeedsatthe argon, Incomparisonto helium mixesispreferredforweldingsectionsover1.6mmthick. For sectionsupto1.6mmthick Argon shieldinggasispreferredand the basemetal. ▲ ▲ ▲ Welding coppertoothermetals. Fillet weldedjointswithlimitedaccess. Minor repairofrelativelythinsections. # and Copper Alloys. m250 mm ° ° ° ° ° 100-300 C 400-475 350-420 300-375 250-375 C C C C # Welding TECHNICAL AND TRADE INFORMATION 363 C is soldering). The ° C or greater. ° C (use of a filler metal with a melting point less than 450 C (use of a filler metal with a melting point ° Electrode Code Electrode Welding Polarity Design the thermal gradient into the joint. tolerances which depend upon the brazing alloy and the parent metal used. The optimum joint gap typically lies between 0.04 and 0.20mm. Bronzecraft AC-DC (ECuSn-C) can be used to weld Copper-Tin and Copper-Zinc alloys. and Copper-Zinc (ECuSn-C) can be used to weld Copper-Tin AC-DC Bronzecraft be deposited using the required and the weld metal should Large butt angles are stringer bead technique. 1. clean and free of oxides etc. joint surfaces are The 2. correct joint gap for the particular brazing filler metal. provision of the The 3. the filler metal flows up establishment of the correct heating pattern so that The Standard solvent or alkaline degreasing procedures are suitable for cleaning copper Standard solvent or alkaline degreasing procedures are suitable for cleaning copper base metals. if mechanical methods are used to remove surface Care must be taken oxides. chemically remove surface oxides, To an appropriate pickling solution such as ChromeBright‚ should be used. 1. the joints to be joined must be controlled to within certain distance between The Brasses ECuSn-A or ECuSn-CAC-DC Bronzecraft DC+ 1 C in Figure Copper Alloy Recommended AWS CIGWELD Electrode Joint Phosphor Bronze ECuSn-A or ECuSn-CAC-DC Bronzecraft DC+ 1 C in Figure 6) Brazing of Copper and Copper Alloys: of Copper and Copper 6) Brazing 5) Manual Metal Arc Welding (MMAW) of Copper & Copper Alloys: Copper & Copper of (MMAW) Welding Arc Metal 5) Manual WELDING OF COPPER AND COPPER ALLOYS COPPER AND COPPER OF WELDING 5.2Alloys: of Copper Welding Arc Manual Metal Table 3 - Recommendations for MMAW of Brasses and Phosphor Bronzes. 3 - Recommendations Table The principle of brazing is to join two metals by fusing with a filler metal.The filler metal must have a lower melting point The 450 than the base metals but greater than a narrow gap between the part by capillary action. filler metal is usually required to flow into copper and copper alloys,Brazing is used widely for the joining of Aluminium bronzes containing exception of with the lead.greater than 10 percent aluminium and alloys containing greater than 3 percent Brazing of copper is used extensively in the electrical manufacturing industry, mechanical services, and in the building heating, fields. ventilation and air-conditioning achieve an adequate bond during brazing,To the following points should be considered: Joint designs should be similar to that shown in Figure 1. be similar to that shown in Figure Joint designs should (DC+) should be used with a Direct Current electrode positive stringer bead technique. over 3.0mm require a preheat of 250 Sections 6.1 Surface Preparation: 6.2 Joint Design Considerations: www.cigweld.com.au 364 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au 6.3 Flameadjustment: 6) Brazing ofCopperand Alloys: WELDING OFCOPPER AND COPPER ALLOYS .Generallyajointoverlapofthreeorfourtimesthethicknessthinnest 2. Figure 3-CommonJointdesignsforBrazing. shows nohaze. The whiteinnerconeisclearly definedand acetylene aremixedatthesamerate. Aneutralflameiswhereequalamountsofoxygenand Use aneutralflame. achieve thedesiredstrength. The aimistouseaslittlematerialpossible member tobejoinedissufficient. TECHNICAL AND TRADE INFORMATION 365 COMWELD Tobin Bronze 211 (Braze Welding). Bronze 211 (Braze Tobin COMWELD T Flux Coated. COMWELD Comcoat Dilution in hot caustic soda dip. Dilution in hot caustic with hot water. Wire brushing and rinsing Wire brushing and steam. If flux has been used, methods: must be removed by one of the following the residue requirement depends on the strength required in the alloy most suited to the job The Alloys commonly used are: Incomplete flux removal may cause weakness and failure of the joint. may cause Incomplete flux removal Typical joint designs are shown in Figure 4 over the page. joint designs are shown in Figure Typical ▲ ▲ ▲ ▲ ▲ joint, to corrosion, resistance operating temperature and economics. 7) Braze Welding of Copper: Welding 7) Braze 6) Brazing of Copper and Copper Alloys cont.: and Copper of Copper 6) Brazing WELDING OF COPPER AND COPPER ALLOYS COPPER AND COPPER OF WELDING Braze welding is a technique similar to fusion welding except with a filler metal of lower melting point than the parent metal. fusion welding except with a filler metal of lower melting point than the parent Braze welding is a technique similar to of the filler metal deposited as well as the actual Braze welding process derives its strength from the tensile strength The filler metal and parent metal.bond strength developed between the Oxy-acetylene is usually preferred because of its easier flame setting and rapid heat input. 7.1 Choice of alloy: 6.4 Flux Removal: 7.2 Joint Preparation: www.cigweld.com.au 366 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Typical jointdesignsareshowninfigure4below. 7.2 JointPreparation: WELDING OFCOPPER AND COPPER ALLOYS 7) Braze Welding ofCoppercont.: Figure 4- Typical jointdesignsforBrazeweldingof copper. TECHNICAL AND TRADE INFORMATION 367 . ° to 50 ° . Distance of inner cone from metal surface ° to 50 ° Grinding wheel or wire brush and water. Sand blasting Dilute caustic soda dip. Use slightly oxidising flame. Use slightly oxidising and Brass Flux,Use COMWELD Copper to both and apply mix to a paste with water sides of joint. paste or heated and dipped in dry flux. Rod can be coated with only. Preheating is recommended for heavy sections Blowpipe tip to metal surface 40 3.25mm to 5.00mm. rod to metal surface 40 Filler Figure 5 - Braze welding forehand technique. Figure Any of the following methods may be used to remove flux residue: After preheating or after the joint is raised to a temperature sufficient to permit After preheating or after the joint is raised to a temperature sufficient to permit alloying of the filler rod and copper, the end of the rod melt a globule of metal from and deposit it into the joint,surface. wetting or tinning the When tinning occurs, begin welding using forehand technique. Do not drop filler metal on untinned surfaces. See figure 5. ▲ ▲ ▲ 0.81.62.43.24.05.06.0 1.6 1.6 1.6 2.4 2.4 3.2 5.0 2.0 3.75 4.25 7.0 8.5 10.0 13.5 12 15 15 20 20 26 26 Plate Thickness(mm)Plate Rod(mm) Filler (Cu.Acetylene Consumption Blowpipe L/Min) Size Tip 7) Braze Welding of Copper cont.: of Copper Welding 7) Braze WELDING OF COPPER AND COPPER ALLOYS COPPER AND COPPER OF WELDING 7.8 Flux Removal: Table 5 Data for the Braze welding of Copper 5 Data Table 7.7 Technique: Welding 7.3 Flame adjustment: 7.4 Flux: 7.5 Preheating: 7.6 Blowpipe and rod angles: www.cigweld.com.au 368 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Refer to Table 1onthenextpagefordetailsregardingvarious weldingconsumablestojoindissimilar metals. welding operatortoselectaconsumableandprocedurepurelybasedonhisorherpreviousexperience. Often itisnotpossibletoobtainthebasematerialanalysisasincaseofmaintenanceorrepairandleft etc. chemicalenvironmentorwearbyabrasion, temperatures, elevated eg. It isessentialthatthetwomaterialsbeidentifiedandwhereverpossibledesigncriteriaobtained, dissimilarmaterialsaretobejoined by welding. orinsomecasesmore, itwillberequiredthattwo, duetoengineeringdesign, At times, WELDING OFDISSIMILARMETALS .Amtra hti o omnyue,butischoseninhighchemicalattack Amaterialthatisnotcommonlyused, F. ahrta h atio.Aprocedurecommonlyusedistobutter thesurfaceof selectaconsumablemostsuitedtothecopperalloy For castirontocopper/brass, rather thanthecastiron. E. Whenweldingsteeltocopper/brassselectaconsumablethatismost D. .We edn atio oml te n osbysanessel anickel-iron Whenweldingcastirontomildsteelandpossiblystainlesssteel, C. thena suchasthe310variety, Should thestainlesssteelbeofaheatresistingtype, B. Onecommoncombinationofmaterialsisstainlesssteeltomildandthis A. onthenextpage) Welding Recommendations(refer to Table 1. steel withaENiCu-Belectrodepriortothejoiningoftwomaterials. Itmaybenecessary tobutterthematingsurfaceofmild a ENiCu-Belectrode. This materialcanbeweldedtomildsteelbyusing isMonel. applications, Autocraft SiliconBronzetocompletethejoint. the castironwithCastcraft55/Nicore55 welding wireiscommonlyusedwithmanycopperalloygrades. AutocraftSiliconBronzegasmetalarc compatible withthegradeofcopper/brass. recommended. consumable suchasCastcraft55electrodeorNicore usually specifiedbytheweldingengineer. The decisiontousethesematerialsis metal andceramicrefiningindustries. makingthemidealforfurnaceapplicationsassociatedwiththeoil, C, to 1,200° These 310 materialsresistoxidationup 310 consumableisrecommended. manual metalarcelectrodesandgaswiresareavailable. Both combination canbesuccessfullyweldedwitha309typeconsumable. ® thenuseeitherBronzecraft AC/DC or , ® flux corewireisoften

TECHNICAL AND TRADE INFORMATION 369

* See welding recommendations A, B, C, etc, on the previous page. previous the on etc, C, B, A, recommendations welding See *

idSelMnlF Monel Steel Mild / / N/A N/A N/A

Mild Steel Austenitic Manganese - Austex Autocraft 309LSi Verti-Cor 309LT Not recommended Not 309LT Verti-Cor 309LSi Autocraft Austex - Manganese Austenitic Steel Mild

* Castcraft 55 * Nicore 55 Nicore * 55 Castcraft * Comweld Nickel Bronze Nickel Comweld

®

Cast Iron Copper/Brass E * Bronzecraft AC/DC * Autocraft Silicon Bronze N/A Comweld Mang. Bronze or Bronze Mang. Comweld N/A Bronze Silicon Autocraft * AC/DC Bronzecraft * E Copper/Brass Iron Cast

Comweld Nickel Bronze Nickel Comweld

Mild Steel Copper D Bronzecraft AC/DC Autocraft Silicon Bronze N/A Comweld Mang. Bronze or Bronze Mang. Comweld N/A Bronze Silicon Autocraft AC/DC Bronzecraft D Copper Steel Mild

Comweld Nickel Bronze Nickel Comweld

Mild Steel Cast Iron C Castcraft 55 N/A Nicore 55 Nicore N/A 55 Castcraft C Iron Cast Steel Mild Comweld Mang. Bronze or Bronze Mang. Comweld

®

Weldall

Mild Steel Stainless Steel A Satincrome 309Mo-17 Autocraft 309LSi Verti-Cor 309LT Not recommended Not 309LT Verti-Cor 309LSi Autocraft 309Mo-17 Satincrome A Steel Stainless Steel Mild

Recommendations*

Material 1 Material 2 Welding MMAW GMAW FCAW Gas & TIG Welding TIG & Gas FCAW GMAW MMAW Welding 2 Material 1 Material Table 1. Welding Consumables for Joining Dissimilar Metals Dissimilar Joining for Consumables Welding 1. Table WELDING OF DISSIMILAR METALS DISSIMILAR OF WELDING www.cigweld.com.au 370 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au What isHardfacing andwhere isitused? HARDFACING INFORMATION hardfacing applicationscarriedoutinindustry; A widerangeofCobalarcelectrodeandStoodywireproductsareavailable forthethreemaintypesof ornitriding. surfaces solelybyheattreatmentssuchasflamehardening, Italsoexcludesthehardeningof bronzesurfacing. friction over-lays topreventgalling-eg. corrosion preventionorresistancetohightemperaturescalingtheapplicationoflowhardness, Hardfacing isaparticularformofsurfacingthatexcludestheapplicationmaterialsprimarilyfor conditions. Italsoapplieswhere corrosion andelevated temperatures arepresentwithoneormoreoftheaboveservice gallingandcavitation”. erosion, impact, wear orlossofmetalbyabrasion, sprayingoralliedweldingprocessfor the mainpurposeofreducing component bywelding, wear-resistant materialtothesurface “The applicationofhard, A furtherdefinitionofhardfacingis: heatandcorrosion. thedesiredpropertiesbeingthosethatwillresistabrasion, dimensions’, ‘The depositionoffillermetalonasurface toobtainthedesiredpropertiesand/or orhardfacing isdefinedas; According tothe ‘hardsurfacing” American Welding Society, most otherwearpreventiontreatments: itcanbeseenthathardfacinghasmoretoofferthan By expandingthisdefinitionalittlefurther, metal ofspecificpropertiesoncertainareaspartsthatareexposedtowear’. alayerorlayersof byoneofvarious weldingtechniques, ‘Hardfacing istheprocessofdepositing, .Bothbuild-upandoverlayapplications. 3. Hard surfacingoroverlayapplications. 2. Build-uporre-building applications. 1. .Hardfacingisappliedonlytospecificareasofmetalpartsthatareexposedwear. 4. There areawidevariety ofdeposittypes Metalofspecificpropertiesisdeposited. 3. This meansthathardfacingprovides Alayerorlayersofmetalcanbedeposited. 2. Thus itispartofawellestablishedpracticewithwhich Itisperformedbywelding. 1. combating wear. therebyprovingamosteconomicalway of requirements ofapieceequipment, Hardfacing canbeappliedselectivelyandindifferentthicknessestosuittheexact There isoftennoneedtoprotecttheentiresurfaceofacomponentfromwear. conditions. eachspecificallydesignedtowithstandcertainformsofwearandservice available, protection. Itcanbeappliedinathicknessrequiredtogivelonglasting protection indepth. existingequipmentcanbeemployed. majority ofcases, There areveryfewnewskillstobelearnedandinthevast people arefamiliar. TECHNICAL AND TRADE INFORMATION 371 for further “Use of buffer layers” of worn components to their original size of new, or as new, components to protect them component to its original dimensions. component to its original added resistance to wear. from wear during service. High alloy welding consumables are available for overlay applications which offer far better wear resistance than the original component material.price of these welding consumables the Despite the higher working life of the component can be extended by over twice that of the original component. Further more, if overlays are used as part of a preventative maintenance program the original component can be manufactured from a less expensive base material. For the build-up or rebuilding For and shape using suitable build-up or build-up and overlay alloys as described above. surfacing The overlay or hard - Used to return the part or eg. Mangcraft, 61etc. Ferrocraft - Used by itself to give a component eg. 101HC. 650 and Stoody Cobalarc Build-up and overlay can be used together to re-build a part to its original size and protect the contact surface from further wear. Some alloys can serve as both a build-up and overlay deposit, such as wire which is Cobalarc Mang Nickel-O recommended for heavy build up. During service the final layers of Mang Nickel-O can work harden under heavy impact to form a wear resistant overlay. “Buttering layers”“buffer layers” or are a form of build-up or intermediate layer, deposited prior to the application of an overlay or hard surfacing deposit. See the details. 1. 2. What is Hardfacing and where is it used? where and Hardfacing is What HARDFACING INFORMATION HARDFACING 2. Surfacing or overlay applications. Hard 3. Build-up and overlay applications. 1. applications Build-up or re-building Hardfacing (or build-up and or overlay ) is therefore used in two main areas: (or build-up and or overlay ) is therefore Hardfacing www.cigweld.com.au 372 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au .What isthebasemetalofcomponent? 1. How tochoosetherighthardfacing consumable Why shouldHardfacing becarriedout? HARDFACING INFORMATION osmbe coolingrateandstressreliefrequirements. consumable, welding interpass, from oneanotherbutmustbeidentifiedinordertoestablish accuratepreheat, They arenoteasy to distinguish carbon andlowalloysteelsusedinequipmentmanufacture. There aremanytypesof distinguished fromausteniticmanganesesteelswhicharenon-magnetic. Carbon andlowalloysteels. following fourquestions: Hardfacing alloyselectionandcorrectweldingproceduresarebestdeterminedbyansweringthe welding consumabletouseandwhatprocedureadopt. Knowing thebasemetalcompositionofcomponentisimportantindecidingwhat What finishisrequired? 4. What typeofwearisbeingexperienced? 3. What weldingprocess istobeused? 2. What isthebasemetalofcomponent? 1. The mostcommonferrousbasemetalsusedfallintotwobroadclassifications: .Hardfacing minimisetheinventoryofspare parts: 5. Hardfaced partscanbemanufactured from cheaperbasemetals: 4. Hardfacing reduces overall costs: 3. Hardfacing increases theoperating efficiencyofequipmentbyreducing 2. Hardfacing extendsthelifeofworncomponentsandequipment: 1. ▲ ▲ Austenitic Manganesesteels. Carbon andlowalloysteels. - Ifwornpartsareusuallyrefurbishedthereisnoneedtokeep highstockholdings. use. cheaper basemetalthanonewhichisnotdesignedtobehardsurfacedbefore - A partwhichishardsurfacedbeforeusecanoftenbemanufacturedfroma new component. - The costofrefurbishingaworncomponentistypically50-75%the therefore increasetheoperatingefficiencyofequipment. causefewershutdownsorstoppagesand - Hardfacedcomponentslastlonger, downtime: 250% comparedtothatofanewornonhardfacedcomponent. - Build-uporhardsurfacingcanextendthelifeofacomponentbyasmuch Carbon andlowalloysteelsarestronglymagneticcaneasilybe TECHNICAL AND TRADE INFORMATION 373 C to avoid ° in this handbook. These high manganese (typically 14%) steels are strong and tough and as manganese (typically 14%) steels are high These Welding equipment available. Welding skills available. Operator or outdoors. location - indoors Welding to be hardfaced. Size and shape of component and area position - can component be moved to allow downhand welding? Welding consumables. of hardfacing Availability eg. Borium. Stoody Tube eg. 350. Cobalarc 1. Manual Welding Metal Arc 2. Flux Welding Arc Cored 3. Welding Arc Submerged A1 coating, the flux with no alloy contribution from electrodes Tubular type = A4 with an alloy additive flux coating, steel rod type = Low carbon ▲ ▲ ▲ ▲ ▲ ▲ Welding of Steels Welding such are often used in the manufacture of components subject to both abrasion and extreme in the manufacture of components subject such are often used impact. steels, Unique to manganese impact service to they can be work hardened during high the surface and yet tough, is hard and abrasion resistant on yield a component which and strong ductile underneath. carbon and low alloy steels, Unlike are rarely preheated; manganese steels below approximately 300 during welding must be kept fact base metal temperature in embrittlement. practices such as step welding, Welding “welding in water” spraying or water often carried out to avoid base metal embrittlement. are Manganese steels are an excellent base for The welding processes most commonly used today for hardfacing are: The TIG) welding are or welding and gas tungsten arc (GTA Other processes such as oxy-acetylene applications because of their low deposition rates. more often used for specialist hardfacing when selecting a suitable welding process / consumable include: to be considered Factors the application of chromium white iron hard surfacing deposits such as Stoody 101HC. the application of chromium white iron Generally speaking as alloy content increases base metals become more difficult to weld and the become more difficult to weld and the as alloy content increases base metals Generally speaking cooling become more critical. and interpass temperatures and slow use of correct preheat Please refer to the The most common type of welding process used with a wide range of extruded and tubular most common type of welding The for build-up and hard surfacing applications as well as for joining welding electrodes available applications. A1 types in A4 and electrodes are those designated as most common types of manual The Consumables for Build-up and wear Welding AS/NZS 2576 - Australian/New Zealand Standard resistance. How to choose the right hardfacing consumable right hardfacing choose the How to HARDFACING INFORMATION HARDFACING Austenitic manganese steels. Austenitic manganese Note:AS/NZS 2576. Guide for an explanation of See Consumables Classification Charts in this Pocket 2. be used? is to welding process What 1. Manual Welding. Metal Arc www.cigweld.com.au 374 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au .Submerged Arc Welding. 3. Cored Arc Welding. Flux 2. .What typeofwearisbeingexperienced 3. How tochoosetherighthardfacing consumable HARDFACING INFORMATION because oftheflexibilityinalloytypesavailable inatubular wire The B1typewire/fluxcombinationisthemostpopularoptionused components automatically. The submergedarcweldingprocessiscommonlyusedtobuild-uporhardsurfacelarge Australian/New ZealandStandard AS/NZS 2576. pleasereferto A detailedtreatmentoftheseweartypesisbeyondthescope ofthishandbook, Experience hasshownthattherearethreemajortypesofwear: from onecomponenttoanotherandapplicationanother. withwearmodesdiffering Unfortunatelythisisneverthecase, to theonesetofwearconditions. select aweldingconsumableforparticularapplicationifthecomponentwas always subjected Itwouldbeeasierto welding alloywearperformanceandverificationthroughpracticaltests. aknowledgeof aknowledgeofthewear typesexperienced, pastexperience, factors including; This solutionisusuallyarrivedatbyconsideringacombinationof specific wearproblemathand. In selectingabuild-uporhardsurfacingalloytheaimistoprovidebestsolution omnyue nteatmtcmd,witheither: Commonly usedintheautomaticmode, achievable inpractice. applications becauseoftheflexibilityinalloyselectionandwiresizehighdepositionrates The fluxcoredarcweldingprocesshasbecomeincreasinglypopularforbuild-upandhardfacing because theweldingarcisvisibleduringwelding. Selfshieldedwiresarealsocalledopenarc shielded (B7type)wiresarethemostpopular. orout-of-doorsself Because ofthehighlevelbuild-upandhardsurfacingcarriedout “on site” The mostcommontypesoftubularwiresarethosedesignatedasB5andB7in AS/NZS 2576. surfacing deposit. continuous tubularelectrode(insteadofasolidwire)isusedtoprovidethebuild-uporhard wherea A semi-automaticprocesswhichisavariant ofthegasmetalarcweldingprocess, 7 type= Tubular wires whichare selfshieldingorrequire no externalshieldinggas, B7 type= Tubular wires whichare usedwithanexternalgasshielding, B5 ▲ ▲ ▲ Alowcarbonsteelwire/stripwithanalloyadditiveflux(B4typein AS/NZS 2576) Analloyadditivesolidwire/stripwithanflux(B3typein AS/NZS 2576)or, - Analloyadditivesolidwire/stripandneutralflux(B2typein AS/NZS 2576), - Analloyadditivetubularwire/stripandneutralflux(B1typein AS/NZS 2576), - - Abrasive wear, g Stoody100HC-O. eg. Stoody101HC-G. eg. Environmental wear. Metal-to-metal wear, . TECHNICAL AND TRADE INFORMATION 375 surfaces which are in intimate contact. In rolling wear, stresses are often high contact and wear occurs by a fatigue mechanism. The three major types of wear can be further sub-divided into; types of wear can be further sub-divided three major The In impact wear, repeated impact parts encounter plastic which can cause brittle fracture or gross deformation. In erosive wear, parts encounter high velocity fluids (liquids or gaseous) with or without solid particles. are: two major types of erosion experienced The of a part by the action of solid particles Wear impinging on the surface. of a part by the action of liquid droplets Wear or bubbles on the surface. In low stress abrasion, the abrasive particles, which are usually small and unconstrained, scratch the surface continuously to cause wear. particles are not The fractured or ground up during service. In sliding wear, friction occurs between two Abrasive wear: Abrasive Metal-to-metal wear: Metal-to-metal How to choose the right hardfacing consumable right hardfacing choose the How to HARDFACING INFORMATION HARDFACING ▲ 3. is being experienced cont. type of wear What ▲ 2. Rolling wear: 3. Impact wear: 1A. Solid particle erosion: 1B. and cavitation erosion: Liquid droplet 2. abrasion: (scratching) Low stress 1. Erosion: 1. or sliding wear: Adhesive www.cigweld.com.au 376 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Impact: Temperature: Loading: .Gougingabrasion: 4. Highstress (grinding)abrasion: 3. ▲ ▲ What typeofwearisbeingexperiencedcont. Limiting ServiceConditions How tochoosetherighthardfacing consumable HARDFACING INFORMATION Environmental wear: Abrasive wear: 200 > 200 < ehnssi eodtesoeo hshnbo,pleasereferto AS/NZS 2576. mechanisms isbeyondthescopeofthishandbook, Adetailedtreatmentofenvironmentalwear above toexacerbatethewearofacomponent. Corrosion andelevated temperaturescancombinewiththeabrasivewearmechanismsdetailed nTbe1 h evc odtoso od impactandtemperaturearegradedasfollows: theserviceconditionsofload, In Table 1. select anappropriateCobalarchardfacingproduct. component mustbeconsideredalongwiththemainwearmechanismsidentifiedinorderto impactandtemperatureona The severityofloading, types identifiedfromaspecificapplication. isaguide toselectingtheappropriateCobalarchardfacingproductbasedonwear Table 1. LOW HIGH or groovethesurfaceduringservice. gouge are usuallylarge(rocks>50mmindiameter), which theabrasiveparticles, In gougingabrasion, fractured orground-upduringservice. are are initiallysmall(rocks<50mmindiameter), which theabrasiveparticles, In highstressabrasion, 500 > ° ° ° C 500 C < C = - Servicetemperaturesgreaterthan500 - Servicetemperaturesfromambientto200 = = = = ° LOW loading MODERATE loading HIGH loading LOW impact HIGH impact C - Servicetemperaturesgreaterthan200 causing nofractureorplasticdeformationofthewearsurface. causing fractureorplasticdeformationofthewearsurface, where thereisnolocaldeformationofthewearsurface. where thereisgrossdeformationofthewearsurface, where thereissomelocaldeformationofthewearsurface, ° C. ° C, ° C andlessthan500 ° C,

TECHNICAL AND TRADE INFORMATION 377

Stoody 850-O is not recommended for high impact applications impact high for recommended not is 850-O Stoody

† †

* See previous page for limiting service condition definitions. R = Recommended. HR = Highly Recommended. Highly = HR Recommended. = R definitions. condition service limiting for page previous See *

Stoody 850-O Stoody

†

toy95G -O 965-G, Stoody

° IH<200 HIGH 750 650, Cobalarc - - - - R R R --- R ------C ● ● ● ● ●

° ------R ------R R R C

O <500 LOW Toolcraft Cobalarc ● ● ● ● ●

toySprBidU-,LOW Up-G, Build Super Stoody

° IH& <200 & HIGH 350, Cobalarc ------R R R C ● ● ● ● ●

° ------R R --- C

IH<500 HIGH Austex, Cobalarc ● ● ● ● ●

Stoody Dynamang-O Stoody

° - - - - - R R ------R ------C

IH<200 HIGH Mangcraft, Cobalarc ● ● ● ● ●

rso rso bain(Grinding) abrasion erosion erosion

atcedoltsrs bainabrasion abrasion stress droplet particle

Loading Impact Temp. Sliding Rolling Impact Solid Liquid Low High stress Gouging Gouging stress High Low Liquid Solid Impact Rolling Sliding Temp. Impact Loading

Cobalarc product Limiting service conditions* Metal-to-metal Abrasive wear Abrasive Metal-to-metal conditions* service Limiting product Cobalarc WEAR TYPE WEAR Cobalarc Product Selection by Wear Type - Table 1: Table - Type Wear Selection by Product Cobalarc HARDFACING INFORMATION HARDFACING www.cigweld.com.au 378 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au HARDFACING INFORMATION WEAR TYPE Cobalarc Product Selectionby Wear Type - Table 1: Cobalarc product Limiting service conditions* Metal-to-metal Abrasive wear Loading Impact Temp. Sliding Rolling Impact Solid Liquid Low High stress Gouging particle droplet stress abrasion abrasion erosion erosion abrasion (Grinding) Cobalarc CR70, ● ● HIGH <500°C ------R R HR HR HR Stoody 101 HC-G-O Cobalarc 9e, ● ● HIGH <500°C ------R R HR HR HR Cobalarc Borochrome ● ● LOW <500°C ------R HR HR HR R Stoody Fineclad-O Stoody Tube Borium, ● LOW <200°C ------HR R HR R R Bronzecraft AC-DC ● ● LOW <200°C R R R ------Comweld Manganese ● LOW <200°C R R ------Bronze and Comweld Comcoat C ● ● ● Comweld Nickel HIGH <200°CHRRRRRR------Bronze and Comweld Comcoat N

* See previous page for limiting service condition definitions. R = Recommended. HR = Highly Recommended. TECHNICAL AND TRADE INFORMATIONTECHNICAL AND TRADE HARDFACING INFORMATION

Cobalarc Applications by Industry Sector AGRICULTURAL EQUIPMENT

APPLICATION Cobalarc electrode Stoody wire ▲ Slasher Blades Toolcraft Stoody 965 G-O ▲ Tools and Drill Bits Toolcraft - ▲ Scarifier Points Cobalarc 750, Stoody 850-O Cobalarc 9e ▲ Plough Shares Cobalarc CR70 Stoody 101 HC G-O ▲ Ammonia Injector Knives Cobalarc 9e, Stoody Tube Borium ▲ Subsoiler teeth Cobalarc CR70, Stoody 101 HC G-O Stoody Tube Borium ▲ Ripper Shanks Cobalarc 9e ▲ Furrow Shovels Cobalarc 9e ▲ Post Hole Augers Cobalarc 9e ▲ Pilot bit Cobalarc Toolcraft ▲ Rollers and Tractor Machine Parts Cobalarc 350 Stoody Super Buildup G-O ▲ Root Cutters Cobalarc CR70, Stoody 101 HC G-O Cobalarc 9e

www.cigweld.com.au 379 380 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au ATMVN,MNN,CRUSHING&QUARRYING MINING, EARTHMOVING, HARDFACING INFORMATION * Manufacturedfromausteniticmanganesesteel ▲ ▲ ▲ ▲ ▲ ▲ ▲ Stoodywire ▲ ▲ ▲ ▲ Cobalarc electrode ▲ ▲ ▲ ▲ APPLICATION Cobalarc Applications byIndustrySector rse oe* agrf,Cblr eDynamang Cobalarc9e Mangcraft, Mantle* Gyratory Crusher Crusher RollShells*, Crusher Cones*, rligAgr - oaacC7,--Sod 0 C 100HC Stoody101HC, 100HC Stoody101HC, 100HC Stoody101HC, ------CobalarcCR70, Cobalarc9e --- Cobalarc9e --- - Drilling Augers Cobalarc650 --- Cobalarc350 --- Cobalarc350 Teeth andPoints Cobalarc350 Idlers andIdlerRolls Loader Buckets Grouser Bars Rippers Track Pads iigSresCblr R0 toy11H,100HC Stoody Stoody101HC, Cobalarc--- Cobalarc 650 --- Cobalarc350 --- CobalarcCR70, --- Kiln Trunnions Cobalarc9e, Cobalarc9e, Chutes 100HC Stoody 101HC, --- 100HC Stoody101HC, Sizing Screens --- Stoody Pug MillPaddles Stoody 100HC Stoody101HC, CobalarcCR70, Fan Blades CobalarcCR70, Cobalarc Stoody Cobalarc Impact Breaker Bars* CobalarcCR70, Hammer Mill Cobalarc Crusher Jaws*, amr*Mncat oaac9eDynamang Cobalarc9e Mangcraft, Hammers* agrf,Cblr eDynamang Cobalarc9e Mangcraft, ul-pHr ufcn ul-pHardSurfacing Build-up HardSurfacing Build-up Cobalarc 9e oaacStoodyFineclad Borochrome Cobalarc Stoody Stoody TubeBorium Borochrome Cobalarc Borochrome Cobalarc 9e - toy11H,100HC Stoody101HC, --- Stoody SuperBuildup Stoody SuperBuildup Stoody SuperBuildup Stoody SuperBuildup Stoody 965 - Stoody 965 Fineclad Fineclad TECHNICAL AND TRADE INFORMATION 381 Cobalarc Borochrome Stoody Fineclad Austex Cobalarc 9e Build-up Hard Surfacing Build-up Hard Surfacing BarsKnivesBase Cutters and Austex Rolls Elevator Cobalarc 9e Cobalarc Toolcraft Leveller or Blades Kicker HammerReturn Plates 61 Ferrocraft AustexBorochrome Cobalarc Cobalarc 9e, Fineclad Stoody Rolls Cobalarc Borochrome Stoody Fineclad Shredder GridCane Preparation Cobalarc --- Cane Harvester CR70, Cobalarc Cobalarc 9e, --- Autocraft 309LSi Stoody 101 HC, 100 HC Cobalarc 9e --- Stoody 101 HC, 100 HC ---101 HC, Stoody 100 HC Preliminary Cane ---Cane ShredderScraper, and Trash 7016, Ferrocraft Cobalarc 9e, Cobalarc Cobalarc CR70, --- Autocraft 309LSi Stoody 101 HC, Supre-Cor 5 100 HC Cane Crushing --- CR70, Cobalarc --- Spiky Feed RollsSpiky Feed Cobalarc Cobalarc CR70, Autocraft 309LSi Stoody 101 HC, 100 HC ▲ ▲ ▲ ▲ ▲ ▲ Cobalarc Applications by Industry Sector Applications Cobalarc APPLICATION▲ electrode Cobalarc wire Stoody HARDFACING INFORMATION HARDFACING ▲ SUGAR INDUSTRY www.cigweld.com.au 382 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au DREDGING INDUSTRY HARDFACING INFORMATION ▲ ▲ ▲ ▲ ▲ ▲ ▲ Stoodywire ▲ ▲ ▲ Cobalarc electrode ▲ ▲ ▲ APPLICATION Cobalarc Applications byIndustrySector Bearing Box agns te oaacBrcrm,StoodyFineclad StoodyFineclad StoodyFineclad, --- CobalarcBorochrome, 100HC Stoody101HC, --- CobalarcBorochrome, 100HC Stoody101 HC, CobalarcBorochrome, Stoody --- Stoody Manganese Steel --- CobalarcCR70, Dredge Pump CobalarcCR70, Cobalarc Cobalarc350 Dredge Pump Manganese Steel Carbon Steel abnSelCblr 5 Stoody965 Stoody965 Stoody Dynamang StoodyFineclad, Stoody Cobalarc650 Cobalarc650 Stoody965 CobalarcMangcraft, --- Stoody StoodyFineclad Stoody Cobalarc CobalarcBorochrome, StoodyFineclad --- Manganese Steel --- Cobalarc650 Carbon Steel CobalarcBorochrome, ------Bucket Pins Cobalarc350 Cobalarc350 CobalarcBorochrome, Dredge Pump --- Dredge Ladder Ladder Roll --- Pipeline Ball Dredge Bucket melr oaacC7 toy11H,100HC Stoody101HC, Cobalarc9e Cobalarc9e CobalarcCR70 StoodyFineclad StoodyFineclad SuperBuildup Dynamang CobalarcBorochrome Heads and Teeth Dredge Cutter CobalarcBorochrome Side Plates Mangcraft, Impellers Pump Casings Pump Casings ne ozeCblr R0 toy11H,100HC Stoody101HC, Dynamang CobalarcCR70 Mangcraft, Cobalarc9e Lower Tumblers Cobalarc9e Lower Tumblers Inlet Nozzle Rolls Joints Lips ul-pHr ufcn ul-pHardSurfacing Build-up HardSurfacing Build-up Super Buildup Super Buildup TECHNICAL AND TRADE INFORMATION 383 Stoody Fineclad Stoody Fineclad Stoody Fineclad Super Buildup Cobalarc Borochrome Stoody Fineclad Stoody Tube Borium Stoody Tube Build-up Hard Surfacing Build-up Hard Surfacing Austex, Weldall Cobalarc 9e Austex Cobalarc Mangcraft Flights Cobalarc 9e and Pins Mill Hammers Austex, Dynamang Bearings, Hangers Shredder Cones --- Shredder Knives Assembly Brick Pin --- Teeth Roll Crusher --- Cobalarc 9e --- Cobalarc Borochrome Cobalarc Borochrome Cobalarc 9e ------Stoody Fineclad --- Stoody Fineclad 101 HC, Stoody 100 HC Muller TyresMuller Auger Pug Mill Cobalarc Pug Mill Knives --- Cobalarc CR70 BladesFeeder --- Cobalarc Borochrome ------BoriumTube Stoody BoriumTube Stoody --- Stoody 101 HC, 100 HC Stoody Fineclad --- Manganese Steel Cobalarc Screws Bag Packer Cobalarc 9e --- Tank Slurry --- Cobalarc Borochrome Stoody --- Cobalarc Borochrome Stoody 101 HC, 100 HC --- Stoody Fineclad Stoody Fineclad Screw Flight Shaft ---Drag Chain Links ---Cage Bars Cobalarc CR70 Cobalarc CR70 Cobalarc --- 9e Cobalarc --- 101 HC, Stoody 100 HC Stoody 101 HC, 100 HC Kiln Trunnions Cobalarc 350 Stoody --- Agitator Shaft ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ Cobalarc Applications by Industry Sector Applications Cobalarc APPLICATION▲ electrode Cobalarc wire Stoody HARDFACING INFORMATION HARDFACING CEMENT, INDUSTRIES BRICK & CLAY www.cigweld.com.au 384 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au IRON AND STEELINDUSTRY HARDFACING INFORMATION ▲ ▲ ▲ Stoodywire ▲ ▲ ▲ ▲ Cobalarc electrode ▲ ▲ ▲ APPLICATION Cobalarc Applications byIndustrySector ce ovyr - oaacC7,-- toy11H,100HC Stoody101HC, StoodyFineclad StoodyFineclad --- 100HC Stoody101HC, Stoody965 ------Stoody CobalarcCR70, --- Cobalarc9e, --- Cobalarc650, Cobalarc9e, Cobalarc350 Screw Conveyors ------Coupling Boxes Coke OvenPusher --- Coke Chutes Blast FurnaceBells adSigrCp -- Cblr oohoe - Sod 0 C 100HC Stoody101 HC, Stoody965 Stoody965 100HC Stoody101HC, --- CobalarcBorochrome, ------Cobalarc650, --- Cobalarc650, Cobalarc350 CobalarcCR70, Sand SlingerCups --- Ingot Buggy Wheels --- Wobblers Pig IronCasting Grizzly Barsand he CobalarcBorochrome Shoes ne ozeCblr R0StoodyFineclad CobalarcCR70 Cobalarc Toolcraft Cobalarc9e Inlet Nozzle and Tracks Machine Rails Fingers ul-pHr ufcn ul-pHardSurfacing Build-up HardSurfacing Build-up oaac70SuperBuildup Cobalarc 9e Cobalarc 750 Cobalarc Borochrome Cobalarc 750 Stoody SuperBuildup Stoody SuperBuildup (burden area) Stoody 965 Stoody 850 TECHNICAL AND TRADE INFORMATION 385 When a hardfacing deposit is placed on When a hardfacing there is a a softer base materials “sink in”tendency for it to under high loading. overcome this a strong, To tough the base layer is deposited onto materials prior to hardfacing. When a component is subjected to heavy impact and/or flexing there is the possibility that relief checks which are of common in the higher hardness range hardfacing products will act as stress concentrators and propagate through to the base materials, particularly where the base material is a high strength steel. use of a suitable buffer layer between The the base and hardfacing deposit will overcome this problem. In many instances components which have been hardfaced and put into service wear unevenly and when presented for hardfacing again there are areas of the original hardfacing deposit still existing. the softer,For multilayer deposits and/or deposits which have not fractured under impact, hardfacing can be re-applied directly. However for fractured and very hard deposits it is necessary they be removed by grinding, gouging etc. to prior re-hardfacing. If this is not possible the use of buffer layer will secure the existing hardfacing and provide a tough base for subsequent hardfacing layers. The term buffer layer is used to describe the presence of an intermediate deposit between the of an intermediate deposit between the layer is used to describe the presence term buffer The of cases is both desirable and actual hardfacing deposit and in a number base material and the necessary. USE OF BUFFER LAYERS BUFFER USE OF HARDFACING INFORMATION HARDFACING 2. Hardfacing on components subject to heavy Impact/Flexing. 3. Components. Worn Hardfacing over Partly NOTE: When applying buffer layers, particularly on 11-14% manganese steel or the higher strength base materials ensure that the buffer layer extends beyond the hardfacing deposit. of relief checks or cracks will overcome the possible propagation This occurring along the edge of the hardface deposit. 1. on a soft material for high load service. Hardfacing www.cigweld.com.au 386 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au .DotPattern. 3. StringerBeads. 2. ContinuousCoverage. 1. HARDFACING DEPOSITPATTERNS HARDFACING INFORMATION The dotsizeisgenerally15-20mmdiameterby8mmhighandplacedatabout50mmcentres. particularlyforthe11%-14%austenitic manganesesteels. useful inkeeping theheatinputdown, Itis thedotpatternisused. shovelsetc. For lesscriticalareassuchasthesides/endsofbuckets, pattern isgenerallyused. or “waffle” coarse andfinematerialthe “checker” For conditionswherethereisacombinationof beads andsogiveselfprotection. allows thefinematerialstocompactbetween this transverse (across)thepathofmaterialtravel, In finesandyconditionsthestringerbeadsshouldbe along thetopofhardfacingbead. toslide allowingthelargelumpsofrocketc. travel, bead isdepositedinthedirectionofmaterial For teethworkingincoarserockyconditionsthe tempers etc. sheepfoot rockchutes, buckets/bucket teeth, teeth, ripper widely usedformanyapplicationsincluding, stringerbeadsare Other thancompletecoverage, necessary toensureadequatecoverage. Sufficientover-lapping ofeachbeadis bucket lips. mixerpaddlesanddredge valve seats, sand chutes, Typical exampleswouldbepumpandfanimpellers, subject toahighdegreeoffineabrasionorerosion. Itisalsorequiredonparts crusher jawsandcones. tracks, shafts, suchasrolls, a criticalsizeorshape, Is usedforre-buildingandhardfacingpartsthathave three mainpatternsusedare:- The serviceconditionsandthestateofrepair. factors includingthefunctionofcomponent, The amountofhardsurfacingandthepatterncoveragewillbedeterminedbyanumber TECHNICAL AND TRADE INFORMATION 387 tractor track grousers, anvils, pneumatic tools, shredder bars. crossings, track components. Machine tools, lathe tools, shears, drills, guillotine blades, cutting knives, punches, dies, metal forming tools. points, plough shears. stainless steels. dissimilar irons / steels. strong welds between Forms rails, Tramway crossings, bearings at medium temperatures, Cobalarc Product Selection by Alloy Type and Application and Type Alloy Selection by Product Cobalarc HARDFACING INFORMATION HARDFACING Group 1.Steel ProductsCobalarc Mangcraft,Stoody Dynamang-O steels. Alloy TypeAustex,Cobalarc Austenitic manganese AS/NZS Austenitic 1215-B7 1215-A4 class Description & Applications 1315-A4 Tough, work hardens on impact. Tough, heat resistant. corrosion and Crusher jaws, rolls, mantles, ball mill liners. Cobalarc 350,Stoody SuperBuildup-G Low carbon Cobalarc martensiticToolcraft 1435-A4 steels. 1435-B5/7 strength and metal-to-metal wear Excellent compressive Cobalarc 650,Cobalarc 750, resistance. Stoody 965-G-O steels. Tool Stoody 850-O High carbon 1560-A4 martensitic steels. 1855-A4 Strong, secondary hardening characteristics. 1860-A4 and surfacing of clutch parts, Re-building points and railway Hard, relatively in-expensive, good general abrasion 1855-B5/B7 resistance. Surfacing of post-hole augers, earth scoops, conveyor screws, 1865-B7 drag line buckets, pump housings, teeth, subsoiler scarifier www.cigweld.com.au 388 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au HARDFACING INFORMATION toy11H-- crmu bainrssac.Idealforgouging (coarse)abrasion abrasionresistance. & Applications highlevelofchromiumcarbidesforexcellent Description Strong, 2355-A4 AS/NZS Austenitic AlloyType chromium Stoody 101HC-G-O Cobalarc CR70, White Irons Chromium class 2. Group oaac9,Cmlx 40A tog highlevelofcomplexcarbides forexcellentabrasion Strong, 2460-A1 Complex Cobalarc 9e, oohoe hoimarso eitne Idealforlowstressscratching(wetor abrasionresistance. highlevelofchromiumcarbidesforexcellent Strong, dry)abrasionconditionswithrelativelylowimpactloading. 2560-A4 2565-B7 Martensitic chromium carbide Stoody Fineclad-O Borochrome, Cobalarc Cobalarc Product Selectionby Alloy Type and Application Group 3. Alloy Type AS/NZS Description & Applications Description tungstencarbide(WC)irondepositresistantto Hard, class AS/NZS 3460-A1 AlloyType Tungsten Stoody Tube Borium, Composites Tungsten Carbide 3. Group rn.Cuhrcnsadmnls wn amr,grizzlybars, swinghammers, Crusherconesandmantles, conditions. 2360-B5/B7 irons. carbide rn.Szn cen,bl illnrpae,dredgepumpimpellers, ballmilllinerplates, Sizingscreens, relativelyhighimpactloading. Idealforwiderangeofabrasionconditionswith resistance. irons. carbide chromium rn.Wet applicationsinminingandcrushingindustries, irons. ihmti.agrbae n et,olwl rls bulldozerendbits. oildrillcollars oilwelldrills, ripperpoints, augerbladesandteeth, ditcherteeth, Rockdrills, Idealforearthcuttingandboringapplications. severeabrasionandlowimpactloading. rich matrix. in aniron granules carbide harvesting andmillingequipment. earthmovingbuckets andsugar shovelteeth, scarifier points, caes a lds bucket lipsandsideplates. fanblades, scrapers, agriculturalimplements, pugmillpaddles, crusher jaws, blades andslurrypumpcomponents. fan cementchutes, sandslingers, agricultural implements, TECHNICAL AND TRADE INFORMATION 389 Light load bearings, and pistons. Hydraulic rams pump rotors. Cobalarc Product Selection by Alloy Type and Application and Type Alloy Selection by Product Cobalarc Group 4.Copper AlloysBronzecraft AC-DC, Type Alloy Comweld PhosphorManganeseBronze, AS/NZS6300-C1 Comweld bronzeComcoat C 6200-A2 class Description & Applications Comweld High tensile brass.Nickel Good bearing properties,corrosion resistant. wear & Bronze,Comweld 6300-C1Comcoat N Low friction bearing characteristics, wear and corrosion Nickel load bearings, Medium crankpress, transmission housings, bronze Ni). (9-13% 6400-C1 resistant. Low friction bearing characteristics, work hardenable, 6400-C1 Gear teeth, cams, bearings, percussion heads, slides, service where work hardening is required. corrosion resistant. HARDFACING INFORMATION HARDFACING www.cigweld.com.au 390 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Cost ofpower($/kWhr)x Volts x Amps C($perkgofweldmetaldeposited); POWER COST; Flux Price($/kg)xConsumptionRate(kghr) B(SAWonly)($perkgofweldmetaldeposited): FLUX COST; Electrode or Wire Price($/kg) A($perkgofweldmetaldeposited): WELDING ELECTRODEOR WIRE COST; Other importantfactorsrelatingtotheselectionofweldingprocess/consumableare:- Points toconsiderincalculationofanestimatedcostinclude:- thenthecalculationoftruecosthardfacingcomponentisimportant. rebuild ratherthanreplace), toextendtheworkinglifeofacomponent(ie. thatis, Based onthefactthatdecisiontohardfaceisaneconomicone, HARDFACING INFORMATION Cost Calculations: Costing Information: Deposition Efficiency*(%) Deposition Rate(kg/hr) Deposition Rate(kg/hr) .OperatingfactororDutycycle(%). 3. Depositionefficiency(%). 2. Depositionrate(kgofweldmetal/hr). 1. labourandoverheadcosts. Power, machiningetc.). grinding, 5. Post weld requirements(heattreatment, preheatetc.). 4. Preparationpriortowelding(includinggrinding, 3. Costofweldingconsumables. 2. Volume ofbuild-uphardsurfacingdepositrequired. 1. = A ($/kg) = C($/kg) = B($/kg) TECHNICAL AND TRADE INFORMATION 391 ) x F x 0.008 3 35 - 40 = E ($ / kg) = D ($ / kg) # 80 - 90 25 - 30 † ProcessMMAWFCAW SAW Efficiency (%) Deposit 60 - 75 (%) Operating Factor Typical 90 - 95 15 - 20 Operating Factor* (%) Operating Factor* Operating Factor* (%) Operating Factor* *Deposition Efficiencies and Operating Factors for Hardfacing Cost Calculations: for Hardfacing Factors *Deposition Efficiencies and Operating COSTING INFORMATION: COSTING HARDFACING INFORMATION HARDFACING Total cost (TC) of hardfacing the steel component: Total of Build-up or hard surfacing deposit (cm Volume TC ($) = F ($ / kg) = A + B + C + D + E F ($ / kg) = LABOUR COST; weld metal deposited): D ($ per kg of x Deposition Rate (kg / hr) Labour Cost ($ / hr) OVERHEAD COST;OVERHEAD per kg of weld metal deposited): E ($ (kg / hr) Overhead cost ($ / hr) x Deposition Rate cost;Total F ($ per kg of weld metal deposited): † Semi-automatic operation. # SAW wire only. www.cigweld.com.au 392 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Deposition Rates Electrode Efficiency(DepositionEfficiency) DEPOSITION DATA 6gas÷107.7gramsx100=155.06%ElectrodeEfficiency(DepositionEfficiency). 167grams ÷ Ø3.2mmx50mmlongafterwelding=16.3grams, weight offive(5)electrodestubends, Ø3.2mmx380mmlongbeforewelding=124grams, weight offive(5)electrodecorewires, 2kg-2.167kgPlateafterwelding=167grams, Plate beforewelding: Ferrocraft 22Ø3.2mmx380mm. e.g. 163.3gramsx100=91.85%ElectrodeEfficiency(Deposition Efficiency). 150grams ÷ Ø4mmx50mmlongafterwelding=24.7grams, weight offive(5)electrodestubends, Ø4mmx380mmlongbeforewelding=188grams, weight offive(5)electrodecorewires, 2kg-2.15kgPlateafterwelding=150grams, Plate beforewelding: Satincraft13Ø4mmx380mm. e.g. Mass oftheCore Wire of5electrodes Weight oftestplateincludingweldmetal Electrode Efficiency%toISO2401and AS/NZS 1553.1= calculated byusingthefollowingformula; The efficiencyofanelectrodeis consumed (notincludingfluxandstubends)inmakingtheweld. difference betweentheweightofweldmetaldepositedandfiller 1995depositionefficiency)isthe Technically toISO2401-1972electrodeefficiency(AS/NZS1553.1: 95grams x60/1000=5.7kg/hr. weldedin60seconds. 2kg-2.95kgPlateafterwelding=95grams, Platebeforewelding: e.g. Measured periodoftime(normally60seconds). Deposition Rate= Weight oftestplatebeforewelding formula formeasuringdepositionrates. andthefollowingshows Deposition ratesarecalculatedbydoingactualweldingtests, increased inthecaseofGMAWandFCAWdepositionratewillalsoincrease. Whenelectricalstickoutis When weldingcurrentisincreasedsotodoesthedepositionrate. machine adjustmentsorotherreasons. cleaningspatter, chippingslag, electrode changeovers, notallowingforstopsandstartssuchas, Deposition rateisbasedoncontinuousoperation, hour (kg/hr). Depositionrateisexpressedinkilogramsper metal isdeposited(melted)ontoasurface. wireorrod)istherateatwhichweld The depositionrateofaweldingconsumable(electrode, eoiinRts lcrd fiiny andElectrode Weld MetalRecovery! Electrode Efficiency, Deposition Rates, What are thedifferences? - - Weight ofcorewirethe5stubends Weight oftestplatebeforewelding - Weight oftestplateafterwelding÷ X 100 TECHNICAL AND TRADE INFORMATION 393 Average Efficiency 60% 95% 98% 85% 88% 92% 92% 2 2 2 2 2 2 X 100 Weight of test plate after welding Weight - Weight of the Consumable Weight e.g. Satincraft 13 Ø4mm x 380mm. Plate before welding: after welding = 150grams, 2kg - 2.15kg Plate weight of five (5) electrodes, Ø4mm x 380mm long before welding = 261.20grams, 150grams ÷ Metal Recovery (Process Efficiency). Weld x 100 = 57.43% 261.20grams e.g. 22 Ø3.2mm x 380mm. Ferrocraft Plate before welding: after welding = 167grams, 2kg - 2.167kg Plate weight of five (5) electrodes, Ø3.2mm x 380mm long before welding = 281.50grams, 167grams ÷ Metal Recovery (Process Efficiency). Weld x 100 = 59.33% 281.50grams Generally process efficiencies can be stated as averages for costing purposes. following table The suggested process efficiency percentages. outlines CIGWELD’s welding processes to be employed, If the welding application calls for the Oxy-Acetylene or GTAW that 100% of the then it is prudent to use all of the consumable by joining stub ends to ensure filler metal is utilised. Electrode weld metal recovery to ISO 2401-1972 allows us to calculate the amount of welding the amount of welding allows us to calculate to ISO 2401-1972 weld metal recovery Electrode such as, weld metal less any waste actually be deposited into the finished consumable which will stub ends, not adhered to the test plate. slag and spatter quoted efficiency of 60%, 100kgs of electrodes are used with a An example is when the net result end up in the deposited weld metal. the weight of that electrode will actually is that only 60kg of 40% (40kg) of the electrode is waste. remaining The plate tests are carried out by weighing the test weld metal recovery rates practical achieve To before and after welding, the following before welding and then using weighing the consumables 50mm stub ends.formula allowing for stub ends than If the welder discards more than 50mm efficiency) will be lower. the recovery rate (process = Metal Recovery % to ISO 2401 Weld of test plate before welding Weight Gas Tungsten Arc Welding (GTAW) & Oxy-Acetylene Welding (OAW)Welding & Oxy-Acetylene (GTAW) Welding Arc Tungsten Gas 100% Welding Process Welding Gas Metal Arc Welding (GMAW) Welding Arc Gas Metal Arc, Short Ar + 25% CO Stoody Flux Cored Hardfacing WiresStoody Flux Cored Hardfacing in result depending upon the shielding gases used,GMAW and FCAW average efficiencies can vary machine settings, out, stick spatter losses, wire sniped off before starts etc. Gas shielded 80% Manual Metal Arc Welding (MMAW) Welding Arc Manual Metal (GMAW) Welding Arc Gas Metal (FCAW) Welding Arc Flux Cored (FCAW) Welding Arc Flux Cored (FCAW) Welding Arc Flux Cored Arc, Spray types, E70T-4 types, E71T-1 types, E70T-5 Ar + 25% CO self shielded Ar + 25% CO Ar + 25% CO 82% General Process Efficiencies Process General Electrode Weld Metal Recovery (Process Efficiency) Recovery (Process Metal Weld Electrode DEPOSITION DATA DEPOSITION Gas Metal Arc Welding (GMAW) Welding Arc Gas Metal (FCAW) Welding Arc Flux Cored Arc, Pulse E70C-6M types, Ar + 25% CO CO Ar + 25% www.cigweld.com.au 394 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au nldn,wligprmtr,aclnt,travelspeedandmachinecharacteristics. arclength, weldingparameters, including, Resultsareinfluencedbymanyfactor actualonthejobfiguresmayvary. The information providedinthistableisaguideonly, DEPOSITION DATA ercat1X . 1 .019 66% Recovery Weld Metal 109% Efficiency Electrode Ratekg/hr 0.90 Deposition 110 Amps (mm) Size 3.2 Ferrocraft 12XP Product CIGWELD oaacC7 . 6 .026 71% 69% 64% 62% 70% 69% 206% 191% 112% 62% 54% 109% 115% 55% 60% 59% 116% 1.70 57% 1.20 1.30 60% 114% 1.00 108% 1.15 63% 105% 111% 56% 0.95 113% 61% 58% 165 110% 59% 115 145 97% 62% 1.80 1.10 115 125 63% 101% 0.90 1.30 66% 1.80 90% 100 4.0 64% 157% 1.30 58% 95% 3.2 4.0 155% 56% 1.50 112% 180 3.2 130 4.0 1.10 113% 125 69% 90% 95 3.2 1.60 180 2.80 90% 1.20 125 Cobalarc CR70 92% 2.00 1.70 Cobalarc CR70 4.0 91% 170 4.0 Cobalarc 750 1.20 3.2 120 3.2 111% 1.30 Cobalarc 750 4.0 165 Castcraft 55 1.00 210 3.2 1.30 120 Castcraft 55 150 Satincrome 316L-17 4.0 0.92 170 Satincrome 316L-17 3.2 120 Alloycraft 90 1.20 4.0 145 Alloycraft 90 4.0 3.2 110 Ferrocraft 61 160 3.2 Ferrocraft 61 4.0 115 Ferrocraft 7016 3.2 Ferrocraft 7016 4.0 150 Ferrocraft 16TXP 3.2 Ferrocraft 4.0 16TXP Ferrocraft 22 3.2 Ferrocraft 22 Ferrocraft 21 4.0 Ferrocraft 21 Ferrocraft 11 Ferrocraft 11 Satincraft 13 Satincraft 13 Ferrocraft 12XP Electrode Efficienciesand Weld MetalRecoveryRates: The following Table listssomepopularCIGWELDconsumablesandtheirDepositionRates, IWL lcrds eoiinRts lcrd fiinis and Electrode Efficiencies, DepositionRates, CIGWELD Electrodes, Electrode Weld MetalRecoveryRates s TECHNICAL AND TRADE INFORMATION 395 nd are Weld Metal Recovery Rates Recovery Metal Weld CIGWELD Solid and Flux Cored Wires, Flux Cored Solid and CIGWELD and Deposition The following Table lists some popular CIGWELD consumables and their Deposition and Weld Weld and their Deposition and some popular CIGWELD consumables lists Table following The Metal Recovery Rates: CIGWELDProductAutocraft LW1-6 0.8 Size (mm) Volts 20 Amps 150 WFS 12.0 Deposition m/min 2.5 Metal Weld Rate kg/hr Recovery 96% Shield-Cor 4XPShield-Cor 15Shield-Cor 11 2.8 0.9 1.2 30 17 17 450 120 150 3.5 3.9 3.0 6.4 0.7 1.0 86% 75% 80% Verti-Cor 3XPVerti-Cor Metal-Cor XPMetal-Cor XPSupre-Cor 5Supre-Cor 5 110TXPTensi-Cor 110TXPTensi-Cor 309LTVerti-Cor Shield-Cor 4XP 1.6 1.2 1.6 29 1.2 1.6 26 1.6 2.4 28 1.2 22 400 28 26 2.4 250 29 350 26 170 12.0 280 29 320 10.0 400 6.6 190 7.8 5.0 375 5.9 8.1 3.8 5.0 11.4 5.6 5.4 2.3 3.0 3.3 5.8 88% 92% 3.7 7.0 94% 86% 88% 89% 90% 84% 84% Satin-Cor XPSatin-Cor XPSatin-Cor XPSatin-Cor XPSatin-Cor XP 3XPVerti-Cor 3XPVerti-Cor 3XPVerti-Cor 1.6 3XPVerti-Cor 1.6 3XPVerti-Cor 2.4 2.4 29 30 2.4 1.2 30 1.2 31 1.2 350 32 400 25 1.6 1.6 400 26 450 28 6.5 500 7.0 27 200 28 4.2 250 5.0 320 6.0 300 6.7 5.4 350 6.0 9.9 15.0 5.7 6.8 6.2 9.5 8.2 2.7 87% 3.8 89% 5.9 85% 4.1 86% 6.4 90% 86% 84% 88% 86% 81% Autocraft LW1-6Autocraft LW1-6Autocraft LW1-6Autocraft Silicon BronzeAutocraft 316LSiAutocraft 316LSiAutocraft AL5356 0.9 0.9Autocraft AL5356 1.0Satin-Cor XP 1.2 26 24 0.9 28 1.2 32 1.0 180 22 180 1.2 240 26 300 22 1.6 12.0 24 180 13.2 13.5 250 10.8 180 28 220 10.0 3.1 3.2 4.8 8.5 16.3 300 5.6 14.0 2.8 5.5 96% 95% 1.5 4.4 95% 2.5 97% 97% 4.3 90% 98% 92% 86% DEPOSITION DATA DEPOSITION The information provided in this table is based on welding with constant voltage (C.V.) GMA Welding machines.Welding GMA a information provided in this table is based on welding with constant voltage (C.V.) Results may vary The influenced on the job by shielding gases used, machine settings, stick out, spatter losses, wire sniped off before starts etc. www.cigweld.com.au 396 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au ** HeightofReinforcement=2mm. * Includesspatterlossesand50mmstubendloss. Basis ofCalculations Instructions forUseofthisData qaeBt ons Welded bothsides Square ButtJoints, Manual Arc Electrode ConsumptionCalculatorGuide DEPOSITION DATA m .m .80.29 0.23 0.14 0.48 WithReinforcement** 0.38 0.23 WithReinforcement** 1.6mm 1mm 6mm 0 Root 5mm Gap(R) 3mm Thickness Plate hr = Massofelectrodesrequired = M Where Electrode requirementshavebeencalculatedasfollows: adjustments inthetabulatedvalues mustbemadetocompensateforsuchdifferences. Wherevariations fromthegivenconditionsorjointpreparationsareencountered, given below. The basisforthefollowingtabulationsis will aidinestimatingmaterialrequirementsandcosts. This data types ofelectrodesforweldingthevarious weldjointsusedthroughoutindustrytoday. The followingtablesprovidedataontheapproximatemassinkilogramsrequiredofdifferent centimetre forsteel. volumetric value isconvertedtomassbymultiplyingthefactor0.0079kilogramspercubic This metal tobeadded(areaofthecrosssectionweldmultipliedbylength). To arriveatthemassofweldmetaltobedepositeditisnecessarycalculatefirstvolume iesosmteo ed Apo. linermetreofweld(Approx.) metreofweld*(Approx.) Dimensions on go lcrdsprlna kgofweldmetaldeposited per kgofelectrodesperlinear Joint .m .60.34 0.25 0.16 0.56 0.41 0.26 2.5mm 1.6mm 1mm Proportion ofelectrodelost = M= Massofweldmetaltobedeposited E = D D 1 - E TECHNICAL AND TRADE INFORMATION 397 Joint kg of electrodes per linear per kg of weldmetal deposited Joint kg of electrodes per linear kg of weldmetal deposited per 3mm5mm6mm8mm 0.06 0.16 0.24 0.42 0.04 0.10 0.14 0.25 10mm12mm16mm20mm25mm 0.65 0.95 1.68 2.62 4.10 0.39 0.57 1.01 1.57 2.46 Dimensions metre of weld* (Approx.) liner metre of weld (Approx.) Dimensions metre of weld* (Approx.) liner metre of weld (Approx.) Dimensions metre of weld* (Approx.) liner metre of weld (Approx.) Fillet Weld leg length Weld Fillet per linear kg of electrodes kg of weldmetal deposited per PlateThickness6mm (F) Face 8mm Root10mm Gap (R) 12mm16mm 1.6mm20mm 1.6mm Root 1.6mm25mm 1.6mm 3mm 1.6mm 3mm 1.6mm 3mm 3mm 3mm 3mmReinforcement** With 3mm 3mm 0.39 0.63 0.87 1.33 Reinforcement** With 2.22 3.37 5.14 0.23 0.38 0.52 0.80 1.33 2.02 3.08 PlateThickness12mm (F) Face 16mm Root20mm Gap (R) 25mm 1.6mm 1.6mm Root 1.6mm 1.6mm 3mm 1.6mm 1.6mm 3mmReinforcement** With 0.92 1.46 2.12 3.33 Reinforcement** With 0.55 0.88 1.27 2.00 Double Vee Butt Joints,Vee butts) sides (double groove both Double Welded Single Vee Butt Joints, Butt Vee Single butts) (single groove Horizontal-Vertical (HV) Fillet welds (HV) Fillet Horizontal-Vertical DEPOSITION DATA DEPOSITION * Includes spatter, 50mm stub ends and back gouging losses. ** Height of Reinforcement = 2mm. * Includes spatter, 50mm stub ends and back gouging losses. ** Height of Reinforcement = 2mm. * Fillet weld figures are calculated based on true mitre fillets.* Fillet overwelded fillets can increase these figures by 33% Convex or or more. www.cigweld.com.au 398 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au .AutopakGasMetal Arc Welding (GMAW -MIG) 6. Wires AluminiumGasMetal Arc Welding (GMAW -MIG) 5. Wires StainlessSteelGasMetal Arc Welding (GMAW -MIG) Wires4. Submerged Arc Welding (SAW) 3. Wires forMildandLow Alloy Steels Cored(FCAW) Arc Welding Wires Flux 2. GasMetal Arc Welding (GMAW -MIG) Wires1. forMildandLow Alloy Steels Consumable Weights &Lengths Tables: DEPOSITION DATA mo ie/5k ak5 12 22 29 41 52 km ofwire/250kgPack m fwr e er .5618515.7 8.5 6.1 5.4 4.85 3.1 gms ofwirepermetre 99 1.7 9 gms ofwirepermetre 63 28.5 5.1 15.7 35.5 21 gms ofwirepermetre 8.5 24.6 13 4.85 gms ofwirepermetre 7.5 4 gms ofwirepermetre 2.2 gms ofwirepermetre erso ieprk 8 2. 184 327.5 10 582 111 16 metres ofwireperkg 36 198 28 63 50 metres ofwireperkg 41 113 77 metres ofwireperkg 200 132 254 metres ofwireperkg 450 metres ofwireperkg IESZ m)0910121.6 1.2 1.0 1.6 0.9 1.2 WIRE SIZE(mm) 4.0 0.9 1.2 3.2 WIRE SIZE(mm) 2.4 0.9 1.6 2.4 2.0 WIRE SIZE(mm) 1.2 2.0 1.6 0.9 WIRE SIZE(mm) 1.2 0.8 WIRE SIZE(mm) 0.6 WIRE SIZE(mm) for MildandLow Alloy Steels (350kg Pack) TECHNICAL AND TRADE INFORMATION 399 2 2 2 - a + b - b 2 2 2 2 c c a 2 √ √ √ Square Plate from Circular Plate the area of the For largest square plate that can be cut from a circular plate A = D Length of side of largest square plate. S = 0.7071 x D, D = 1.4142 x S c = b = Pythagoras Theorem a = D - d 2 + h 2 R √ D - d D - d Mathematical Symbols Mathematical TECHNICAL FACTS AND FIGURES FACTS TECHNICAL Frustum of an Oblique Cone Frustum Apex Height = H, H = D x h Horizontal Y, Distance = Y = D x S Frustum of aFrustum Right Cone Apex Height = H, H = D x h Side Height = SH, SH = www.cigweld.com.au 400 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Triangle Octagon A=0.433xS Hexagon P=3xS P=a+bc Circle Equilateral Triangle Scalene Triangle Rectangle Square Trapezium Geometric Shapes-Perimeters and Areas TECHNICAL FACTS AND FIGURES D P =Sumof4Sides A=0.828xL A=0.866xB P =8xS P =6xS P = D =P eiee Area = A Perimeter =P P =Sumof3sides B+H A=BxH P =2(B+H) P =4xS π π x D A =Hx(L+B) S =a+bc A = A =Sx A = A =BxH A =S or A = or √ π π 4 2 2 S (S-a)b)c) 2 x D R 2 2 2 2 2 2 TECHNICAL AND TRADE INFORMATION 401 ) 2 - d 2 ) x H x H 2 3 2 2 - d 2 x H x H 3 2 2 2 = 3.1416 3 π x H (D x R x R x D 6 π π π π N.B. or V = 0.5236 x D or V = 0.7854 x D or V = 0.2618 x D V = H x B x L V = V = V = V = V = L x B x H or V = 0.7854 x H (D 2 2 x D 4 π x D ) 2 π d 2 - ) 2 2 d x D + H 2 + R 2 - π 2 4 4 2 2 x D = SH x MD x W x MD x (D x D x D x H + 2 x x D x SH + H π √ π π π π π 4 LW = SH = or SA = 0.7854 (D SA = or SA = LW = 2 x LW SA = SA = 2 (L x B) + 2 (L x H) + 2 (B x H) SA = 2 (L x B) + 2 (L + 4B + 4H = 4L LW SA = SA = Surface Area = SA Area Surface = LW Welding Length of V = Volume contains 1000 litres. of water has a mass of 1000 kg of water 3 3 Square Tanks Geometric Shapes - Surface Area, Surface Shapes - Geometric Volumes and Welding Length of Triangular Prism Triangular TECHNICAL FACTS AND FIGURES FACTS TECHNICAL Hollow Cylinder Sphere Cylinder Cone Rectangular & Annulus 1 litre of water has a mass of 1kg. has a mass of 1 litre of water 1 m 1 m www.cigweld.com.au 402 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au nscx25 mscc/e .9 nscpsix0.006895=N/mm kgx2.2045=lb cm/secx0.394=in/sec lbx0.4536=kg in/sec x2.54=cm/sec metrex3.281=feet feet x0.3048=metre tl .58 olsjue .35 tl s .9 P kPa x0.14504=psi gramsx0.035=oz psix6.895=kPa joulesx0.73756=ft.lb ozx28.349=grams ft.lb x1.35582=joules mmx0.0394=inch inch x25.4=mm nmnx005 /i /i 9.8=i/i s .9 P MPa x0.14504=ksi ksix6.895=MPa m/minx393.78=in/min in/min x0.0254=m/min bh .56=k/rk/rx224 bh /nhx3.7=JmteJ/metrex.0254=J/inch J/inchx39.37=J/metre kg/hrx2.2045=lb/hr MPa x145.04=psi L/minx2.119=cft/hr kgx0.157=stones lb/hr x0.4536=kg/hr psix0.006895=MPa cft/hrx0.4719=L/min stonesx6.350=kg m/minx3.281=ft/min in/min x0.423=mm/sec kmx0.621=miles ft/min x0.305=m/min MetrictoImperial cmx0.394=inch ImperialtoMetric mile x1.609=km inch x2.54=cm MetrictoImperial Imperial toMetric Conversion Data Common Welding Conversion Data TECHNICAL FACTS AND FIGURES /”95m10l 5.0g10k 245l 0 1016mm 990.6mm 914.4mm 762mm 40” 660.4mm 39” 508mm 36” 558.8mm 457.2mm 30” 431.8mm 2204.58lb 26” 20” 2023.81lb 406.4mm 1785.71lb 22” 1000kg 381mm 18” 918kg 355.6mm 17” 1102.29lb 810kg 304.8mm 661.37lb 453.60kg 16” 254mm 220.46lb 15” 500kg 203.4mm 551.15lb 152.4mm 317.52kg 272.16kg 1000lb 300kg 154.32lb Unit 14” 101.6mm 12” 50.8mm 100kg 132.27lb 250kg 226.80kg 700lb 10” 600lb 110.23lb 70kg 181.44kg 8” 9.5mm Unit 6” 66.14lb 60kg 4” 22.68kg 113.40kg 500lb 2” 55.11lb 8.0mm 50kg 400lb 37.48lb 6.4mm 21.77kg 3/8” 30kg 250lb 33.07lb 18.14kg 50lb 5.6mm 5/16” 25kg 22.05lb 17kg 11.02lb 4.8mm 1/4” 14.97kg 45lb 5.50lb Unit 15kg 13.61kg 2.20lb 4.0mm 7/32” 40lb 3.2mm Metric 10kg 3/16” 11.34kg 5kg 33lb 2.5kg Imperial 9.07kg 3.0mm 5/32” Unit 30lb Lengths 1kg 2.8mm 7.26kg 1/8” 25lb 4.54kg 2.4mm .120” 20lb 2.27kg 2.0mm 7/64” .91kg 16lb Imperial 1.6mm 3/32” 10lb Unit .45kg 1.3mm 5/64” Metric 5lb 1.2mm 1/16” 2lb Pack Weights 1.0mm Unit .052” 1lb 0.9mm .045” Metric 0.8mm .040” 0.6mm Imperial .035” Unit .030” Pack Weights .025” Metric Unit Imperial Sizes Electrode eoiinRt HeatInput=Joules Deposition Rate nry&SedPressure&Stress Energy &Speed eghWeight &GasFlow Length mscx034=i/i psix0.0703=kg/cm mm/sec x0.394=in/min 2 (Volts x Amps x60 2 kg/cm N/mm 2 2 x 14.223=psi x 145.04=psi ÷ WFS) TECHNICAL AND TRADE INFORMATION 403 .5118 13 .5315.5512 13.5 14 .6890.7087 17.5 18 .8465.8661 21.5 22 .6102.6299 15.5 16 .7677.7874 19.5 20 .9252 23.5 .0197 .5 33/64 .5156 13.10 .3740 9.5 .3150.3346.3543 8 8.5 9 13/16 53/64 .8125 .8281 20.64 21.03 .1772.1969.2031 4.5 5 5.5 43/64 .6719 17.07 .1575 4 21/32 .6563 16.67 .0394.0591 1 1.5 .4724.4921 12 12.5 31/32 63/64 .9688 .9844 24.61 25 .3937.4134.4331 10.4528 10.5 11 11.5 57/64 29/32 .8906 .9063 22.62 23.02 .9449 24 .2756.2953 7 7.5 .2362.2559 6 6.5 47/64 3/4 .7344 .7500 18.65 19.05 .0787.0984.1181 2.1378 2.5 3 3.5 37/64 19/32 .5781 .5938 14.68 15.08 INCHES mm INCHES mm 15/3231/64 .46881/2 .4844 .5000 11.91 12.30 12.7 .9646 .9843 24.5 1.0000 25 25.4 23/643/825/64 .3594 .3906 .3750 9.13 9.92 9.53 55/64 .8594 7/8 .8750 .8858 21.83 22.23 22.5 5/1621/64 .312511/32 .3281 .3438 7.94 8.33 8.73 27/32 .8071 .8438 .8268 20.5 21. 21 43 11/643/16 .171913/64 .18757/3215/64 .1969 4.37 .2188 .2344 4.76 5.16 5.56 5.95 11/16 45/64 .6693 .6875 23/32 .7031 .7188 17 17.46 .7283 17.86 18.26 18.5 5/32 .1563 3.97 .6496 16.5 1/641/32 .01563/64 .03131/165/64 .0469 .40 .0625 .0781 .79 1.19 1.59 1.98 17/32 35/64 .5313 9/16 .5469 .5625 13.49 .5709 13.89 14.29 14.5 1/89/64 .1250 .1406 3.18 3.579/32 5/819/64 41/64 .2813 .6250 .2969 .6406 7.14 15.88 7.54 16.27 7/16 25/32 51/64 .4375 .7813 .7969 11.11 19.84 20.24 15/16 .9375 23.81 13/3227/64 .4063 .421929/64 10.32 .4531 10.72 11.51 59/64 .9219 .9055 61/64 .9531 23.42 23 24.21 1/417/64 .2500 .2656 6.35 6.75 49/64 .7656 .7480 19.45 19 3/327/64 .0938 .1094 2.38 2.78 39/64 .6094 .5906 15.48 15 Inch to Millimetre Conversion Millimetre Inch to TECHNICAL FACTS AND FIGURES FACTS TECHNICAL www.cigweld.com.au 404 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au ovrin nhsmn x5=Feet/Hour Inches/min. Conversion: Some oftheabovefiguresare “rounded”. TECHNICAL FACTS AND FIGURES ConversionSpeeds Tables- TravelFeed and Wire 9 .0401.56515.90 15.25 14.60 13.95 13.30 12.70 625 600 12.10 575 11.45 550 10.80 525 500 10.15 min. 475 9.50 450 8.90 425 8.25 7.60 152.5 min. 400 144.5 7.00 137.5 375 6.35 Metres/ 350 129.5 5.70 122.0 325 5.10 2.54 300 4.90 114.0 2.41 min. 275 Inches/ 107.0 2.29 4.55 250 4.30 99.0 2.16 225 91.5 2.03 4.05 200 3.80 84.0 1.900 254.0 Metres/ 76.5 241.0 1.775 min. 3.55 228.5 3.30 69.0 190 1.650 57.9 60.9 216.0 1.525 3.05 180 54.9 203.0 2.80 170 1.400 Inches/ 2540 51.9 190.0 1.275 2410 160 48.6 min. 177.5 2285 150 1.150 45.6 165.0 1.015 2160 .965 140 42.6 Metres/ 152.5 2030 .915 130 39.6 140.0 1900 500 .865 120 36.6 127.5 475 1775 .810 110 33.6 450 115.0 1650 .760 30.6 min. 101.5 425 1525 .710 27.3 96.5 Inches/ 400 24.3 1400 .660 91.5 375 1275 .610 21.3 86.5 350 18.3 1150 .560 81.0 100 325 1015 .510 15.3 76.0 95 12.3 300 .455 965 71.0 90 .405 9.0 276 915 66.0 85 7.5 250 .355 865 61.0 80 .305 4.5 6.0 225 810 56.0 75 200 .255 .205 760 51.0 70 190 45.5 710 .150 65 180 40.5 .125 660 60 170 35.5 610 .075 .100 55 160 30.5 560 50 150 25.5 510 20.5 45 Metres 455 140 40 15.0 405 130 12.5 38 355 120 36 10.0 305 7.5 110 Metres 34 255 100 205 32 perhour 90 150 30 80 125 28 70 100 26 60 permin 75 24 cm 50 40 22 20 30 25 18 permin 16 20 15 mm 14 12 permin 10 8 perhour 6 Feet 5 4 3 per min Inches nhsmn x25.4=mm/min. Inches/min. x.6=Metres/Hour mm/min. TECHNICAL AND TRADE INFORMATION 405 6 3 2 -1 -2 -3 -6 Name PrefixMegaKiloHectoDecadecicentimillimicro Symbol M k h da d c m Value µ x10 x10 x10 x10 x10 x10 x10 x10 GaGd Gallium Gadolinium Po Pm Polonium Promethium CsCu CaesiumDy CopperEr DysprosiumEs ErbiumEu EinsteiniumF EuropiumFe FluorineFm IronFr Ne Fermium No Ni Neon Francium Nobelium Nickel O Np Os Neptunium Oxygen Osmium Ph Pb Phosphorus Pa Pd Lead U Protactinium Tl Palladium Tm Uranium V Thallium Thulium W Vanadium Xe Tungsten Y Xenon Yb Yttrium Zr Ytterbium Zn Zirconium Zinc CaCd CalciumCe CadmiumCf CeriumCl Chlorine CaliforniumCmCo CuriumCr Cobalt Chromium Md Mg Mendelevium Magnesium Mo Mn N Molybdenum Manganese Nitrogen Na Sodium Nd Nb Sn Neodymium Niobium Sr Tin Tb Strontium Ta Terbium Tc Tantalum Technetium Ti Te Th Tellurium Titanium Thorium AsAt ArsenicAu AstatineB GoldBa BoronBe BariumBi BerylliumBk BismuthBr BerkeliumC Ho Bromine I Holmium Carbon Iodine In Ir K Kr Indium Iridium Krypton Potassium La Li Lanthanum Lithium Lr Re Lu Lawrencium Rhenium Lutetium Rh Rhodium Rn S Ru Sb Radon Sc Sulphur Ruthenium Antimony Se Scandium Si Selenium Silicon Sm Samarium Ac ActiniumAgAl SilverAm AluminiumAr Americium Argon Ge Germanium He H Hf Helium Hafnium Hydrogen Hg Mercury Pr Praseodymium Pu Pt Ra Plutonium Platinum Radium Rb Rubidium Symbols for Elements Metric Multiplying Factors Metric TECHNICAL FACTS AND FIGURES FACTS TECHNICAL www.cigweld.com.au 406 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au Chart showsapproximatenumberofCOMWELDweldingrodsperkg. *In cal/gm˚C TECHNICAL FACTS AND FIGURES aaim()5.513 .1 6.0 7.29 19.3 4.5 0.115 0.056 0.034 0.126 1730 232 3380 1660 50.95 118.70 183.92 47.90 Vanadium (V) Tungsten (W) Titanium (Ti) Tin (Sn) 6.68 2.78 0.050 0.211 630 660 121.76 26.97 Antimony (Sb) Aluminium (Al) elru T)176 5 .4 6.24 0.048 452 127.61 Tellerium (Te) ic(n 53 1 .9 7.1 18.7 0.094 0.028 419 1132 65.38 238.07 Zinc (Zn) Uranium (U) 3.75 0.068 704 137.36 Barium (Ba) totu S)8.370-2.6 0.971 10.5 0.862 12.41 8.9 - 21.45 0.296 0.056 13.56 0.177 10.0 0.058 11.37 7.44 0.109 1.74 770 0.032 22.65 98 961 19.32 0.033 7.87 63 1960 0.065 8.93 8.6 0.031 1453 0.107 1769 0.245 87.63 22.991 107.88 6.92 7.1 0.031 0.031 1.55 0.109 -39 1.87 102.91 2625 0.093 39.1 0.103 327 1240 58.69 195.09 8.64 9.80 650 Strontium (Sr) 2443 0.045 0.111 1063 Sodium (Na) 0.158 200.61 1535 Silver (Ag) 0.054 95.95 1083 Rhodium (Rh) 1492 207.21 Potassium (K) 54.94 0.056 0.030 Platinum (Pt) 24.32 1800 192.2 Nickel (Ni) 804 197.0 Molybdenum (Mo) 850 55.85 Mercury (Hg) 63.54 30 58.94 Manganese (Mn) Magnesium (Mg) 321 271 Lead (Pb) 140.13 52.01 Wrought(Fe) Iron, 40.08 Iridium (Ir) 132.91 Gold (Au) Copper (Cu) 112.41 209.00 Cobalt (Cp) Chromium (Cr) Cerium (Ce) Calcium (Ca) Caesium (Cs) Cadmium (Cd) Bismuth (Bi) lmn n tmcMlig*pcfcDensity *Specific Point Melting Weight Atomic Symbol Element and Physical Properties ofMetals Comweld Rodsperkg. m(5 m rne(5 m 1mte (700mm) CastIron Aluminium (1metre) Bronze (750mm) Copperand (750mm) Steel mm Diameter . . 24.3 8 - - - 12 19 46 82 185 5 8 19 34 68 5.5 9 21 37 84 6.3 5.0 3.2 2.4 1.6 ˚ etgms/cm3 Heat C TECHNICAL AND TRADE INFORMATION 407 3000 kg load test) reading (direct MPa Strength 750800850900950100011001200 615 625 640 - - - - - 62 64 66 67 68 69 71 72 ------540560580600620640660680 505700 520725 535 520 535 550 565 580 590 605 52 53 54 55 56 57 58 59 60 1739 61 1802 1868 1922 1984 2015 2069 2108 2150 - 340360380400420440460480 320500 340520 360 380 395 415 435 450 470 485 34 37 39 41 43 45 46 48 49 1102 51 1166 1231 1290 1355 1417 1481 1546 1610 1674 180200220240260280300320 170 190 210 230 250 265 285 305 - - - 20 24 27 30 32 598 658 723 780 850 923 972 1041 100120140160 95 115 135 150 - - - - 327 393 455 527 (diamond pyramid) H.V. 30 kg load HRc Vickers hardnessVickers Brinell (steel ball HB) Rockwell hardness Approx. Tensile Comparison of Hardness Scales of Hardness Comparison TECHNICAL FACTS AND FIGURES FACTS TECHNICAL NOTE: only approximate. quoted are Figures www.cigweld.com.au 408 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au TECHNICAL FACTS AND FIGURES MASSES OFCOMMONMETALS noe .582 8.52 8.80 8.85 8.52 8.52 8521 8.71 8810 8.94 8858 8521 8521 8.30 8.82 7.30 8.55 8.11 8730 8.85 8970 8.91 7.58 4.51 8.44 7.72 7.93 8.55 11.37 8.55 8329 1.74 8842 6.86 7304 8089 2.7 8.75 8.95 Inconel 7576 4517 8.9 8.91 Monel 7.85 7720 11373 7929 Nickel 8441 1746 8.35 8.85 6887 Cusilman 7.67 Everdur 2691 7.30 8.15 Nickel Silver Cupro-nickel 7.61 4.51 8899 8938 7849 Manganese bronze 11.34 7.75 7.93 Phosphor bronze 1.74 Aluminium bronze 7.14 7688 8.41 Stainless Steel(27%Cr) 2.69 Stainless Steel(16%Cr) Stainless Steel(18/8) 8.89 Tin 8.94 7.85 Titanium Magnesium 7.68 Lead Aluminium Zinc Brass Tin Bronze Copper Steel Cast Iron pcfcGaiykg/m Specific Gravity 3 gms /cm 3 TECHNICAL AND TRADE INFORMATION 409 C) ˚ C ˚ F ˚ 154.4 158.0 161.6 165.2 168.8 172.4 176.0 179.6 183.2 186.8 190.4 197.6 201.2 204.8 107.6 111.2 114.8 118.4 122.0 125.6 129.2 132.8 136.4 140.0 143.6 147.2 150.8 152.6 156.2 159.8 163.4 167.0 170.6 174.2 177.8 181.4 185.0 188.6 194.0 195.8 199.4 203.0 109.4 113.0 116.6 120.2 123.8 127.4 131.0 134.6 138.2 141.8 145.4 149.0 105.8 C F ˚ 68 70 72 74 76 78 80 82 84 86 88 92 94 96 42 44 46 48 50 52 54 56 58 60 62 64 66 ˚ 67 69 71 73 75 77 79 81 83 85 87 90 91 93 95 43 45 47 49 51 53 55 57 59 61 63 65 41 C in the left column, or 10 ˚ C ˚ number, equals -12.2 x ˚C ) + 32 numbers) and read to the left side for degrees Celsius ( side for degrees Celsius and read to the left numbers) 9 bold bold F, the reading ˚ x ( ˚F - 32 ) ˚F = ( F 95 5 ˚ 53.657.260.864.468.0 20.0 71.6 21.1 75.2 22.2 78.8 23.3 82.4 24.4 86.0 25.6 89.6 26.7 27.8 96.8 28.9 100.4 30.0 104.0 31.1 33.3 34.4 35.6 -184-148-112-76-40 6.67 -4 7.78 32 8.89 35.639.2 10.0 42.8 11.1 46.4 12.2 50 13.3 14.4 15.6 16.7 17.8 18.9 -220 5.56 98.6102.2 33.9 35.0 51.855.459.062.666.2 19.4 69.8 20.6 73.4 21.7 77.0 22.8 80.6 23.9 84.2 25.0 87.8 26.1 91.493.2 27.2 95.0 28.3 29.4 30.6 31.7 32.2 32.8 89 192.2 -202-166-130-94-58 6.11 -22 7.22 14 8.33 33.837.4 9.44 41.0 10.6 44.6 11.7 48.2 12.8 13.9 15.0 16.1 17.2 18.3 -238 5.00 F). eg. 10 ˚ F in the right column. ˚ C F ˚ 12 14 16 18 20 22 24 26 28 30 32 36 38 40 -120 -100 -80 -60 -40 -20 0 2 4 6 8 10 -140 37 39 11 13 15 17 19 21 23 25 27 29 31 33 34 35 -130 -110 -90 -70 -50 -30 -10 1 3 5 7 9 -150 ˚ number, equals 50 bold C -11.1 -10.0 -8.89 -7.78 -6.67 -5.56 -4.44 -3.33 -2.22 -1.11 0 2.22 3.33 4.44 -84.4 -73.3 -62.2 -51.1 -40.0 -28.9 -17.8 -16.7 -15.6 -14.4 -13.3 -12.2 -95.6 2.78 3.89 -3.89 -2.78 -1.67 -0.56 0.56 1.11 1.67 -11.7 -10.6 -9.44 -8.33 -7.22 -6.11 -5.00 -23.3 -17.2 -16.1 -15.0 -13.9 -12.8 -90.0 -78.9 -67.8 -56.7 -45.6 -34.4 ˚ -101 TEMPERATURE CONVERSIONS TEMPERATURE TECHNICAL FACTS AND FIGURES FACTS TECHNICAL TEMPERATURE CONVERSION FORMULA:TEMPERATURE ˚C = To find a temperature conversion, find a temperature To column (the read the centre or the right side for degrees Fahrenheit ( degrees Fahrenheit or the right side for reading the www.cigweld.com.au 410 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au or therightsidefordegreesFahrenheit ( reading the ofn eprtr ovrin readthecentrecolumn(the To findatemperatureconversion, EPRTR OVRINFRUA ˚C= TEMPERATURE CONVERSIONFORMULA: TECHNICAL FACTS AND FIGURES TEMPERATURE CONVERSIONS 266 254 243 232 221 210 199 188 177 166 154 143 132 121 110 100 93 82 71 60 49 38 36.7 271 260 249 238 227 216 204 193 182 171 160 149 138 127 116 104 99 88 77 66 54 43 37.2 36.1 ˚ C bold ubr equals482 number, 510 490 470 450 430 410 390 370 350 330 310 290 270 250 230 212 200 180 160 140 120 100 98 520 500 480 460 440 420 400 380 360 340 320 300 280 260 240 220 210 190 170 150 130 110 99 97 ˚ ˚ F C ˚ F intherightcolumn. ˚ ) g 250 eg. F). 5 527 516 504 493 482 950 471 914 460 878 449 842 438 806 427 770 416 734 404 698 393 662 382 626 371 590 360 554 349 518 338 482 327 446 316 413 304 392 293 356 282 320 284 248 212 208.4 6 532 521 510 499 488 968 477 932 466 896 454 860 443 824 432 788 421 752 410 716 399 680 388 644 377 608 366 572 354 536 343 500 332 464 321 428 310 410 299 374 288 338 277 302 266 230 210.2 206.6 ˚ 5 95 F x (˚F-32)= ˚ ,readingthe F, bold 9 bold numbers) andreadtotheleftsidefordegreesCelsius( x ˚C)+32 ubr equals121 number, ˚ 538 C ˚ ntelf oun or10 C intheleftcolumn, 1000 ˚ 980 960 940 920 900 880 860 840 820 800 780 760 740 720 700 680 660 640 620 600 580 560 540 ˚ 990 970 950 930 910 890 870 850 830 810 790 770 750 730 710 690 670 650 630 610 590 570 550 530 F C 1832 1796 1760 1724 1688 1652 1616 1580 1544 1508 1472 1436 1400 1364 1328 1292 1256 1220 1184 1148 1112 1076 1040 1004 1814 1778 1742 1706 1670 1634 1598 1562 1526 1490 1454 1418 1382 1346 1310 1274 1238 1202 1166 1130 1094 1058 1022 986 ˚ F ˚ C ˚ C) TECHNICAL AND TRADE INFORMATION 411 ft lbf 120 110 100 90 80 70 60 50 40 30 20 10 0 0 90 80 70 60 50 40 30 20 10 160 150 140 130 120 110 100 joules 9 8 7 6 5 4 3 2 1 0 17 16 15 14 13 12 11 10 kgfm 2 kgf/mm 140 135 130 125 120 115 110 105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 2 0 90 80 70 60 50 40 30 20 10 200 190 180 170 160 150 140 130 120 110 100 lbf/in (x 1000) 2 STRENGTH CONVERSIONSSTRENGTH ENERGY CONVERSIONS IMPACT 5 0 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 tonf/in 0 50 950 900 850 800 750 700 650 600 550 500 450 400 350 300 250 200 150 100 1400 1350 1300 1250 1200 1150 1100 1050 1000 MPa TECHNICAL FACTS AND FIGURES FACTS TECHNICAL STRENGTH AND IMPACT ENERGY DATA - CONVERSIONS DATA ENERGY AND IMPACT STRENGTH www.cigweld.com.au 412 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au oe 15psi=100kPa Note: temperature. prolongedperiods producingacolourindicativeofhigher been attemperatureforalimitedperiod, They alsoapplyonlywhenthesteelhas These coloursareasseenbydaylightandapplytoplaincarbonsteels. efehygon,andcareshouldbetaken toavoidapplyingheatdirectlythegroundsurface. be freshlyground, Inordertoobtainareasonableresultthesurfaceshould below applyonlytoplaincarbonorlowalloysteels. andthecolourstemperaturesindicated various alloyingadditionscanhaveamarked effectonoxidation, shouldbenotedthat It andvary incolour withtemperature. the materialduetoextremelythinoxidefilms, These arecoloursproducedonacleansurfaceof of temperaturemaybeobtainedbytheusetempercolours. anapproximateidea however, Where thesearenotavailable, combining reasonableaccuracywithconvenience. theuseoftemperature-indicatingcrayonsisstronglyrecommendedas Where preheatingisrequired, TECHNICAL FACTS AND FIGURES TEMPER COLOURS TEMPERATURE INDICATION Gas Pressures -Gas Welding andCutting rsuewe ul15 P Apo.200psi) (Approx. 2000psi) (Approx. (30psi) 1550kPa (15psi) 13700kPa (15psi) (15psi) 200kPa Pressure whenfull Acetylene cylinder: 100kPa Pressure whenfull 100kPa Oxygen Cylinder: 100kPa Oxygen Pressure Acetylene Pressure (Manual) Gas Cutting: Oxygen Pressure Acetylene Pressure Gas Welding: rys le340 280 300 230 Greyish Blue Cornflour Blue Violet Dark Straw aeBu 320 290 220 250 200 Pale Blue Dark Blue Brownish Red Straw Pale Straw ˚ ˚ ˚ ˚ ˚ ˚ ˚ ˚ ˚ C C C C C C C C C TECHNICAL AND TRADE INFORMATION 413 crystalline form colourless liquid Heavy, colourless, viscous liquid powder powder Clear, bitter liquid White powder White crystalline subst. White powder; Marble- White powder White powder smelling of chlorine Fine, heavy red powder Colourless crystals Small purple crystals O Large white crystals O Large, colourless crystals 2 2 O crystals Small colourless O Large blue crystals 2 O Green crystals 2 2 1OH 1OH 3 2 2 7H 3 4 5H 2 4 4 3 7H 3 4 4 4 4 3 OH Strongly fuming liquid Cl White crystalline solid COOH Brown liquid SO CO O 4 4 3 2 2 O Colourless gas 3 SO 2 2 Hydroxide chlorite Coke, Charcoal Carbon (impure) Cblack solid Brittle Green Vitriol Iron sulphate FeSO Liquid Ammonia Ammonium Hydroxide NH LithargeRed leadSal Ammoniac LimeSlaked Vinegar Ammonium Chloride Lead MonoxideTetroxide Triplumbic Calcium Hydroxide NH Pb Acetic Acid (weak) PbO Ca(OH) CH Orange powder Chile SaltpeterGlauber SaltsLaughing GasLimewater Sodium Nitrate Sodium Sulphate Nitrous Oxide NaNO Solution of Calcium Na N Ca(OH) Bluestone (Blue Vitriol)Bluestone (Blue Caustic Soda Copper SulphateEpsom Salts Sodium Hydroxide CuSO Magnesium Sulphate NaOH MgSO Deliquescent White Muriatic Acid or,Acid Muriatic Spirits of Salts Oil of VitriolBlack leadAcid Hydrochloric Bleaching powder Sulphuric Acid Calcium chloro-hypo HCl Carbon or Graphite CaOCI H fuming Strongly C Black powder Baking soda Sodium Bicarbonate NaHCO Chalk, Limestone, Calcium Carbonate CaCO Caustic Potash Hydroxide Potassium KOH White Deliquescent Washing SodaWashing Sodium Carbonate Na Condies Crystals Permanganate Potassium KMnO Lime (quicklime) Calcium OxideSaltpeter (Nitre) Nitrate Potassium CaO KNO powder White Marble (more or less) CHEMICAL NAMES AND FORMULA OF COMMON NAMES OF COMMON AND FORMULA NAMES CHEMICAL NAMECOMMON CHEMICAL NAME FORMULA DESCRIPTION TECHNICAL FACTS AND FIGURES FACTS TECHNICAL www.cigweld.com.au 414 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au TECHNICAL AND TRADE INFORMATION 415 www.cigweld.com.au 416 TECHNICAL AND TRADE INFORMATION www.cigweld.com.au