STRENGTH THROUGH COOPERATION

Repair and maintenancewelding

2

Welding, an important repair method

The descriptions include details of

recommended consumables:

•MMA:OKcoveredelectrodes

•MIG/MAGwelding:OKAutrodsolid

wires

• FCAW:OKTubrodurflux-cored

wires

• TIGwelding:OKTigrodwires

Furtherinformationaboutrepair

weldingcanbefoundinESAB’sRepair

andMaintenanceWeldingHandbook.

ESAB’srangeofweldingconsumables

isoneofthemostextensiveinthe

market.Thewelding

consumables

catalogueprovides

detailed information

about product

information and

comprehensive

selection charts for

differentmaterials.

Furtherproduct

information can be

found on your local

ESABwebsite

underProducts/

Welding

consumables.

Thecataloguefeaturessome450

individualconsumables.

A. Consumablesformildsteels

B. Consumablesforlow-alloyedsteels

C. Consumablesforstainlessand

high-alloyedsteels

D. Consumablesforaluminiumalloys

E. Consumablesfornickel-based

alloys

F. Consumablesforcopper-based

alloys

G. Consumablesforcastiron

H. Consumablesfordissimilar

materials

I. Consumablesforhardfacing

J. Specialproducts

ESAB’sconsumablesfactorieshave

variousinternationalcertifications,

includingISO9001certifiedquality

managementsystems,manufacturer/

productapprovalsrequiredbythe

EuropeanPressureEquipment

Directiveandthe

ConstructionProduct

Directive,andISO

14001/OHSAS

18001certified

environmental,health

and safety

programmes.

Occupationalhealth

and fire safety must

begivenappropriate

consideration in

repairwelding.

Workingconditions

areoftenworsecomparedtonormal

productionenvironments.Information

about the health and safety aspects of

weldingconsumablesisprovidedin

thesafetydatasheetofeachproduct.

The sheets can be printed from your

localESABwebsite.

Weldingisthemostcommon

methodofjoiningmetals,widely

appliedinworkshopsforthe

manufactureofproducts.Welding

is also an important repair method

forrestoringdamagedandworn

workpiecesandotheritems.

Thisbrochureprovidesanoverview

of common applications of repair

andmaintenancewelding:

• Gougingandcutting

• Difficult-to-weldsteels

•Weldingdissimilarmetals

• Surfacingandhardfacing

•Weldingcastiron

•Weldingwearresistantsteels

•Weldingaluminium

An overview of repair

and maintenance

applications

• Basicsofrepairwelding

• Weldinginstructionsfor

different materials

• Hardfacing

• Illustratedapplications

• Consumablesproduct

data

• Applicationindex

3

Cr-ekv = %Cr + %Mo + 1,5%Si + 0,5%Nb

Ni-

ekv

= %

Ni +

30%

C +

0,5

%M

n

0

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

M+F

A + M

A+M+F

A+F

5 %

10 %

20 %

40 %

80 %

100 %

(1)

(A)(A1)

(2)

(B1)

(B)

(3)

Ferrite

Austenite

Martensite

0 %

Fer

rite

Schaeffler diagram. (1) Non-alloy steel S355,

(2) stainless steel AISI 316L, (3) dissimilar weld

welded without consumables, (A) electrode OK

48.00 for mild steels and (A1) its dissimilar weld,

(B) over-alloyed electrode OK 67.70 and (B1)

its dissimilar weld.

Gouging electrode OK 21.03

Thegougingandcuttingelectrodeis

commonly used in repair applications

fortheremovalofwelddefects,for

removingcrackspriortowelding,for

preparinggroovesandholesandfor

cuttingsheetsandbars.Thearc

gougingelectrodeisequallysuitable

fornon-alloyedsteelsandstainless

steels,castiron,aluminiumandcopper

alloys,exceptpurecopper.

Arcgougingisbasedonthesame

principleastheweldingelectrode;the

arcburnsbetweentheendofthe

electrodeandtheworkpiece.However,

thespecialcoatingofthearcgouging

electrodeformsapowerfulgasspray

whichblowsawaythematerialmelted

bythearc,providingashapesuchas

agroove.Theworkcanbecarriedout

usingordinaryMMAwelding

equipment;compressedairorspecial

electrodeholdersarenotrequired(air

carbonarcgouging).Theseelectrodes

requireveryhigharcvoltagestowork

properly.Whilecarbonarcgougingisa

lotmoreeffectiveatremovingmaterial,

itrequiresspecialequipmentanda

compressedairsupplywhichmaynot

bealwaysavailable.

Electrodediametersare2.5–5.0mm;

thevoltagerangeis130–180Ampsfor

aØ3.2mmelectrodeand170–230

AmpsforaØ4.0mmelectrode.The

arcisinitiatedbystrikingtheelectrode

moreorlessat90degreestothework

Gouging and cutting electrode

Dissimilar metals

piece and once the arc is

established the electrode must

havea10to15degreeinclination

totheworkpiece.Immediately

thereafteritshouldbemoved

rapidlybackandforthatthe

sametimemovinginthedirection

ofthedefect..Deepgroovescan

bemadebyrepeatedgouging.

Normally,weldingcanfollow

withoutfurtherpreparation;

however,whengougingstainless

steel,thecarbonisedsurfacelayer

shouldberemovedbygrinding.

Consumables

Theproductrangeincludesanumberofoveralloyedconsumables.

• 18%Cr-8%Ni-6%Mn(AWS307)

OK67.45

OKAutrod/Tigrod16.95

OKTubrod14.37

OKTubrod15.34

• 23%Cr-13%Ni

CrNioveralloyed(AWS309L)

OK67.60

OKAutrod/OKTigrod309LSi

Shield-Bright309L,309X-tra

• 23%Cr-13%Ni-3%Mo

Cr-Nioveralloyed(AWS309MoL)

OK67.70

OKAutrod/OKTigrod309MoL

Shield-Bright309MoLX-tra

•A high Ni alloy

Adissimilarjointofheat-resistingCrMosteelandstainlesssteel(forhightemperatures)

OK92.26

OKAutrod/Tigrod19.85

Inmanyapplications,thereisoftena

needtojoinnon-orlow-alloyedsteel

withausteniticstainlesssteel,e.g.

S355/AISI316.Thesearecalled

dissimilarjoints.Withtherightchoice

ofconsumables,thesejointsareeasy

toweld.Suitablefillermaterialsare

overalloyedstainlessconsumables

whichgiveaweldmetalthatmixes

withnon-stainlesssteeltoformahigh-

tensileausteniticoraustenitic-ferritic

welddespitebeing“tempered”.When

selectingconsumables,theSchaeffler

diagramcanbeusedtodeterminethe

microstructureoftheweld.

4

Bevel gear repair.

Drive shaft repair on a

heavy duty vehicle.

Repair of a broken

driveshaft.

Repair of a broken trans-

former support.

Removing a broken bolt. Hydraulic ram.

Repairandmaintenanceweldingoften

involvesrepairingso-called“difficult-to-

weld”steels.Theseincludehigh

carbonsteels,quenchedand

temperedsteels,tool-makingsteels,

wearresistantsteelsandspringsteels.

“Unknown”steelsareoftenincludedin

thisgroup–asaprecaution,ifthe

compositionisnotknownorthetype

ofsteelisunclear,thesesteelsshould

betreatedasdifficult-to-weldsteels.

Typicalapplicationsincludeshafts,

gears,machinecomponents,etc.

Intermsofweldability,acommon

characteristic of these steels is their

hightendencytohardenalongwith

hardandbrittleHAZstructures,which

resultinahighcrackingtendency

duringwelding.Preventingthese

requirespreheatingorpostheat

treatment,whichisoutofthequestion

inmanyrepaircases.

Weldingwithausteniticstainlessor

nickel-basedconsumablesisa

commonandeffectivemethodof

preventinghydrogencracks(cold

cracks).Theseweldmetalstolerate

highdilution,andtheyhaveahigh-

tensileausteniticoraustenitic-ferritic

microstructure.Furthermore,the

solubilityofhydrogen–thesourceof

cracking–issohighthatitstopsthe

damaginghydrogenfromenteringthe

heataffectedzone(HAZ),thereby

preventingtheformationofcracks

despitethehardeningoftheHAZ.The

most commonly used consumable in

repairweldingisaustenitic-ferritic

stainlesssteel29%-9%Ni.

Thereareotherinterestingapplications

fortheseconsumables,suchas

removingabrokenboltwithan

electrode,orrepairingascratched

hydrauliccylinderpiston.Anewbolt

headisbuiltontopofthebroken-off

bolt;thiscanthenbeusedtoturnthe

boltandpullitoutofthehole.

Scratchesonhydraulicramscanbe

builtupandgroundsmooth.

Difficult-to-weld steels

Consumable29%Cr-9%Ni(AWS312)

• Auniversalconsumableforrepairwelding

• Theweldmetalhasahightoleranceforimpurities

• Theweldmetaltolerateshighdilution

OK68.82:the“miracleelectrode”ofrepairwel-ding

OKAutrod312/OKTigrod312

18%Cr-8%Ni-6%Mn

• Ahigh-tensileweldmetal(AWS307)

OK67.45

OKAutrod16.95/OKTigrod16.95

OKTubrodur14.71,alsowithout shieldinggas

A high Ni alloy

• Thehighesttensilestrenghofallweldmetals

• Lowestcracksensitivity

OK92.26

OKAutrod19.85/OKTigrod19.85

5

Marinedieselexhaustmanifold.Newprice€ 820.00.

Repaired for € 225.00 Exhaustoutlet.Nosparesavailable.Repairnecessary.

Castironsareironalloyswhichcontain

2–5%carbonandsomesiliconand

manganese.Certaincastirongrades

mayalsocontainotherelements.The

mostcommongradesaregreycast

ironandductileiron.Graphite(carbon)

growsasflakesingreycastironand

asspheresinductilecastiron.Welding

castironisdifferentfromsteelwelding,

andmostcastirongradesaredifficult

toweld.Castironshavealowtensile

strengthanddeformabilitywhich

makesthembrittle.Forthatreason,

weldingstressescaneasilycause

cracksandflawsinweldjoints.Cast

ironhardenseasilyattheHAZaround

theweld.Inaddition,pieceswhich

needrepairingwilloftenhave

absorbedoilorothercontaminants,

whichalsomakesweldingdifficult.

Weldingisneverthelesspossible,and

cast iron pieces are commonly

repairedbywelding.

CastironisnormallyMMAweldedby

cold-weldingwhichmeansgenerating

aslittleheatasaspossibleinthework

piece.Inpractice,thismeanswelding

shortbeadsandhammeringthem

lightlytoreleasestresses.After

welding,eachmustbehandwarm

untiltouchablebeforeweldingthenext

beadinordertoreducestresses.

Bufferingisbeneficialinsomecases;

thisinvolvessurfacingthejointfaces

beforecompletingtherestofthejoint

ifpossible.Iftheworkinvolves

repairingacrack,holesshouldbe

drilledateachendofthecrackto

preventitfromprogressingfurther.

Nickelornickel-ironelectrodesare

used,sincetheseprovideasoft,high-

tensileandmachinableweldmetal.

Weldsshouldbestressrelievedby

peening.

Cast iron

Consumables for welding

cast iron

Ni consumable

• AslightlysofterweldthanNiFe

OK92.18

NiFe consumable

• AslightlystrongerweldthanNi

• LesssensitivetoimpuritiesthanNi

• CheaperthanNi

OK92.58orOK92.60

Nicore55,coredwire

6

Wear resistant steels

onlythesheetthicknessbutalsothe

hydrogencontentandheatinputof

theweld.Roughvaluesare:

400HB:

• fromapprox.20mm:75-150ºC

(dependingonplatethickness)

500HB:

• fromapprox.10mm:100-200ºC

(dependingonplatethickness)

RautaruukkiandSSABhaveproduced

goodbrochuresontheweldingof

thesesteels.

Consumablesareselectedonacase-

by-casebasisdependingonthe

propertiesrequiredfromtheweld.

Generally,softandhightensile

consumablessuchasOK48.00and

correspondingwiresareusedinjoint

welding.Theweldsareoftenlocated

inplaceswherethesesofter

consumablescanbeused.

Especiallywhenweldinglarge

thicknessofwearresistantsteel,the

needforpreheating–whichisrequired

forhardersteelgradesininstallation

conditions–canbeeliminatedby

usingausteniticstainless

consumables;themostcommonof

theseisthe18%Cr-8%Ni-6%Mn

composition.Ifahighstrengthweldis

required,low-alloyedhighstrength

consumablesareused,butforroot

runsnon-alloyedconsumablesshould

beused.Ifahighlywearresistantweld

isrequired,hardfacingconsumables

areusedtoprovidesuitablehardness

inthefinalpass,whenfillerpassesare

madewithsoftconsumables.Despite

theirhighresistanceagainstabrasion,

thesewearresistantsteelsmay

sometimesrequirehardfacingto

improvethewearresistanceofthe

surface-inmostcasesonlylocally.In

thiscase,weldingahigh-tensilebuffer

layerbeforehardfacingprevents

crackingofthebasemetalorthe

hardfacingweld,anditalsoprevents

thehardfacingweldfromcoming

loose.Suitableconsumablesare

austenitic stainless consumables such

as18%Cr-8%Ni-6%Mn(”AWS307”)

or23%Cr-13%Ni(”AWS309L”).

Consumablessuitableforhardfacing

includehardenable,highchromium

contentalloysteelsandsimilar,see

page9.

Wearresistantsteelsareusedin

applicationswherethewearresistance

providedbyregular,reasonablysoft

structuralsteelsisnotenough.Typical

applicationsincludestructureswhichare

exposedtoabrasionfromsoil,rockor

gravelinlocationssuchasquarries,

mines,loadersandearthmovers,e.g.

conveyors,lipshrouds,dumper

platforms,screens,chutes,etc.Modern

wearresistantsteels,suchas

Rautaruukki’sRaex400/500andSSAB’s

HARDOX400/500(thenumberrefersto

thesurfacehardnesswhichis400or

500HB)areeasytoweld.

RAEXAR400istwotothreetimesmore

wear-resistantandthe500isthreeto

fourtimesmorewear-resistantthan

structuralsteelS355.Wearresistant

steels are normally hardened and

sometimesquenched(i.e.temperedand

quenched).Duetothehardenabilityof

wearresistantsteels,thickersheets

mustbepreheatedtopreventcracking.

Theneedforpreheatingdependsonnot

Typical applications for wear resistant steels.

Consumable

• Undermatching(soft/tough)non-alloysteel

OK48.00

OKAutrod12.51

• Overalloyedstainlesssteel

18%Cr-8%Ni-6%Mn

OK67.45

OKAutrod16.95

OKTubrodur14.71

• Matchinglowalloyedsteel

OK75.75

OKAristoRod13.29

OKTubrod14.03ja15.09

• Hardfacingconsumable,

hardnessabout30-35HRC

OK83.28

OKAutrod13.89

OKTubrodur15.43

• Hardfacingconsumable,

hardnessabout50-60HRC

OK83.65

OKAutrod13.91

OKTubrodur15.50

7

Aluminium

Duetoitsleightweight,good

conductivity,highcorrosionresistance

andweldability,aluminiumiswidely

used in many industrial applications

fromshipbuildingtotransport

equipment,packingmaterials,andthe

electricalandaviationindustries.

Aluminiumisalight-weightmetal

whosespecificweightisapproximately

athirdofthatofsteel.

Aluminiumweldingisverycommon.

Productionweldinggenerallyinvolves

MIGorTIGwelding.MMAweldingis

usedrarely,generallyinsmallrepair

applicationsandespeciallywhengas-

shieldedarcweldingcannotbeused

orequipmentisnotavailable.

Themeltingpointofaluminiumis

around600°C.Aluminium’sthermal

conductivityisfourtimesthatofsteel,

whichmeansthatarelativelyhigh

amountofheatisrequiredwhen

weldingaluminium.Thickmaterials

requirepreheating.Thethermal

expansioncoefficientofaluminiumis

approximatelytwiceashighasthatof

steel,whichmeansthatdistortionfrom

weldingissimilarlyhigher.

Duetoitsgoodcorrosionresistance,

the aluminium surface has an

extremelythinoxidefilmwithamelting

pointofover2000°C.Thislayermust

beremovedfromtheapplicationarea

beforewelding–forexample,usinga

stainlesssteelbrush–andits

reformationduringweldingmustbe

prevented.InMIGandTIGwelding,

thearcbreakstheoxidefilmandthe

inertshieldinggas(argon)preventsits

formation.InMMAwelding,theflux

coatingoftheelectrodedissolvesthe

oxidefilmandprotectstheweldpool.

Propercleaningoftheweldingareais

important,asaluminiumishighly

susceptibletoporesintheweld.The

porosityisduetotheveryhigh

solubilityofhydrogeninmolten

aluminium.Astheworkhardens

rapidly,someofthedissolvedgases

remainintheweldandformpores.

Manyaluminiumalloysarefairly

susceptibletoheatcracks,which

meansthattheweldiseasilycracked

astheweldpoolhardens.Forthat

reason,therightchoiceof

consumablesisimperativetoavoid

creatingacracksensitivecomposition

intheweldpool.

Inadditiontopurealuminium,there

aredifferentaluminiumalloys,such

asAlMn,AlMg,AlSiandAlMgSi.

Recommendedconsumablesfor

aluminium alloys are specified in

thetableonpage11.

The consumable is chosen based

ontheworkpiecealloy.Dueto

theirhighcorrosionresistanceto

seawater,AlMgalloysareoften

referredtoassea-water

aluminiums,andtheyareusedin

boatsandships.

Consumables for aluminium

Consumable alloy type: AlSi12

• Usedforcastalloys

OK 96.50

OK Autrod/OK Tigrod 4047

Consumable alloy type: AlSi5

• UsedforAlMgSialloys

OK Autrod/OK Tigrod 4043

Consumablealloytype:AlMg5

• UsedforAlMg3,AlMg5 andAlMgSialloys

OK Autrod/OK Tigrod 5356

8

should be determined first before

choosingtheconsumable.

Abrasive wearoccurswhenhard

particlesslideacrossametalface,

removingmaterialfromthesurface.

Increasingthesurfacehardness

usuallyreduceswear.Suitable

consumablesincludehigh-carbon

contentalloysteelswhichprovidea

hardweld,i.e.ithardensduring

coolingafterwelding.Themost

commonalloyingelementsare

chrome,molybdenum,tungstenand

vanadium.Withmanyalloying

elements,carbonformscarbides

whosehardnesscanbeashighas

3000HV.

Metal-on-metalwear occurs

whentwometalsurfacesslide

againstoneanother–forexample,

inrotatingordraggingmetal

surfaces.Thehighsurfacepressure

betweentwometalsurfaces

generatessmallscale“microwelds”

(sticking).Asthemotioncontinues,

theweldfailsonthesideofthe

weakerbasemetal,causingsurface

wear.Low-alloysteelsaresuitable

foranti-wearapplications.

Impact wear occurswhenametal

surfaceissubjectedtoimpactswhich

causelocalbreakagesordistortion,

suchasinrockcrushing.The

magnitudeofweardependsonthe

strenghandhardnessofthemetal.

Manganesesteelisacommonand

idealmaterialduetothework

hardeningofitssurface,whichmeans

that the surface hardness increases

whiletheinsideremainstough.

Corrosion(“rusting”)hasmany

forms.Itcanbeuniformacrossthe

surfaceorlocalised.Corrosion

removesmaterialfromthemetal

surface.Corrosioncanbeprevented

byusingcertainstainlesssteels

whichcontainasufficientlevelof

chromeandinmanycasesnickel

andmolybdenum.

Wearandtearcausesconsiderable

costsindifferentindustriesasworn-out

materialsandequipmentrequire

repairing.Surfacingisacommonlyused

methodforrepairingworn-outpieces

andextendingtheirlife.Surfacingisalso

ausefulmethodforextendingthe

servicelifeofnewpartsbeforetheyare

putintoservice.Surfacingisoften

referredtoashardfacing,eventhough

hardnessisnotalwaysdesirablein

termsofwearresistance.Hardfacing

specificallyreferstosurfacingusinga

hardandwearresistantconsumable.

Dependingontheapplication,softer

consumables and corrosion resistant

consumables can also be used for

surfacing.

Therearevariousformsofwear,and

thisshouldbethemainfactorwhen

choosingconsumables.Theformsof

wearcanbedividedintothefollowing

categories:abrasion,metaltometal,

impactwear,corrosionandhigh

temperatures.Thereforetheconditions

Surfacing and hardfacing

9

Cracks, e.g. OK 84.78 Cracks, e.g. OK 84.78 No crackse.g. OK 67.45

e.g. OK 84.78Transverse cracks in a hardfacing layer.

High temperaturesmakematerials

softerandoxidizestheirsurface.High

chromecontentpreventsthereduction

ofhardnesstogetherwithcertainother

alloyingelements.Highchrome

contentpreventsoxidisation.

Avastrangeofsurfacingconsumables

isavailablewithdifferentcompositions,

characteristics and micro structures

anditisnotalwayseasytochoosethe

bestorthemosthard-wearing

consumable.Thereisnosingle

universalmaterial;consumablesare

selectedonacase-by-casebasis

dependingontheconditions.

Iftheweldistobemachinedusing

cuttingtoolsafterwelding,thismust

betakenintoaccountwhenchoosing

consumables.Thehardnesslimitfor

machinabilityisapproximately40HRC,

althoughcertainhigh-powermachines

and steel bits can be used to machine

harderwelds.

Inhardfacing,preheatingisoften

requiredeithertopreventthe

hardeningbasemetalfromcracking–

i.e.theweldbeadbecomingdetached

–ortopreventthehardfacing

consumablefromcracking.

Thepreheatingrequirementsof

hardfacingconsumablesarespecified

ontheproductpageofthe

consumablescatalogues.Theriskof

crackingcanbereducedbysurfacing

(“buffering”)theworkpiecesurfacefirst

usingahigh-tensileausteniticstainless

Consumable

Hardness range: 30–35 HRC

• A“soft”hardfacingconsumable

• Highmachinability

• Metal-on-metalwear:Slipsurfaces,shafts,rollers,wheels,gears,etc.

OK83.28

OKTubrodur15.43,alsoØ1.2mmandwithoutshieldinggas

OKAutrod13.89,Ø1.0and1.2mm

Hardness range: 50–60 HRC

• Universalhardfacingconsumable

• Resistanttobothimpactsand abrasion

• Excavationandearthmoving machinery,agriculturalandforestrymachinery,feedworms,etc.

OK83.50,alsoforweldingwithsmalltransformers

OK83.65,excellentwelding properties

OK84.58,reasonableresistancetocorrosion

OKTubrodur15.50,alsoØ1.2mm

OKTubrodur15.52,alsowithout shieldinggas

OKAutrod13.91,Ø1.0and1.2mm

Hardness range: 60–65 HRC

• “Chromeiron”

• Highresistanceagainstabrasionfromgranularmaterialsetc.

• Lowimpactstrength

• Feedworms,fanblades,drag buckets,etc.

OK84.78,easytoweld,high efficiency electrode

OKTubrodur14.70,alsowithout shieldinggas

Tools and hardfacing

• Hot-worktoolsteel

• Hotworktools,etc.

OK85.58

High-speed steel

• Bladesofcuttersandcuttingtools

• Woodcuttingblades

OK85.65

Hardfacing consumables for

corrosion resistance

• Stainlesssteel13%Cr

OK84.42

PZ6166

HardfacingofMnsteels

• Improvingsurfacewear resistance

OK84.58and84.78

OKTubrodur15.52and14.70

SurfacingofMnsteels

• Mnsteeltypeconsumables

13%Mn:OK86.08

13%Mn-3%Ni:OK86.28,OKTubrodur15.60

-Niimprovesthetensilestrengthoftheweld

14%Mn-18%Cr:OK86.30,OKTubrodur15.65

-Cralloyimprovesheatandcorrosion resistance

consumable;suitablematerialsare

specifiedinthepreviouschapter,

“Difficult-to-weldsteels”.

10

Base metal MMAwelding

MIG/MAGwelding

MAGcoredwirewelding

MAGcoredwirewelding

TIGwelding

OK OK AristoRod, OK Autrod

OK Tubrod(Metalcored)

OK Tubrod(Rutile cored)

OK Tigrod

Non-alloy structural steels (EN 10025-2)

S235xxx,S275xxx,S355xxx 48.00 12.50,12.51 14.12 15.14 12.64

Normalised fine-grain structural steels (EN 10025-3)

S275N,S355N,S420N 48.00 12.50,12.51 14.12 15.14 12.64

S460N 55.00 12.63,12.64 14.02 15.14 12.64

S275NL,S355NL,S420NL 48.08,55.00 13.28,(12.50,12.63)* 14.04 15.11,(15.17)* 13.28

S460NL 48.08,55.00 13.28,(12.63)* 15.11,(15.17)* 13.28

*)-40oC *)-40oC

Thermomechanical rolled fine-grain steels (EN 10025-4)

S275M,S355M,S420M 48.00 12.50,12.51 14.12 15.14 12.64

S460M 55.00 12.63,12.64 14.02 15.14 13.28

S275ML,S355ML,S420ML 48.08,55.00 13.28,(12.50,12.63)* 14.04 15.11,(15.17)* 13.28

S460ML 48.08,55.00 13.28,(12.63)* 15.11,(15.17)* 13.28

*)-40oC *)-40oC

Weatheringstructuralsteels(EN10025-5)

S235J0W,S235J2W 73.08 13.26 14.01 PZ6112,15.17 13.26

S355J0WP(esim.COR-TENA) 73.08 13.26 14.01 PZ6112,15.17 13.26

S355J0W,S355J2W(esim.COR-TENB) 73.08 13.26 14.01 PZ6112,15.17 13.26

Quenched and tempered structural steels (EN 10025-6)

S460Q,S460QL 48.08,55.00 12.63,12.64 14.02 15.17 13.28

S500Q,S500QL 74.78 55 14.02 15.11 13.13

S550Q,S550QL 74.78 55 14.03 DualShield55 13.29

S620Q,S620QL 75.75 69 14.03 DualShield62 13.29

S690Q,S690QL 75.75 69 14.03 15.09 13.29

S890Q,S890QL 75.78 89 Coreweld89

Ultra-strongstructuralsteels(Rautaruukki)

Optim900QC 75.78 89 Coreweld89

Optim960QC 75.78*) 89*) Coreweld89*)

Optim1100QC 75.78*) 89*) Coreweld89*)

*)Slightlyundermatchingconsumables

Heat-resisting non-alloy and alloy steels: plates (EN 10028-2) and tubes(EN 10216-2)

P235GH...P355GH 48.00 12.50,12.51 14.12 15.14 12.64

16Mo3 74.46 13.09 14.02 DualShieldMoL 13.09

13CrMo4-5 76.18 13.12 DualShieldCrMo1 13.12

10CrMo9-10 76.28 13.22 DualShieldCrMo2 13.22

X10CrMoVNb9-1 76.98 13.38 13.38

Wearresistantsteels

e.g.Hardox400...600andRaexAR400...500

Ifamatchingstrength/hardnessisnotrequired:

non-alloy,high-tensileconsumable 48.00 12.50,12.51 14.12 15.14 12.64

Matchinghardness:suitablehardfacingconsumable

for final passes 83.50 13.91 15.52

Matchingstrength:low-alloyconsumable 75.75 69 14.03 15.09 13.29

Austenitic stainless steels

18Cr-8Ni steels (“stainless”) Shield-Bright

1.4404(304L),1.4307(304L),1.4301(304)etc. 61.30 308LSi 15.30 308L,308LX-tra 308LSi

1.4541(321),1.4550(347) 61.30,61.81 308LSi,347 15.30 308L,308LX-tra 308LSi,347

18Cr-12Ni-3Mosteels(”acid-resistant”) Shield-Bright

1.4404and1.4432(316L),1.4401and1.4436(316)etc. 63.30 316LSi 15.31 316L,316LX-tra 316LSi

Recommended welding consumablesfor different base metals

11

Base metal MMAwelding

MIG/MAGwelding

MAGcoredwirewelding

MAGcoredwirewelding

TIGwelding

OK OK AristoRod, OK Autrod

OK Tubrod(Metalcored)

OK Tubrod(Rutile cored)

OK Tigrod

High-alloy special steels

1.4438(317L) 64.30 317L 317L

1.4539(e.g.Outokumpu904L) 69.33 385 385

1.4547(e.g.Outokumpu254SMO) 92.45 19.82 19.82

1.4652(e.g.Outokumpu654SMO) 92.59 19.81 19.81

Austenitic-ferriticstainlesssteels(duplexsteels)

1.4162(esim.OutokumpuLDX2101) 67.56 2307 2307

1.4462(esim.Outokumpu2205) 67.50 2209 15.37 14.27 2209

1.4410(esim.Outokumpu2507) 68.53 2509 14.28 2509

Aluminium and aluminium alloys

1050A(Al99,5),1070A(Al99,7),1200(Al99,0) 1070 1070

4045(AlSi10) 4043,4047 4043,4047

5019(AlMg5),5086(AlMg4),5754(AlMg3) 5356 5356

5083(AlMg4,5Mn0,7) 5183 5183

6060(AlMgSi),6061(AlMg1SiCu) 4043,5356 4043,5356

6063(AlMg0,7Si),6082(AlSi1MgMn) 4043,5356 4043,5356

7021(AlZn5,5Mg1,5Si),7029(AlZn4,4Mg1Si) 5356 5356

Cast iron

Differentcastirongradest 92.18,92.58 Nicore55

Dissimilar metals (“steel/stainless steel welding”)

Non-alloyorlow-alloy/austeniticstainlesssteel Shield-Bright

Workingtemperaturelessthan300oCandnoannealing 67.60,67.70 309LSi,309MoL 309L,309LX-tra 309LSi,309MoL

Workingtemperatureover300oCand/orannealing 92.26 19.85 19.85

Repair welding

Difficult-to-weldsteels,“unknown”steels,, 68.82,67.45 312,16.95 15.34 OKTubrodur14.71 312,16.95

highlyhardenablesteels,etc. 92.26 19.85 19.85

Mnsteels Hardenable alloy steels

20HRC(->45)* 30-50HR 50-60HRC 55-60HRC

OK86.08* OK83.27 OK83.50 OK83.53

OK83.28 OK83.65 OK84.84

OK86.28* OK83.29 OK84.58 OKTubrodur15.80

OK86.30* OK83.30 OKTubrodur15.52 OKTubrodur15.81

OKTubrodur15.60* OKAutrod13.89 OKAutrod13.90 OKTubrodur15.82

OKTubrodur15.65* OKTubrodur15.43 OKAutrod13.91

OKTubrodur15.40

OKTubrodur15.42

Stainless Cr steels Chrome irons

OK84.42 OKTubrodur15.73 OK84.78

OK84.52 OK84.80

OKTubrodur14.70

Austenitic CrNi steels AusteniticCrNiMnsteels Ferritic-austenitic CrNi steels Tool-making steels

OK67.70 OK67.42* OK68.81* OK85.58

OKAutrod309LSi OK67.45* OK68.82* OK85.65

OK67.52* OKAutrod312 OKTubrodur15.84

OKAutrod16.95*

OKTubrodur14.71*

Ni alloys Co alloys (“stellites”)

OK92.26* OK92.35*Stellite6 Stellite12 Stellite1

OKAutrod19.85* (”HastelloyC”)

(”Inconel600”)

Low

Low

Low

High

High

Thermal and corrosion resistance

Impactresistance

Hardness

High*Workhardeningconsumable

Selection of hardfacing consumables, comparison of properties

Otheralternativesexistformanybasemetals;askyourESABrepresentativeforfurtheradvice.

Arc gouging and cutting electrodeSpecialcoatedelectrodeOK21.01forarcgougingDifficult-to-weld steels and dissimilar metals

Consumable C(%) Si(%) Mn(%) Cr(%) Ni(%) Other(%)

OK electrode

67.45 0.1 0.5 6.0 18.5 8.5

67.60 0.03 0.7 0.9 24.0 13.0

67.70 0.03 0.7 0.9 23.0 13.0 Mo:2.8

68.82 0.12 1.0 0.9 29.0 9.0

92.26 0.02 1.0 6.6 15.8 >67 Nb:1.7

OK Autrod/Tigrod

309LSi 0.02 0.8 1.8 24.0 13.0

309MoL 0.02 0.5 1.6 22.0 15.0 Mo:2.8

312 0.10 0.5 1.7 29.0 9.5

16.95 0.1 1.0 6.5 18.5 8.5

19.85 0.05 0.5 3.0 20.0 >67 Nb:2.5

OK Tubrodur

14.71 0.1 0.1 5.5 19.0 9.0

Consumables for hardfacingConsumable C(%) Si(%) Mn(%) Cr(%) Ni(%) Hardness1)(HRC)

OK electrode

83.28 0.1 0.5 0.7 3.2 28-32

83.50 0.4 0.5 1.0 6.0 Ni:0.6 50-60

83.65 0.8 4.0 0.5 2.0 58-63

84.42 0.12 0.5 0.5 13.0 49-55

84.58 0.7 0.6 0.7 10.0 53-59

84.78 4.5 0.8 1.5 33 59-63

85.58 0.35 1.1 1.0 1.8 W:8,Co:2 42-50

85.65 0.9 1.5 1.3 4.5 Mo:7.5,W:1.8 59-61

OK Autrod

13.89 0.7 0.4 2.0 1.0 Ti:0.2 50-60

13.91 0.45 3.0 0.8 9.0 50-60

OK Tubrodur

14.70 3.5 0.4 0.9 22.0 Mo:3.5,V:0.4 48-59

15.43 0.14 0.5 1.1 1.0 Mo:0.5,Ni:2.2 30-40

15.50 0.7 0.8 0.8 5.5 Mo:1.0 55-62

15.52 0.4 0.3 1.2 5.0 Mo:1.2,Al:0.6 50-57

Cored wire

PZ6166 0.03 0.7 1.2 13 Ni:4.5,Mo:0.5 30-40

1)Hardnessofdepositedmetal

WeldingconsumablesforcastironConsumable C(%) Si(%) Mn(%) Ni(%) Fe(%)

OK electrode

92.18 0.9 0.9 0.6 >92 3.5

92.58 1.5 0.7 0.8 51 46

Cored wire

Nicore55 2.0 3.0 1.0 51 46

WeldingconsumablesforaluminiumalloysConsumable Si,Mg(%) Al(%)

OK electrode

96.50 Si:12 remainder

OK Autrod/Tigrod

4047 Si:12 remainder

4043 Si:5 remainder

5356 Mg:5 remainder

ESAB AB

Box8004,SE-40277Göteborg,Sweden.

Phone:+4631509000.Fax:+4631509390.

E-mail:info@esab.se

www.esab.com

Welding consumables product data

Reg.No:XA00095820–01/2012.