1

WELDWELL NEW ZEALAND proudly present their range of arc welding electrodes in this book.We have manufactured electrodes in New Zealand since 1967. There are constant changes in this fieldbecause technology never stands still and we have access to welding electrode research to back our activitiesin the market place. We provide technical people to service our clients throughout Australasia, in countries ofthe Pacific Basin and in South East Asia.Therefore if you require help or advice with your welding problems, please ask and we will gladly assist.Included in our factory facilities is our own laboratory for materials, quality control and equipment to enablequick evaluation of new developments. This enables us to provide you, the customer, with the top qualityelectrodes you need for each application.The Weldwell Electrode Factory operates to the Telarc accredited ISO 9001 Quality Assurance System.

CONTENTSINTRODUCTION Selecting the right Electrode

Classification SurveyAmerican ClassificationAustralian Classification

Page2235

SECTION ONEWELDING FUNDAMENTALSDefinition of arc welding termsArc Welding - The ProcessWelding EquipmentThe Welding ElectrodeThe Welding CurrentWelding Positions and Weld JointsWelding TechniqueDefects due to faulty techniqueDistortionMetallurgical facts about iron and steel

Mild SteelHigh Tensile and Alloy SteelsStainless SteelManganese SteelCast IronsNon Ferrous Metals

HardfacingCutting with the electric arc

799

101011121316171718181920212122

SECTION TWOTECHNIQUES FOR SELECTEDAPPLICATIONS 23

SECTION THREEWELDWELL WELDING ELECTRODESELECTRODES FOR IntroductionWELDING MILD STEEL Weldwell PH 28

WIA Austarc 12PWeldwell PH 45EWeldwell PH 46Weldwell PH 48AWeldwell PH 68Weldwell PH 78Weldwell PH C18Weldwell PH 22Weldwell PH 7024Weldwell PH 31AHobart Pipemaster 60Hobart Pipemaster 70

2829303132333435363738394041

LOW HYDROGEN Introduction 42ELECTRODES FOR Weldwell PH 27 43WELDING MILD Weldwell PH 27P 44AND MEDIUM TENSILE WIA Austarc 16TC 45

Weldwell PH 56S 46Weldwell PH 56R 47

Low Temperature Weldwell PH 75 48Weldwell PH 77 49Weldwell PH C6H 50Weldwell KV3 51

ELECTRODES FOR Introduction 52WELDING HIGH Weldwell PH 118 53TENSILE STEEL

ELECTRODES FOR Introduction 54WELDING CREEP Weldwell KV3 55RESISTANT STEELS Weldwell KV5 56

PageELECTRODES FOR IntroductionWELDING STAINLESS Electrode Recommendation 57STEELS Weldwell PH RS308LC 58

Weldwell PH BM310Weldwell PH RM316LCWeldwell PH RM318LCWIA Staincord 316L-16Weldwell PH RS309LCWeldwell PHRS309MoLCWeldwell PH 22.9.3LR

58595960606161

ELECTRODES FOR IntroductionWELDING PROBLEM Weldwell Elite RSPSTEELS Weldwell Elite Hi-Ten 8

626364

ELECTRODES FORGOUGING ANDCUTTING

IntroductionAustarc C&G

6566

ELECTRODES FORWELDING CASTIRON

IntroductionSupercast NiSupercast NiFe

676868

ELECTRODES FORHARDFACING

IntroductionWeldwell PH MNWeldwell PH 250Weldwell PH 400Weldwell PH 600Weldwell PH 700Abrasocord 43Vidalloy 11Vidalloy 30

697071727374757676

ELECTRODES FORSPECIAL METALS

IntroductionBronze ArcAlly Arc

777879

SECTION FOURMISCELLANEOUS

Relationship between stress and energy 80Deposition rate conversion chart 80Physical properties of metals and alloys 81Conversion chart - inch/millimetre 81Work, energy, foot pounds - force to joules 82Steel testing by spark method 82American Welding Society standard welding symbols 83Mensuration 85Comparative hardness scales 86Arc welding lenses 86Care and Storage of electrodes 87Recommendations for storage and drying 88Electrode Agency Approval Grades 89Electrode Quantities per Packet 90Weld Deposition and Costing Data 91Weldwell Distributors 97Weldwell Branches Inside Back Cover

2

SELECTING THE RIGHTELECTRODE

INTRODUCTION

PICKING THE RIGHT ELECTRODE is a matter of analysing the conditions applying to a particular job and thendetermining the type and size of electrode best suited to those conditions.Such an analysis is if the operator makes a practice of always checking the following factors:

(1) What is the base metal to be welded?(2) Dimensions of the section to be welded.(3) What type of current is available?(4) What welding position, or positions, will be used?(5) What sort of fit up does the work permit?(6) Must weld deposit possess any specific properties such as corrosion resistance, high tensile

strength, ductility, etc?(7) Must weld meet requirements of any code, standard, specification or approval.

After carefully checking the above factors the operator should have no difficulty in selecting a Weldwell electrode typewhich will provide the arc stability, smoothness of bead, easy slag removal, and minimum spatter which are soessential to fast, top quality arc welding.

CLASSIFICATION CROSS REFERENCE LIST(Nearest Equivalents)

ELECTRODES FOR WELDING MILD STEELWeldwell AWS A5.1:2004 AS/NZS1553.1:1995 BSEN499:1995PH 28 E6013 E4112-0 E350R11Austarc 12P E6013 E4112-0 E350R11PH 31A E6011 E4111-3 E353C11Pipemaster 60 E6010 E4110-3 E383C21Pipemaster 70 E7010-01 (AWS A5.5) E4810-01 (AS/NZS 1553.2) E382MOC21PH 45E E6020 E4120-0 E35ZRA13PH 46 E6012 E4113-0 E350R12PH 48A E6013 E4112-0 E350R11PH 68 E6013 E4112-A E350R11PH 78 E6013 E4113-2 E350R12PH C18 E7014 E4814-0 E380RR31PH 22 E7024 E4824-0 E380RR53PH 7024 E7024 E4824-0 E380RR53

ELECTRODES FOR WELDING MILD AND MEDIUM TENSILE STEELSPH 27 E7048 H4 E4848-3 H5 E383B31Austarc 16TC E7016-1 H8 E4816-5 H10 E385B12PH 56S E7016 H8 E4816-4 H5 E384B12PH 56R E7016 E4816 E382B4PH C6H E7028 H4 E4828-2 H5 E382B73PH 77 E7018-1 H8 E4818-5 H5 E385B32

AWS A5.5:1996 AS/NZS 1553.2:1999 BSEN 1599:1997KV3 E8015-B3L H4 E6215-B3L ECrMo2LB22HS

ELECTRODES FOR WELDING LOW ALLOY STEEL AND SPECIAL APPLICATIONSWeldwell AWS A5.5:1996 AS/NZS1553.2:1999 BSEN499:1995PH 27P E8018-G H8 E5548-G H5 E463B31PH 75 E7016-C1L H8 E4816-C1L H10 E3862NIB32

ELECTRODES FOR WELDING HIGH TENSILE STEELPH 118 E11018-G H4 E7618-G H5 BSEN757:19997 E69xMn2NiCrMo

ELECTRODES FOR CREEP RESISTING STEELSWeldwell AWS A5.5:1996 AS/NZS1553.2:1999 BSEN 1599:1997KV3 E8015-B3L H4 E5515-B3L H5 ECrMo2LB22H5KV4 E8015-B6 H4 E5515-B6 H5 ECrMo5B22H5KV5 E7015-B2L H4 E4815-B2 LH5 ECrMo1LB22H5

ELECTRODES FOR WELDING STAINLESS STEELWeldwell AWS A5.4:1992 AS/NZS1553.3:1996 BSEN 1600:1997PH RS308LC E308L-17 E308L-17 E19.9LR22PH BM310 E310-16 E310-16 E25.20R22PH RM316LC E316L-17 E316L-17 E19.12.3LR22Staincord 316L-16 E316L-16 E316L-16 E19.12.3LR22PH RM318LC E318-16 E318-16 E19.12.3NbR22PH RS309LC E309L-16 E309L-16 E23.12LR22PH RS309MoLC E309MoL-17 E309MoL-17 E23.12LR22PH 22-9-3LR E2209-16 E2209-16 E22.9.3NLR22

3

Not Specified

AWS A5.1 C 2004 AMERICAN CLASSIFICATION

Arc Welding Electrodes

The American Welding Society classifies electrodes by a letter followed by either four or five digits, eg, the prefix "E" designates ARC WELDING ELECTRODES.

Table 1 Electrode Classification

A5.1 A5.1M Type of Covering Welding Position Type of Current E6010 E4310 High cellulose sodium F, V, OH, H-fillet dcep E6011 E4311 High cellulose potassium F, V, OH, H-fillet ac or dcep E6012 E4312 High titania sodium F, V, OH, H-fillet ac or dcen E6013 E4313 High titania potassium F, V, OH, H-fillet ac, dcep, or dcen E6018c E4318c Low-hydrogen potassium, iron powder F, V, OH, H-fillet ac or dcep

E6019 E4319 Iron oxide titania potassium F, V, OH, H-fillet ac, dcep, or dcen

E6020 E4320 High iron oxide H-fillet ac or dcen F ac, dcep, or dcen

E6022d E4322d High iron oxide F, H-fillet ac or dcen

E6027 E4327 High iron oxide, iron powder H-fillet ac or dcen F ac, dcep, or dcen

E7014 E4914 Iron powder, titania F, V, OH, H-fillet ac, dcep, or dcen

E7015 E4915 Low-hydrogen sodium F, V, OH, H-fillet dcep

E7016 E4916 Low-hydrogen potassium F, V, OH, H-fillet ac or dcep

E7018 E4918 Low-hydrogen potassium, iron powder F, V, OH, H-fillet ac or dcep

E7018M E4918M Low-hydrogen iron powder F, V, OH, H-fillet dcep

E7024c E4924c Iron powder, titania H-fillet, F ac, dcep, or dcen

E7027 E4927 High iron oxide, iron powder H-fillet ac or dcen F ac, dcep, or dcen

E7028c E4928c Low-hydrogen potassium, iron powder H-fillet, F ac or dcep

E7048 E4948 Low-hydrogen potassium, iron powder F, OH, H-fillet, V-down ac or dcep

Notes:

a. The abbreviations , F, H-fillet, V, V-down, and OH indicate the welding positions as follows: F = Flat, H-fillets = Horizontal fillet, V = Vertical, progressions upwards (for electrodes 5.0 mm and under, except 4.0 mm and under for classifications E6018 [E4318), E7014 [E4914, E7015 [E4915], E7016 [E4916], E7018 [E4918], E7018M [E4918M], E7048 [E4948]). V-down = Vertical, progression downwards (for electrodes 5.0 mm and under, except 4.0 mm and under for classifications E6018 [E4318], E7014 [E4914], E7015 [E4915], E7016 [E4916], E7018M [E4948],k OH = Overhead (for electrodes 5.0 mm and under, except 4.0 mm and under for classifications E6018 [E4318], E7014 [E4914], E7015 [E4915], E7016 [E4916], E7018 [E4918], E7018M [E4918M], E7048 [E4948]).

b. The term “dcep” refers to direct current electrode positive (dc, reverse polarity). The term “dcen” refers to direct current electrode negative (dc, straight polarity).

c. Electrodes with supplemental elongation, notch toughness, absorbed moisture, and diffusible hydrogen requirements may be further identified as shown in Tables, 2 and 3.

d. Electrodes of the E6022 ([E4322] classification are intended for single-pass welds only.

Table 2 Tension Test Requirementsa, b, c

AWS Classification Tensile Strength Yield Strength at 0.2% Offset

A5.1 A5.1M A5.1 (ksi) A5.1M (MPa) A5.1 (ksi) A5.1M (MPa)

Elongation Percentage in 4x Diameter Length

E6010 E6011 E6012 E6013 E6018 E6019 E6020 E6022 E6027 E7014 E7015 E7016 E7018 E7024- E7027 E7028 E7048 E7018M

E4310 E4311 E4312 E4313 E4318 E4319 E4320 E4322 E4327 E4914- E4915 E4916 E4918 E4924- E4927 E4928 E4948 E4918M

60 60 60 60 60 60 60 60 60

70 70 70 70 70 70 70 70

Note c

430 430 430 430 430 430 430 430 430

490 490 490 490 490 490 490 490

Note c

48 48 48 48 48 48 48

48

58 58 58 58 58 58 58 58

53 – 72d

330 330 330 330 330 330 330

330

400 400 400 400 400 400 400 400

370-500 d

22 22 17 17 22 22 22

Not Specified 22

17 22 22 22 17c 22 22 22 24

Notes: a. Single values are minimum b. Weld metal from electrodes identified as E7024-1 [E4924-1] shall have elongation of 22% minimum. c. Tensile strength of this weld is a nominal 70 ksi [490 MPa]. d. For 2.5 mm electrodes, the maximum yield strength shall be 77 ksi [530 MPa].

4

AWS A5.1 Continued

Table 3Charpy V-Notch Impact Requirements

AWS Classification Limits for 3 out of 5 specimensa

A5.1 A5.1M Average, Min. Single Value, Min.

E6010, E6011, E6018E6027. E7015E7016b, E7018b

E7027, E7048

E6019E7028

E6012, E6013E6020, E6022E7014, E7024b

E4310, E4311, E4318E4327, E4915E4916b, E4918b

E4927, E4948

E4319E4928

E4312, E4313E4320, E4322E4914, E4924b

27 J at -30oC

27 J at -20oC

Not Specified

20 J at -30oC

20 J at -20oC

Not Specified

AWS Classification Limits for out of 5 specimensb

A5.1 A5.1M Average, Min. Single Value, Min.

E7018M E4918M 67 J at -30oC 54 J at -30oC

Notes:a. Both the highest and lowest test values obtained shall be disregarded in computing the average. Two of these remaining three values shall equal or

exceed 27 J.b. Electrodes with the following optional supplemental designations shall meet the lower temperature impact requirements specified below:

AWS Classification Electrode Designation Charpy V-Notch Impact Requirements,Limits for 3 out of 5 specimens (refer to Note a above)

A5.1 A5.1M A5.1 A5.1M Average, Min Single Value, Min

E7016E7018

E4916E4918

E7016-1E7018-1

E4916-1E4918-1 27 J at -45oC 20 J at -45oC

E7024 E4924 E7024-1 E4924-1 27 J at -20oC 20 J at -20oC

c. All five values obtained shall be used in computing the average. Four of the five values shall equal, or exceed, 67 J.

Table 7Chemical Composition Requirements for Weld Metal

AWS Classification UNSa

NumberWeight Percentb Combined Limit for

Mn + Ni + Cr+ Mo + V

A5.1 A5.1M C Mn Si P S Ni Cr Mo V

E6010E6011E6012E6013E6019E6020E6027

E4310E4311E4312E4313E4319E4320E4327

W06010W06011W06012W06013W06019W06020W06027

0.20 1.20 1.00 N.S N.S. 0.30 0.20 0.30 0.08 N.S.

E6018E7015E7016E7018

E4318E4915E4916E4918

W06018W07015W07016W07018

0.030.150.150.15

0.601.251.601.60

0.400.900.750.75

0.0250.0350.0350.035

0.0150.0350.0350.035

0.300.300.300.30

0.200.200.200.20

0.300.300.300.30

0.080.080.080.08

N.S.1.501.751.75

E7014E7024E7027

E4914E4924E4927

W07014W07024W07027

0.150.150.15

1.251.251.60

0.900.900.75

0.0350.0350.035

0.0350.0350.035

0.300.300.30

0.200.200.20

0.300.300.30

0.080.080.08

1.501.501.75

E7028E7048

E4928E4948

W07028W07048 0.15 1.60 0.90 0.035 0.035 0.30 0.20 0.30 0.08 1.75

E7018M E4918M W07018 0.120.40to

1.600.80 0.030 0.020 0.25 0.15 0.35 0.05 N.S.

Notes:a. SAE/ASTM Unified Numbering System for Metals and Alloys.b. Single values are maximum. N.S. means Non Specified.

5

AS/NZS 1553.1 — 1995AUSTRALIAN/NEW ZEALAND STANDARD

1.4 CLASSIFICATION AND DESIGNATION

1.4.1 Basis of classification Electrodes shall be classified on the basis of the tensile properties of thedeposited weld metal and the operational characteristics of the electrodes. An electrode classified under oneclassification shall not be classified under any other classification.1.4.2 Designation The designation system is illustrated in Figure 1.1 and shall consist of the following :-(a) A letter prefix E, denoting electrode.(b) A 2-digit number which represents approximately one-tenth of the allowable minimum tensile strength

of the deposited weld metal, in megapascals, in two groupings nominally referred to as E41XX andE48XX (see Table 2.4)).

(c) A 2-digit number which indicates the welding position or positions in which the electrode is capable ofmaking satisfactory welds, the type of welding current to be used with the electrode and the type ofcovering on the electrode, in conformity with Table 1.1.

(d) Optional indicators relating to notch toughness grading, attainable diffusible hydrogen status andcoating moisture absorption resistance.

FIGURE 1.1 PRINCIPLES OF DESIGNATION

TABLE 2.1CHEMICAL COMPOSITION REQUIREMENTS OF DEPOSITED WELD METAL

Class-ification

Chemical Composition, maximum percentC S P Mn* Si Ni* Cr* Mo* V*

E41XX 0.15 0.030 0.030 Values not specifiedE48X4E48X5E48X6E48X7E4818E48X8

0.15

0.030

0.030

1.251.251.601.601.601.60

0.900.900.750.750.750.90

0.30

0.20

0.30 A

0.05

E4X99 As specified by the manufacturer

* Total of all these elements not to exceed the following:

E48X4E48X5 1.5 percent

E48X6E48X7 1.75 per centE48X8

TABLE 2.4TENSILE PROPERTIES OF DEPOSITED WELD METAL

IN ALL-WELD-METAL TESTS

Classification Tensile strength *MPa

Minimum Yieldstrength * MPa

Minimum elongationon 5.65/So percent

E41XX 430 to 550 (1) 350 (1) 22E48XX 500 to 620 (2) 420 (2) 22

6

AS/NZS 1553.1 Continued

TABLE 1.1WELDING POSITION, CURRENT AND COVERING

Third andfourth digit

of destination

WeldingPosition

(See Note 1)

Type of currentand polarity(see Note 2)

Type of covering and slag

1011

12

13

14

1516

18

19

20

24

27

28

46

48

99

F,V,OH,HF,V,OH,H

F,V,OH,H

F,V,OH,H

F,V,OH,H

F,V,OH,HF,V,OH,H

F,V,OH,H

F,V,OH,H

F,H-fillet

F,H-fillet

F,H-fillet

F,H-fillet

F,V-downOH,H

F,V-downOH,H

As specified bymanufacturer

dc electrode positiveac or dc electrodepositiveac or dc electrodepositive or negativeac or dc electrodepositive or negativeac or dc electrodepositive or negativedc electrode positive ac or dc electrodepositiveac or dc electrodepositiveac or dc electrodepositive or negativeac or dc electrodepositive or negativeac or dc electrodepositive or negativeac or dc electrodepositive or negativeac or dc electrodepositive ac or dc electrodepositive ac or dc electrodepositiveAs specified bymanufacturer

High celluloseHigh cellulose

High titania viscous slag

High titania fluid slag

Low iron powder, titania

Hydrogen controlled, basicHydrogen controlled, basic

Hydrogen controlled, basicLow iron powderIron oxide titania potassium

High iron oxide

High iron powder, titania

High iron powder, iron oxide

Hydrogen controlled high ironpowder, basicHydrogen controlled, basic

Hydrogen controlled, basicLow iron powderAs described by manufacturer

NOTES:1. The abbreviations F, V, V-down, OH, H, H-fillet indicate the following welding positions, as defined in AS

2812 and AS 3545.F = FlatV = VerticalV-down = Vertical downOH = OverheadH = HorizontalH-fillet = Horizontal fillet (position 2F in AS 3545)

2. See Appendix A for possible exceptions.

TABLE 2.5AVERAGE IMPACT ENERGY VALUES-DEPOSITED WELD METAL

1 2 3 4 5

Grade TestingTemperature

Minimum averagevalue of a set of 3

specimens

Minimum individualvalue

Minimum averagevalue before

rejections

(oC) (J) (J) (J)

ZA023456

No requirement20 0-20-30-40-50-60

No requirement

47

No requirement

31

No requirement

40

7

Arc Voltage: The voltage across the welding arc.Arc Blow: This is peculiar to DC. The arc, instead of playing steadily

on one spot, is deflected away from point of welding byinfluence of surrounding magnetic fields.

Backing Strip: Material (metal, carbon, ceramic, etc) backing up ajoint during welding to help obtain a sound weld. (See Fig 1.)

Buffer (or Butter) Layer: Layer of weld metal on component toprevent crack formation or dilution effects in subsequent weldlayers, (eg hardfacing, cast iron).

Cold Crack: Crack occurring in weld metal or in the heat-affectedzone of the base metal after cooling.

Concave Fillet: Fillet weld having concave face. (See Fig. 2.)Convex Fillet: Fillet weld having convex face. (See Fig. 3.)Crater: Depression at the termination of weld bead.Crater Crack: Crack in weld bead crater.Depth of Fusion: Distance that fusion extends into base metal. (See

Fig. 4.)Dilution: Admixture of base metal and weld metal being deposited.Earth (or Work) Lead: Cable between workpiece and power source.Electrode Lead: Conductor between source of current and electrode

holder.Flux: Fusible material coated onto electrodes for removal of oxides

and other impurities. (See section, ‘The Welding Electrode”.)Fusion: The melting together of filler metal and base metal, resulting

in coalescence.Haloes or “Fish-eyes’: Small, shiny, circular areas displayed on the

surface of weld metal after fracture by a tensile stress.Hardfacing: The process of covering wearing areas with

wear-resistant metal by welding.Heat-affected Zone: The region beneath the weld bead which has not

melted, but whose mechanical properties or micro-structure hasbeen altered by the heat of welding. (See Fig. 4.)

Hot Crack: Crack occurring in weld metal soon after solidificationconimences.

Intermittent Welding: Welding, wherein continuity is broken byrecurring unwelded spaces. (See Figs. 5 and 6.)

Interpass Temperature: In a multiple run weld, the temperature ofdeposited metal before the next pass is started.

Lack of Fusion: A weld fault wherein adequate fusion of weld andbase metal is not obtained. (See Fig. 60, p. 15.)

Leg of Fillet Weld: Distance from root ofjoint to toe of fillet weld.(See Fig. 10,p.8.)

Mitre Fillet: Fillet weld in which the face of the weld isapproximately flat. (See Fig. 7.)

Open-circuit Voltage: Voltage between terminals of power sourcewhen it is energised, but current is not flowing.

Overlap: Protrusion of weld metal beyond bond at toe of weld.Parent Metal: The metal to be welded.Pass: A single welding run along a joint or weld deposit. The result

of a pass is a weld bead.Peening: The mechanical working of metals by relatively light

hammering.Penetration: The depth a weld extends into a joint from base metal

surface. (See Fig. 8, p. 8.)Porosity: Gas pockets or voids in metal.Post-heating: Application of heat to the weldment after welding is

completed.Preheating: Application of heat to the base metal before weldingcommences.

Section One

WELDINGFUNDAMENTALS

DEFINITIONS OF ARC WELDING

TERMS

8

Reinforcement of Weld: Weld metal lying outside the planejoining the toes of a weld. (See Fig. 10.)

Reverse Polarity: Arrangement of DC arc welding leads wherein the work is the negative pole and the electrode is thepositive pole of the welding arc.

Root of Weld: The zone on the side of the first run farthest fromthe welder. (See Figs. 10 and 11.)

Root Face: Unbevelled or ungrooved portion of a fusion face atthe root. (See Fig. 11.)

Slag Inclusion: Non-metallic solid material trapped in weldmetal or between weld and base metal.

Spatter: Metal particles expelled during welding which do notform part of the weld.

Straight Polarity: Arrangements of DC arc welding leadswherein the work is the positive pole and the electrode is thenegative pole of the welding arc.

Tack Weld: Small weld made to hold parts in proper alignmentuntil final welds are made. (See Fig. 45, p. 13.)

Throat Thickness (See Figs. 10 and 11): The minimumthickness of weld metal in:(a) Fillet weld, measured along a line passing through the root.(b) Close square butt joint, measured in the plane of abutting faces.(c) Open square butt weld, measured in centre of original gap

parallel to fusion faces.Effective Throat Thickness: Dimension arbitrarily adopted as

throat thickness for design purposes.Toe: Boundary between weld face and parent metal between

weld faces. (See Figs. 10 and 11.)Underbead or Hard Zone Crack: Crack in the heat-affected

zone which may or may not extend to surface of base metal.(See Fig. 72, p. 18.)

Undercut: A groove melted in the base metal adjacent to the toeof a weld, and left unfilled by weld metal. (See Figs. 54 and55, p. 14.)

Weave Bead: Weld bead made with slow oscillating motion ofthe electrodes.

Welding Sequence: The order of making welds in a weldment.(See Figs. 12-16.)

9

ARC WELDING THE PROCESS

FUSION WELDING is really a melting and casting processin miniature, the various components of the welding process(base metal, weld metal slag, etc) forming the crucible andcontents of a tiny electric furnace.

The electric arc, with a temperature of the order of 6,000oC,is a concentrated and efficient source of heat. This heat isutilised in the metal arc welding process by employing aflux-coated electrode to provide filler metal. The electrodeand parent metal act as poles of the arc, the core wire of theelectrode melting and being transferred across the arc tocoalesce with the molten parent metal and form a bondwhich in most cases, is stronger than the parent metal. Theflux covering melts more slowly than the core wire and a cupis formed at the electrode tip which assists in directing themolten droplets to the required spot.

The weld metal itself, as deposited, has a cast structure, itscomposition is determined by the core wire and coating ofthe electrode, and by the amount of pick-up of parent metalduring welding. For example, a deposit of alloy steel, say,stainless steel on mild steel, no longer has just the propertiesexpected of that alloy, due to dilution with the parent metal.This effect, in many cases, is not important, but, if desired,it may be eliminated by using multi-layer welds.

Welding on materials that have been strengthened by heat-treatment or cold-working generally creates a zone of lowerstrength along the weld boundary. This may not affect theserviceability of the welded joint, but sometimes it isnecessary to restore this strength by further heat-treatment orcold-work.

ADVANTAGES OF WELDING:Some of the advantages that welding has over riveting andcasting methods of assembly are as follows:

1. Welding is usually a cheaper process than riveting forany particular joint, and the joint can often be mademuch more quickly.

2. It gives a stronger joint and permits the use of lessmaterial, thus reducing the weight and cost of thestructure.

3. Weld seams are normally pressure tight, and do notneed caulking as do riveted joints. Joints are smooth,which is important in many applications. Forexample, painting is much easier on welded joints,and turbulence in pipes is reduced.

4. Designs not practicable for riveting may beconstructed by welding.

5. Plate preparation for welding is generally cheaperthan for riveting.

6. Labour necessary can often be cut to less than one-third of that necessary for riveting.

7. Welding is not as noisy as riveting, and permitsbuilding and alterations to proceed with the leastdisturbance to occupants.

8. Welding is more versatile than casting; changes canbe made quickly without having to produce a newpattern.

9. Rolled section is often cheaper than cast section, andfabrication by welding of rolled section may becheaper than casting the same article.

10. No storage of patterns is necessary for welding, aswith castings.

11. Articles of consistent and known quality can beproduced by welding, whereas castings may haveexternal or hidden internal flaws causing theirrejection, or failure in service.

WELDING EQUIPMENTBESIDES THE welding machines and suitable electrodes,the accessories necessary for a welder are:

1. A substantial work table with a fairly heavy mildsteel plate for a top.

2. Leads. Two are required — one from the machineto the electrode holder, called the electrode lead,and one from the job or work table back to themachine to complete the circuit, called the work orearth lead. These leads should be heavy enough tocarry the required current without overheating.They must be kept in good condition and in closeelectrical contact with the holder and the work forthe best utilisation of current.

3. Electrode Holders. These should be heavyenough not to overheat and have well-insulatedhandles to avoid electric shocks and accidentalarcing. Holders are available that are designed forcontinuous welding at high amperages. These arefully insulated and the jaws are made of metalshaving high heat conductivity.

4. Shields. These are necessary for protecting theeyes and face from glare and ultra-violet radiationfrom the arc, and spatter from the weld pool.Special tinted glass is used in the shields to absorbultra-violet rays. A clear piece of replaceable glassis used in front of the coloured glass to protect itfrom spatter and smoke.

5. Clothing. Leather gauntlets and apron should beworn, and clothes should be of material that willdeflect spatter and sparks.

6. Chipping Hammer. Used for deslagging of welds.

7. Wire Brush. Used for removing rust, cleaning slagoff welds, etc.

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THE WELDING ELECTRODEMETAL ARC welding electrodes consist of a core wiresurrounded by a flux coating. The flux coating is usuallyapplied to the core wire by an extrusion process, but a fewtypes of electrodes are still made by dipping the core wireinto a thick slurry of fluxing material and drying out betweenthe application of successive layers.It is important, for uniform running qualities, for the fluxcoating to be concentric with the core wire, and the extrusionprocess allows close control to be kept over this.The coating on arc welding electrodes serves a number ofpurposes:1. To provide a gaseous shield for the weld metal, and

preserve it from contamination by the atmospherewhilst in a molten state.

2. To provide a steady arc by having "arc stabilizer"present, which provide a bridge for current to flowacross.

3. To remove oxygen from the weld metal with"deoxidizers".

4. To provide a cleansing action on the work piece and aprotective slag cover over the weld metal to preventthe formation of oxides while the metal is solidifying.The slag also helps to produce a bead of the desiredcontour.

5. To introduce alloys into the weld deposits in specialtype electrodes, eg the Weldwell hardfacingelectrodes, which have mild steel core wire, butcontain alloys in the coating.

A wide variety of ingredients are used in the coating of arcwelding electrodes. Among them are the minerals limestone,fluorspar, silica, rutile and feldspar for slag and gas shieldformation, ferro-manganese and ferro-silicon for deoxidationof the weld metal; ferro-chromium, ferro-molybdenum andnickel powder to introduce alloys for hardening and raisingthe tensile strength of steel weld metal; potassium andsodium silicates (water glass) to bind the particles togetherand cause them to adhere to the core wire.

STORAGE OF ELECTRODES:Electrodes not stored in a dry place will absorb moisturefrom the atmosphere. Dampness in electrodes may havesome of the following effects:1. Fiery arc.2. Excessive spatter.3. Porosity in weld metal.4. Spalling of flux coating.5. Blistering of electrode tip.6. High arc voltage.7. Introduction of hydrogen into the weld metal, with

increased danger of hard zone cracking on hardenablesteels.

8. Formation of white "fur" on flux coating. In mostcases this does not have any deleterious effect.

Mild steel electrodes may be stored in a warm, dry room.Low hydrogen and some special electrodes (eg stainlesssteel) require to be stored in a proper heated cabinet if thebest results are to be achieved. Provided the temperature ofthe cabinet is 10oC above that of the outside air, and someventilation is allowed, the electrodes cannot pick upmoisture. Mild steel electrodes which have become dampshould be redried at 120oC for 15-30 minutes. Low-hydrogen electrodes should always be dried at thetemperature recommended for that particular electrode.

THE WELDING CURRENTBOTH DIRECT and alternating currents may be used forarc welding. However, most work on mild steel is doneusing AC.AC welding machines have several advantages over DCmachines, among them being a lower purchase cost,higher operating efficiency and negligible maintenance.The quality of welds produced using AC is equally asgood as when DC is used. However, AC is limited in thatit will not satisfactorily run many of the non-ferrous typesof electrodes.The open-circuit voltage of an AC machine is important,because some electrodes need a fairly high voltage toprevent the arc cutting out during welding. The open-circuit voltage depends on the design of the machine.The question of open-circuit voltage is not so importantwith DC machines, since there is not the constant reversalof current necessitating continual re-establishment of thearc.When using AC it does not matter to which terminal theelectrodes and the work piece are attached, but when DCis used more heat is produced at the positive pole withmost electrode types and the manufacturers'recommendations for the most suitable polarity should befollowed. With the welding of mild steels, although eitherpolarity can be employed, it is usual for the work piece to

be made the positive pole. The greater amount of heatgenerated at the work piece in this way assists the weldingoperation, especially when the components have a heavymass. Proper fusion and good penetration are assured inthis way. If on the other hand, the electrode is connectedto the positive pole, the greater heat generated at theelectrode tip results in a faster burn-off rate and theelectrode is deposited more quickly. This increase indeposition rate, however, may not amount to more than5 percent and the advantage gained in this way is offset bythe reduction in depth of penetration obtained with theresulting weld deposit. The burn-off rate with AC supplyis approximately the same for DC supply with theelectrode connected to the negative pole.

Most of the non-ferrous and stainless steel electrodesshould be connected to the positive terminal, but this isrecommended because of the greater arc stabilityobtained.

ARC BLOW:

This is peculiar to DC. The arc, instead of playingsteadily on one spot, is deflected away from the point ofwelding due to the influence of surrounding magneticfields created by welding currents flowing in the work. Itmay often be overcome or minimised by shifting the earthclamp to another part of the work piece.

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12

WELDING TECHNIQUESA Word to Beginners

FOR THOSE who have not yet done any welding, the simplest way tocommence is to run beads on a piece of scrap plate. Use mild steel plateabout 12 mm thick and a 4.0 mm electrode. Clean any paint, loose scaleor grease off the plate and set it firmly on the work bench so that weldingcan be carried out in the downhand position. Make sure that the earthclamp is making good electrical contact with the work, either directly orthrough the work table. For light gauge material, always clamp the earthlead directly to the job, otherwise a poor circuit will probably result.ELECTRODE C TYPE AND SIZE:The type of electrode will depend on the material to be welded and theposition in which welding is to be carried out (ie whether downhand,vertical or overhead). In this case, the general purpose PH28 electrode isthe most suitable. We have already chosen a 4.0 mm electrode, but forother jobs the size will depend on the thickness of the material and thetype of joint to be welded. For example, on thin material a small size isrequired, otherwise holes will burn through. The electrode size shouldallow for adequate root penetration. On vee butt joints, the root run isoften made with 4.0 mm or 3.2 mm electrodes and the remaining weldingis done with 5.0 mm electrodes.Generally, the maximum size which may be used on vertical andoverhead welding is 5.0 mm, but these more specialised applications canbe left for the moment while we concentrate on downhand welding.AMPERAGE:Suitable amperages for the various sizes of electrodes are usually printedon the packets. These amperages may be varied to suit conditions Cwelds on thin plate require low amperages to prevent burn-through,while high welding rates or deep penetration of the weld metal requirehigher amperages. For 4.0 mm set the machine at about 170 amps.There are several effects produced by incorrect amperage. If it is toohigh, spatter becomes excessive, and the weld pool becomes very hot,producing a flattened bead with elongated ripple marks, and the electrodeoverheats. If the current is too low, it is difficult to maintain the arc andprevent the electrode from sticking, the bead is high and rounded, withpoor edge fusion, and penetration is slight. Figures 41, 42 and 43 showthe effects of different amperages.THE WELDER:Place yourself in a comfortable position before beginning to weld. Get aseat of suitable height and do as much work as possible sitting down.Don't hold your body tense. A taut attitude of mind and a tense bodywill soon make you feel tired. Relax and you will find that the jobbecomes much easier. You can add much to your peace of mind bywearing a leather apron and gauntlets. You won't be worrying then aboutsparks setting alight your clothes.Place the work so that the direction of welding is across, rather than to orfrom your body. The electrode holder lead should be clear of anyobstruction so that you can move your arm freely along as the electrodeburns down. if the lead is slung around the back of your neck and overyour shoulder, it allows greater freedom of movement and takes a lot ofweight off your hand. Be sure the insulation on your cable and electrodeholder is not faulty, otherwise you are risking an electric shock.STRIKING THE ARC:Practise this on a piece of scrap plate before going on to more exactingwork. You may at first experience difficulty due to the tip of theelectrode "sticking" to the work piece. it is caused by making too heavya contact with the work and failing to withdraw the electrode quicklyenough. A low amperage will accentuate it. This freezing-on of the tipmay be overcome by scratching the electrode along the plate surface inthe same way as a match is struck. As soon as the arc is established,withdraw the electrode very slightly (2.0 mm) from the plate and feed itinto the weld pool as it melts down. (See Fig. 44.)Another difficulty you may meet is the tendency, after the arc is struck,to withdraw the electrode so far that the arc is broken again. A littlepractice will soon remedy both of these faults.ARC LENGTH:The securing of an arc length necessary to produce a neat weld soonbecomes almost automatic. You will find that a long arc produces moreheat. A very long arc produces a cracking or spattering noise and theweld metal comes across in large, irregular blobs. The weld bead isflattened and spatter increases. A short arc is essential if a high qualityweld is to be obtained, although if it is too short there is the danger of itbeing blanketed by slag and the electrode tip being frozen in. If thisshould happen, give the electrode a quick twist back over the weld todetach it. Contact or "touch-weld" electrodes do not stick in this way,and make welding much easier.

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RATE OF TRAVEL:After the arc is struck, your next concern is to maintain it, and thisrequires moving the electrode tip toward the molten pool at the samerate as it is melting away. At the same time, the electrode has to movealong the plate to form a bead. The electrode is directed at the weldpool at about 20o from the vertical. The rate of travel has to beadjusted so that a well-formed bead is produced. If travel is too fast,the bead will be narrow and strung out and may even be broken up intoindividual globules. If the travel is too slow, the weld metal piles upand the bead is too large.MAKING WELDED JOINTS:Having attained some skills in the handling of an electrode, you will beready to go on to make up welded joints.BUTT WELDS:Set up two plates with their edges parallel, as shown in Fig. 45,allowing a 1.6 mm gap between them and tack weld at both ends. Thisis to prevent contraction stresses from the cooling weld metal pullingthe plates out of alignment. Plates thicker than 6.0 mm should havetheir mating edges bevelled to form a 70-90o included angle. Thisallows full penetration of the weld metal to the root. Using a 4.0 mmelectrode at 170 amps, deposit a run of weld metal on the bottom of thejoint. Do not weave the electrode, but maintain a steady rate of travelalong the joint sufficient to produce a well-formed bead. At first youmay notice a tendency for undercut to form, but keeping the arc lengthshort, the angle of the electrode at about 20o from vertical, and the rateof travel not too fast, will help to eliminate this. The electrode needs tobe moved along fast enough to prevent the slag pool from gettingahead of the arc. To complete the joint in thin plate, turn the job over,clean the slag out of the back and deposit a similar weld.Heavy plate will require several runs to complete the joint. Aftercompleting the first run, chip the slag out and clean the weld with awire brush. It is important to do this to prevent slag being trapped bythe second run. Subsequent runs are then deposited using either aweave technique or single beads laid down in the sequence shown inFig. 12. The width of weave should not be more than three times thecore wire diameter. When the joint is completely filled, the back iseither machined, ground or gouged out to remove slag which may betrapped in the root, and to prepare a suitable joint for depositing thebacking run. If a backing bar is used, it is not usually necessary toremove this, since it serves a similar purpose to the backing run insecuring proper fusion at the root of the weld.FILLET WELDS:These are welds of approximately triangular cross-section made bydepositing metal in the corner of two faces meeting at right angles (Fig. 35).A piece of angle iron is a suitable specimen with which to begin, ortwo lengths of strip steel may be tacked together at right angles.Position the angle iron so that the two legs are at 45o to the bench andrun in a weld bead using a similar technique as for butt welds, using a4.0 mm electrode at 170 amps. When you are familiar with this,position another piece of angle iron with one leg horizontal and theother vertical. This is known as a horizontal-vertical (HV) fillet.Strike the arc and immediately bring the electrode to a positionperpendicular to the line of the fillet and about 45o from the vertical.Some electrodes require to be sloped about 20o away from theperpendicular position to prevent slag from running ahead of the weld.(See Fig. 46.) Do not attempt to build up much larger than 6.0 mm leglength with a 4.0 mm electrode, otherwise the weld metal tends to sagtowards the base, and undercut forms on the vertical leg. Multi-runscan be made as shown in Fig. 47. Weaving in HV fillet welds isundesirable.VERTICAL WELDS:Vertical up.Tack weld a 1 metre length of angle iron to your work bench in anupright position. Use a 4.0 mm electrode and set the current at 140amps. Make yourself comfortable on a seat in front of the job andstrike the arc in the corner of the fillet. The electrode needs to be about10o from the horizontal to enable a good bead to be deposited. (SeeFig. 48.) Use a short arc, and do not attempt to weave on the first run.When the first run has been completed deslag the weld deposit andbegin the second run at the bottom. This time a slight weaving motionis necessary to cover the first run and obtain a good fusion at the edges.At the completion of each side motion, pause for a moment to allowweld metal to build up at the edges, otherwise undercut will form andtoo much metal will accumulate in the centre of the weld. Fig. 49illustrates multi-run technique and Fig. 50 and 51 show the effects ofpausing at the edge of weave and of too rapidly weaving.

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1. UNDERCUT:THIS REDUCTION in cross section weakens the joint and creates aslag trap.

Vertical down.To execute this method, it is advisable to use electrodes whichare designed to have a very quick freezing slag. Generallyhigher amperages are used with fast travel speeds. Theeasiest type to use when learning is the contact PH C18. Theelectrode is pointed slightly upward at approximately 80o andwhen the arc is struck, the tip is pressed onto the work andwelding commences and advances as the electrode is drawnslowly down the work.

OVERHEAD WELDS:Apart from the rather awkward position necessary overheadwelding is not much more difficult than downhand welding.Set up a specimen for overhead welding by first tacking alength of angle iron at right angles to another piece of angleiron or a length of waste pipe. Then tack this to the workbench or hold in a vice so that the specimen is positioned inthe overhead position as shown in the sketch. The electrode isheld at 45o to the horizontal and tilted 10o in the line of travel(Fig. 52 shows this). The tip of the electrode may be touchedlightly on the metal, which helps to give a steady run.

A weave technique is not advisable for overhead fillet welds.Use a 4.0 mm electrode at 160 amps, and deposit the first runby simply drawing the electrode along at a steady rate. Youwill notice that the weld deposit is rather convex, due to theeffect of gravity before the metal freezes. Second and thirdruns are deposited in the order shown in Fig. 53.

Cause Remedy

High amperage. Reduce amperage.

Arc too long. Keep shorter arc.

Angle of electrode tooinclined to joint face.

Electrodes should not be inclined lessthan 45o to vertical face.

Joint preparation does notallow correct electrode angle

Allow more room in joint formanipulation of electrode.

Electrode too large for joint. Use smaller gauge electrode.

Insufficient depositing timeat edge of weave.

Pause for a moment at edge of weaveto allow build-up.(Weaving is more likely to produceundercut than a straight run. Therefore,where possible, use straight runs.)

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2. SLAG INCLUSIONS: Non-metallic particles trapped in the weld metal are called slag inclusions. They may seriously reduce the strength of the welded joint.

Cause Remedy May be trapped in undercut from previous run.

If bad undercut present, clean slag out and cover with run from small gauge electrode.

Joint preparation too restricted. Allow for adequate penetration and room for cleaning out slag.

Irregular deposits allow slag to be trapped.

If very bad, chip or grind out irregularities.

Lack of penetration with slag trapped beneath weld-bead.

Use smaller electrode with sufficient amperage to give adequate penetration. Use suitable tools to remove all slag from corners, etc.

Rust or mill scale, preventing full fusion.

Clean joint before welding.

Wrong electrode for position in which welding is done.

Use electrodes designed for position in which welding is done, otherwise proper slag control of slag is difficult.

If slag is present in a weld, chip, grind or flame gouge until removed, and re-weld. 3. INCOMPLETE PENETRATION: A gap left by failure of the weld metal to fill the root.

Cause Remedy Amps too low. Increase current. Electrode too large for joint. Use smaller electrode. Insufficient gap. Allow wider gap. Angle of electrode. If too inclined, does not give

penetration. Keep nearer to right angle to weld axis.

Incorrect sequence. Use correct build-up sequence. (See Fig. 12.)

4. LACK OF FUSION: Portions of the weld run do not fuse to the surface of the metal or edge of the joint.

Cause Remedy Small electrodes used on heavy cold plate.

Use larger electrodes (pre-heat may be desirable).

Amperage too low. Increase current. Wrong electrode angle. Adjust angle so the arc is

directed more into parent metal.

Speed of travel. If too high, does not allow time for proper fusion.

Scale or dirt on joint surface. Clean surface before welding. NOTE: In overcoming these faults, it is often an advantage if the

job can be positioned to allow welding to be done in the downhand position.

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DISTORTION:DISTORTION in some degree is present in all forms of welding. In manycases it is so small that it is barely perceptible, but in other cases allowance hasto be made before welding commences for the distortion that will subsequentlyoccur. The study of distortion is so complex that only a brief outline can beattempted here.THE CAUSE OF DISTORTION:1. Contraction of the weld metal from the molten state to atmospheric

temperature.2. Different rates of expansion and contraction between the metal adjacent to

and at a distance from the weld.1. Contraction of Weld Metal:Molten steel shrinks approximately 11% in volume on cooling to roomtemperature. This means that a cube of molten metal would contractapproximately 2.2 % in each of its three dimensions. In a welded joint, themetal becomes attached to the side of the joint and cannot contract freely.Therefore, cooling causes the weld metal to flow plastically, that is, the weldmetal itself has to stretch if it is to overcome the effect of shrinking volume andstill be attached to the edge of the joint. If the restraint is very great, as, forexample, in a heavy section of plate, the weld metal may crack. Even in caseswhere the weld metal does not crack, there will still remain stresses "locked up"in the structure. If the joint material is relatively weak, for example, a butt jointin 2.0 mm sheet, the contracting weld metal may cause the sheet to becomedistorted.2. Expansion and Contraction of Parent Metal in the Fusion Zone:While welding is proceeding, a relatively small volume of the adjacent platematerial is heated to a very high temperature and attempts to expand in alldirections. It is able to do this freely at right angles to the surface of the plate(ie "through the weld"), but when it attempts to expand "across the weld" or"along the weld", it meets considerable resistance, and to fulfill the desire forcontinued expansion, it has to deform plastically, that is, the metal adjacent tothe weld is at a high temperature and hence rather soft, and, by expanding,pushes against the cooler, harder metal farther away, and tends to bulge (or is"upset"). When the weld area begins to cool, the "upset" metal attempts tocontract as much as it expanded, but, because it has been "upset", it does notresume its former shape, and the contraction of the new shape exerts a strongpull on adjacent metal. Several things can then happen. The metal in the weldarea is stretched (plastic deformation), the job may be pulled out of shape bythe powerful contraction stresses (distortion), or the weld may crack. In anycase, there will remain "locked-up" stresses in the job. Figures 61 and 62illustrate how distortion is created.

OVERCOMING DISTORTION EFFECTS:There are several methods of minimising distortion effects.1. Peening:This is done by hammering the weld while it is still hot. The weld metal isflattened slightly and because of this the tensile stresses are reduced a little.The effect of peening is relatively shallow, and is not advisable on the lastlayer.2. Distribution of Stress:Distortion may be reduced by selecting a welding sequence which will distributethe stresses suitably so that they tend to cancel each other out. See Figures 12 to16 for various weld sequences. Choice of a suitable weld sequence is probably themost effective method of overcoming distortion, although an unsuitable sequencemay exaggerate it. Simultaneous welding of both sides of a joint by two welders isoften successful in eliminating distortion.3. Restraint of Parts:Forcible restraint of the components being welded is often used to preventdistortion. Jigs, positions, and tack welds are methods employed with this inview.4. Preheating:Suitable preheating of parts of the structure other than the area to be welded cansometimes be used to reduce distortion. Figure 65 shows a simple application.By removing the heating source from a and c as soon as welding is completed,the sections, a, b and c will contract at a similar rate, thus reducing distortion.5. Presetting:It is possible in some cases to tell from past experience or to find by trial anderror (or less frequently, to calculate) how much distortion will take place in agiven welded structure. By correct pre-setting of the components to bewelded, contractional stresses can be made to pull the parts into correctalignment. A simple example is shown in Figures 63 and 64.

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METALLURGICAL FACTS ABOUT IRON AND STEEL PROBABLY 90% or more of all arc welding is done on some alloy of iron. Commercially pure iron is a silver grey, very ductile metal of low tensile strength —too weak for most engineering applications. To give it the necessary hardness and strength other elements, principally carbon, must be added. When the carbon content ranges from 0.10 to 1.5% the material is known as steel — from 2.50 to 4.0%, it is cast iron. In addition to carbon, other alloys are also used to promote strength, ductility and resistance to corrosion, abrasion, and impact; such elements as nickel, chromium, molybdenum, and copper in general increase hardness and enhance the physical properties. They are used extensively in the popular constructional steels. Other elements, such as tungsten and cobalt, are important in the production of high-speed tool steels, not only to increase hardness, but to retain the cutting edge at relatively high temperatures. Elements such as aluminium, titanium, zirconium, vanadium and boron are especially useful in the removal of certain impurities in steel, thus improving its grain structure and response to hardening when heat-treated. As phosphorus and sulphur are generally considered detrimental except in steels where free cutting is a prime requisite, these elements are usually not permitted to exceed 0.05%. In excess of this amount sulphur causes porosity and brittleness in welding. Therefore, it is necessary to exercise care when welding free cutting steels, which have a sulphur content of from 0.09 to 0.20%. Cold finished steels of this type are the cause of much unsatisfactory welding and unfortunately, no simple means, such as the spark test, will disclose the

amount of sulphur. The use of either Weldwell 45S or low hydrogen electrodes is recommended to overcome this problem. In making alloy steels, the physical properties depend not only on the elements added, but upon the heat treatment as well. The degree and duration of heat and the rate of cooling have a profound effect upon the hardness and grain structure. Steels which possess marked hardening ability, such as those with over 0.30% carbon, and varying amounts of other elements, harden in proportion to their rate of cooling. Therefore, in welding, the rapid cooling induced by the cold surrounding area causes such steels to become so hard that they are difficult or impossible to machine. Rapid cooling also sets up stresses which unless relieved by later heat treatment, may produce cracks and subsequent failure. To prevent such conditions, the work or parent metal should be preheated and welded while hot, the exact temperature depending upon the type of material and its response to hardening. This permits the weld and adjoining metal to cool more slowly and more evenly, reducing hardness and producing a more uniform grain structure throughout. More is said of this subject under "High Tensile Steels". It should be remembered that the above conditions apply only to steels having more than 0.30% carbon or when other alloys are present. By far the most welded fabrications today are of structural steel — angles, beams, channels, plates, etc — all of which have low carbon and low hardening ability. When alloys are present in such stock the amount is so small as to be negligible as a hardening factor, therefore the precaution of preheating is unnecessary except on heavy sections where the chilling effect would be severe.

MILD STEEL THIS IS essentially iron with up to 0.30% carbon alloyed with it, and containing usually between 0.4 and 1% manganese, a little silicon, and small amounts of sulphur and phosphorus as impurities.

WELDING TROUBLES HOT CRACKING: Cause Remedy Sulphur, introduced from the steel or surface impurities, causes the weld metal to crack, especially when under restraint.

Use either Weldwell PH 56S, PH 77 or 16TC electrodes on high sulphur steels. Clean surface if dirty.

Rigidity of joint which causes the weld metal to hot-tear before completely solidified.

Re-design to relieve weld joint of severe stresses or use crack-resistant Weldwell PH 56S, PH 77, PH 27 or 16TC.

Insufficient throat thickness. Travel slightly slower to allow greater build-up in throat. Current. Too high a welding current will produce a concave weld, and, by over-heating the metal, induce large crystals to form, which are likely to hot-tear.

Use lower current

Wide gap to be bridged, making throat thickness narrow. Closer set-up tolerance, or deposit run of weld each side of gap to close distance

POROSITY Cause Remedy High sulphur in the steel will cause porosity due to gas being evolved.

Use Weldwell PH 56S, PH 77 or 16TC on high sulphur steels.

Damp electrodes will cause porosity at the beginning of a run.

Dry electrodes before use.

Overdried electrodes. Most electrodes, except the low hydrogen types, require some moisture for best running characteristics. Over-drying will cause porosity towards the end of run

For further details concerning drying of electrodes, check recommendation on electrode data or consult manufacturer.

Excessive current, which overheats the electrode, sometimes causes porosity.

Use lower amperage

Surface impurities such as oil, grease, paint, etc, will sometimes cause porosity

Clean joint before welding.

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HIGH TENSILE AND ALLOY STEELS THESE ARE produced to increase strength without increasing weight, and this is attained by adding alloys, such as manganese, chromium, nickel and molybdenum, or by increasing the carbon content beyond that of mild steel. The result of this is usually to make the steel more difficult to weld satisfactorily. EFFECTS OF WELDING: The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of underbead cracks. 1. The Hardened Zone: Let us picture what happens when welding is carried out on a sample of hardenable steel. At the point where the arc is playing, the parent metal is heated to its melting point. Immediately below the molten pool the metal is white hot, with decreasing temperatures further away. When the arc moves on, the cooler metal below the weld bead has a quenching effect on the very hot metal, with the formation of a hard zone. The hardness of this zone depends on a number of factors, among them being: (a) Composition of the base metal. (b) Temperature of base metal. (c) Mass of base metal adjacent to the weld. (d) Heat input (amperage, amount of build-up per

electrode.) (b), (c) and (d) will affect rate of cooling and consequent hardness. The effect of this hardened zone is to reduce the ductility of the parent metal in the weld area, and this, in some applications, may lead to failure of the joint. 2. Underbead Cracking: The tendency for underbead cracking to occur is due largely to the presence of hydrogen in the weld metal. When steel is heated to approximately 720oC, the crystal structure changes to a form known as austenite, and in this state it is able to "absorb" appreciable quantities of hydrogen, such as may be introduced from the arc atmosphere. When the steel cools again after welding, the crystal structure transforms from austenite to another form, eg pearlite, bainite or martensite. In this state, the steel cannot retain the hydrogen, which diffuses into microscopic cavities in the heat-affected area, where it remains and builds up tremendous pressure. If sufficient hydrogen is present and the heat-affected zone hard enough, this pressure will cause underbead cracking. If the hardness of the heat-affected zone exceeds 36 Rockwell c there is a danger that underbead cracks will form when ordinary mild steel electrodes are used. It is not necessary for the weld to be under restraint for these cracks to form. Even unrestricted welds, if sufficient hardness develops, will produce underbead cracks.

Hard zone cracks are generally not visible on the surface which makes it essential to use a proper technique to ensure their absence.

HOW TO WELD HARDENABLE STEELS: Reduce hard zone by: 1. Preheating. This slows down the rate of cooling after

welding, and reduces the quenching effect on hot metal. The preheat necessary increases with increasing carbon and alloys, and a heavy mass of metal requires a higher preheat than a thin section.

2. Using higher amperage, which produces more heat and slows down rate of cooling.

3. Larger electrode sizes, since they require higher amper-ages, will also introduce more heat into weld.

4. Larger deposits. Short, heavy runs deposited from each electrode raise the area of welding to a higher temperature and slow down cooling.

5. Post-weld treatment, consists of tempering or softening in a furnace, with torches, or by induction heating, is sometimes used to reduce the hardness of the heat-affected zone.

Avoid underbead cracking by: 1 Using correct electrodes. The low-hydrogen types,

PH 56S, PH 77, 16TC, etc, or austenite types, Elite RSP, Hi Ten 8, etc, should be used. The PH 56S and PH 77 etc coatings have a very low hydrogen content, and are used for welding high tensile steels, with freedom from underbead cracking. The weld metal has high ductility, and excellent impact strength even at very low temperatures. Weldwell Elite RSP or Hi Ten 8 deposit austenitic weld metal which retains hydrogen and prevents it from diffusing into the hard zone. They may be used for welding very hardenable steels with a minimum of preheating. They are also resistant to hot-cracking — a common fault with some austenitic type electrodes.

2. Using preheat, higher amperage, heavy runs, etc. The same precautions used for reducing the hardness of the heat-affected zone also assist in preventing underbead cracks, firstly, because a zone of lower hardness is less likely to crack, and secondly, because slower cooling allows more hydrogen to escape from the weld to the atmosphere.

STAINLESS STEELS THESE ARE more accurately called corrosion and heat-resistant steels. They are iron alloys which owe their resistance to corrosion and high temperatures to the presence of chromium alone, or chromium and nickel. Small amounts of other alloys, eg titanium, tungsten, molybdenum, niobium (columbium), are sometimes added. The effect of chromium is to form a tough, impermeable film of oxide on the steel, which resists further attack by corrodents. If this film becomes damaged it immediately re-forms, and continues its protective action. The presence of nickel, in sufficient quantity, increases this corrosion resistance and also increases the strength of the steel at high temperatures.

TYPES: There is a large range of alloys in the stainless steel series. 1. Plain Chromium Steels: (a) Martensitic Stainless Steels — 12-16% Cr: Used for cutlery, spindles and shafts, and applications where good resistance to corrosion and scaling at high temperatures is desired. Can be hardened by heat-treatment. (b) Ferritic Stainless Steels — 16-30% Cr: Used where very high temperature scaling resistance is needed. Also have very good corrosion resistance. Common applications are in furnace parts, oil burners, carburising pots, acid containers, etc

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They are not hardened by heat-treatment, and are subject to gain growth at elevated temperatures, which makes them brittle when cool, although they may still be tough at red heat. 2. Austenitic Nickel-Chromium Steels: The most common of this series is the well-known 18/8 Cr-Ni stainless steel. Other compositions contain 25/20 Cr-Ni, 18/12 Cr-Ni, etc. The addition of 2-3% molybdenum increases resistance to corrosion by sulphuric acid. The outstanding properties of these steels are their corrosion and heat-resistance. It is not possible to harden them by heat-treatment, but they work-harden rapidly. They are non-magnetic or only feebly magnetic.

They are used for a great variety of purposes, eg, in chemical and food plants, gas turbines, furnaces and other high temperature applications. Because of their good corrosion resistance, and, in the case of austenitic steels, work-hardening ability, these types of steels are often used for hardfacing and building-up wearing parts by the arc welding process. It is common practice to use low-cost steels for certain applications, and cover areas subject to corrosion and wear with the appropriate stainless steel weld metal. In this way considerable savings may be effected.

HOW TO WELD STAINLESS STEELS: 1. Straight Chromium Steels: (a) Martensitic Types (12-16% Cr): These steels will harden when welded, and may be too brittle for the service desired. Therefore, a preheat of 400oC, followed by slow cooling after welding, is desirable to keep down the hardness of the heat-affected zone. If possible, tempering at 650-700oC after welding should be carried out on the job to restore toughness.

Electrodes: When welding stainless steels, keep a short arc to avoid loss of chromium and other alloys.

(b) Ferritic Types (16-30% Cr): These are hot hardened very much by welding, but they suffer from excessive grain growth if raised to high temperatures, and this makes them brittle when they cool again. The amount of grain growth will depend on the time for which the steel is at the high temperature. For the strongest weld joint, use a preheat of 150-200oC. If multi-runs are necessary, the interpass temperatures should not exceed 200oC. Post-weld treatment, consisting of tempering at 700-800oC, helps to restore ductility to the heat-affected zone of the weld. 2. Austenitic Stainless Steels: These are very similar to mild steel to weld. There are a few points of difference. (a) Distortion: Coefficient of expansion is 50% higher than mild steel, and the tendency to distort is consequently much greater.

Remedies: Use frequent tack welds. Use balanced and distributed welds to prevent stress from building up, and to spread the heat evenly through the work. Use jigs if possible, to hold the job firm during welding, and also to extract heat from the weld area. Reduce heat input by employing the smallest bead size convenient, and a moderate amperage. A small bead on each side of a plate gives less distortion than a heavy bead on one side. (b) Cracking Certain types of austenitic welds are susceptible to cracking.

Possible Cause Remedy Restraint Design to eliminate restraint at joint or

build up larger bead. Type of joint Design to eliminate fillet welds, which

are more prone to crack than butt welds.

Inadequate penetration Pay attention to welding technique. Design joint to give easy access during welding.

Excessive currents Use lower amperage. Large root gap Use small root gap and slower welding

speed to give adequate build-up. Bead shape Concave beads are more likely to

crack. Hold electrode at smaller angle to give more convex build-up.

Fast welding speed Use slower welding speed to give correct build-up over gap.

Weld metal Electrodes which deposit wholly composition austenitic weld metal are particularly

susceptible to hot-cracking. Weld metal containing a small amount of ferrite is not so likely to crack. For advice on this point, consult the local Weldwell representative or agent.

(c) Weld Decay: If the plain Cr-Ni austenitic stainless steels are heated to 500-900oC and allowed to cool slowly, they become more easily corrodible. Such a condition exists in the heat-affected zone of a weld on this material, and a band is formed parallel to the weld where corrosion resistance is greatly lowered. This is believed to be due to the removal of chromium, as such from the grain by carbon, and its precipitation as chromium carbide, leaving a chromium-depleted alloy in the area adjacent to the grain boundaries, which is of much lower corrosion resistance. When the steel is immersed in a corroding medium, these low-alloy areas are eaten out, and the grains of metal simply fall apart. Titanium or niobium additions are frequently made to stainless steels and act as "stabilizers". These have a greater "hunger" for carbon than has chromium, and hence the areas adjacent to the grain boundaries are not depleted of chromium. Very low carbon stainless steels are also used to avoid weld decay. If it is necessary to weld unstabilized material, and afterwards to restore corrosion resistance, it may be heated after welding to 1100oC and quenched. This technique is, of course, limited by the size of the job and its tendency to distort. Unstabilised weld deposits may also exhibit weld decay, for example, where one weld crosses another. For this reason, some stainless steel electrodes are also stabilized. Niobium or columbium additions are always used in this case, titanium being unsuitable as this metal is oxidised in the electric arc, and goes into the slag.

MANGANESE STEEL AUSTENITIC manganese steel, containing 11-14% manganese is used extensively where severe impact, combined with abrasion is met. This steel work-hardens rapidly when subject to impact, and is very suitable for applications such as crusher jaws, digger teeth, dredge bucket lips, railcrossings, etc. Manganese steel is non-magnetic, or feebly magnetic when cold-worked.

WELDING OF MANGANESE STEEL The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is absolutely essential to keep manganese steel cool during welding. This may be done by skip welding to distribute the heat, or by quenching after each run. Slow cooling from temperatures of over 300oC will embrittle the steel, and a good rule to apply is that the steel should be cool enough to touch with the bare hand before depositing another run. Toughness may be restored to manganese steel by heating to 1060oC and quenching.

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ELECTRODES FOR MANGANESE STEELS:For joining and building up manganese steel, use WeldwellRSP, which deposits 18/8Mo stainless steel weld metal. TheRSP deposit acts as a buffer between the manganese steeland the final deposited weld metal, which can be PH Mn orany of the hardfacing alloy types.

Weldwell PH Mn is designed to produce a 13% manganese-containing weld metal which is very tough and dense, with ahigh yield and tensile strength. It work hardens and withstandsheavy impact loads. Mild steel electrodes should not be used,because dilution with base metal produces a very brittle weld.

CAST IRONSTHESE MAY be conveniently divided into the following groups:(a) Grey iron, which contains between 2.5 and 4% carbon,

mainly in the form of flake graphite, and high silicon. Thisiron is relatively soft. Made by slow cooling of the casting.

(b) White iron, of similar composition to grey iron, but havingmost of the carbon present in the form of intensely hard andbrittle cementite, or iron carbide. The silicon content islower. Made by rapidly cooling the casting with "Chills".

(c) Malleable irons, white heart and black heart. These arewhite cast irons which have been heat-treated to render themmore ductile than grey irons.

(d) Alloy cast irons. These are made for wear, corrosion andheat-resistance, and for extra strength. Examples are "Ni-Resist" (corrosion resistance), "Nicrosilal" (heat resistance),and "Meehanite" (high tensile). Some of these cast ironscontain sufficient alloys to make them austenitic.

(e) Spheroidal graphite cast iron (SG iron, ductile cast iron,nodular cast iron). This is a recent development in the searchfor high strength cast iron. By the addition of a smallamount of magnesium (generally as nickel-magnesiumalloy) during tapping into the ladle the graphite is made toform in minute spheres instead of the usual flake form whenthe casting cools. The result is a cast iron which, in theannealed state, has mechanical properties similar to those ofmild steel.

WELDING OF CAST IRONS:All of the cast irons, except white iron, are weldable. White iron,because of its extreme brittleness, generally cracks whenattempts are made to weld it. Trouble may also be experiencedwhen welding white-heart malleable, due to porosity caused bygas held in this type of iron. It is safer to braze weld using oxy-acetylene and Lo-fuming bronze.

PRECAUTIONS WHEN WELDING CAST IRONS:The factors to consider when welding cast irons are similar,whatever the types. They are: 1. Low ductility, with a danger of cracking due to stresses set

up by welding. (This is not so important when welding SGiron due to its good ductility.)

2. Formation of a hard, brittle zone in the weld area. This iscaused by rapid cooling of molten metal to form a white castiron structure in the weld area, and makes the weldunsuitable for service where fairly high stresses are met.

3. Formation of a hard brittle weld bead, due to pick-up ofcarbon from the base metal. This does not occur with weldmetals which do not form hard carbides, such as "Monel"and high nickel alloys. These are used where machinablewelds are desired.

PREHEATING:Although a large amount of satisfactory weldingis done without preheating, cracking due to the rigidity or lack ofductility of castings, especially complicated shapes, may beminimised by suitable preheating.

1. Local Preheating:Parts not held in restraint may be preheated to about 500oC in thearea of the weld, with slow cooling after welding is completed. 2. Indirect Preheating:By this is meant that in addition to the local 500oC preheat, a pre-heat of about 200oC is given to other critical parts so that theywill contract with the weld and minimise contraction stresses.Such a technique is suitable for open frames, spokes, etc. (SeeFig. 73.)

3. Complete Preheating:For intricate castings, especially those having varying sectionthicknesses such as cylinder blocks, it is advisable to completelypreheat to 500oC followed by slow cooling after welding. Asimple preheating furnace may be made of bricks, into which gasjets project, or filled with charcoal which burns slowly andpreheats the job evenly. In these cases gas welding is oftenpreferred to the use of arc electrodes.

PRINCIPLE OF INDIRECT PREHEATING

POST-HEATING:After any welding on cast iron the slowest cooling possibleshould be allowed, the part either remaining in the preheatingfurnace or cooling under a blanket of insulating powder or sand.It is sometimes the practice to post-heat welded joints to relievestresses and so soften hard areas. This is done with torches or inthe furnace.PEENING:Satisfactory welds may be made on cast iron withoutpreheating by using electrodes depositing soft metal andpeening the weld with a blunt tool (such as a ballhammer)immediately the weld is deposited. This spreads the weldmetal and counteracts the effect of contraction. Depositshort weld runs (about 50mm at a time) and then peen beforetoo much cooling takes place. Supercast Ni or SupercastNiFe are soft and allow peening.WELDING PROCEDURE:Clean the area to be welded of all grease, sand, etc beforewelding commences. Oil-impregnated castings should beheated to burn out all oil, otherwise porosity and poor weldbonds will result. "Gassy" castings will also produceporosity in the weld metal. This may be overcome byheating the weld area to a dull red for a short time beforewelding or by buttering the faces of the contaminatedcasting with Austarc 16TC.Preheat, if necessary, to the desired temperature. Ifpreheating is employed, use the largest electrode suitable forthe job and build up the deposits to the maximum cross-sectional size. The weld is then more able to withstandstresses set up on cooling. When the casting is notpreheated, use small gauge electrodes and scatter the runs todisperse the heat and cooling stresses.To repair cracked castings, drill a hole at the end of thecrack to prevent it spreading further, and grind out to thebottom. Begin welding at the drilled end of the crack, whererestraint is greatest, and move towards the free end.Castings which have to transmit fairly heavy working loadsoften have the weld joint assisted by mechanical means such asbolted straps, or hoops which are shrunk on. Broken teeth oflarge cast iron gears are sometimes repaired by studding. Holesare drilled and tapped in the face of the fracture, and mild steelstuds screwed in. These are then covered with weld metal andbuilt up to the required dimensions. They are afterwardsmachined or ground to shape.

STUDDED GEAR WHEEL TOOTH

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NON-FERROUS METALS

(a) ALUMINIUM: ALUMINIUM AND its alloys, because of their lightness, corrosion resistance and strength, are finding increasing use in chemical plant and structural work. They are made in wrought and cast forms. The alloys may be (a) heat-treatable (containing small amounts of silicon, copper, magnesium, chromium and zinc) and obtain their strength by quenching and age-hardening, or (b) non-heat-treatable (containing mainly manganese and magnesium) and depend on cold-working for extra strength. Welding of Aluminium: Aluminium is very different to steel in its properties and weldability because ...

it has a melting point of 660oC (800oC lower than steel), but requires as much heat per pound to melt it; it has a thermal conductivity five times that of steel, hence heat loss is rapid, making a preheat necessary; it expands twice as much as steel for a given temp-erature increase, with greater danger of distortion; it forms a tough, adherent oxide film on its surface which prevents globules of molten weld from "wetting" the plate; it absorbs hydrogen readily when molten, but rejects it on solidification, creating a danger of porosity.

Hints for the Welder: 1. When welding all but very thin sections, use a preheat

to ensure proper fusion of weld with the base metal, and use copper backing if necessary.

2. Allow for high rate of expansion when setting up jobs. If possible, use jigs to prevent distortion and employ frequent tack welds.

3. Design joints so that the weld has the least possible restraint placed on it to avoid hot-cracking. Butt welds are generally stronger than fillet welds, because of more uniform stress distribution. They are also better than fillet welds in chemical plants because they are easier to clean and less likely to trap corrosive slag.

4. Keep all aluminium type electrodes in a warm, dry place, and dry at 150oC for half an hour before use.

5. Clean the surface of the joints with a wire brush just before welding. 6. After welding, the joints must be thoroughly cleaned

with a brush and hot water to remove slag. (b) COPPER: Copper, and its alloys, the bronzes and brasses, are in most cases, weldable with the arc. 1. Copper: May be "deoxidized" or "tough pitch" copper. "Deoxidized" copper is welding quality. "Tough pitch" copper is not welded satisfactorily with the arc, due to gross porosity forming in the weld junction. 2. Bronzes: Plain bronzes are alloys of copper and tin. Aluminium bronzes contain up to 11% aluminium, which gives high tensile strengths and excellent corrosion resistance. 3. Brasses: Alloys of copper and zinc, with other alloys added in special cases.

Welding of Copper and Alloys: The most important factor is the high rate of conductivity of copper, making a preheat of heavy sections necessary to give proper fusion of weld and parent metal. It also has a high coefficient of expansion — about 35% greater than mild steel — for which allowance must be made in setting up. Hints for the Welder: 1. Preheat to give good fusion. 2. Insulate to prevent loss of heat. 3. When building up parts such as bronze bearings,

cleanse first with petrol to remove oil, dry, and heat to drive oil from cracks.

Electrodes recommended by Weldwell: For copper: Bronze Arc. For bronzes: Bronze Arc. For brasses: Bronze Arc. For aluminium: Ally-Arc

HARDFACING THE PROCESS of covering wearing areas with wear-resistant metal by welding is known as hardfacing. It has a wide application in all fields of industry, and its intelligent use results in longer, more efficient machine life, less down time and less maintenance costs. It is becoming common practice to make wearing parts of cheaper steels and to hardface the wearing areas, thus conserving expensive alloy steels, and still obtaining results that are as good or better than these steels give. Stainless steel overlays on mild steel for corrosion resistance are often employed. TYPES OF WEAR: There are two main types of wear. 1. Shock or impact: The material to resist this kind of wear must be hard enough to resist serious deformation, and yet not so hard as to be brittle and crack under the effect of impact. Electrodes depositing such metal are: (a) Weldwell RSP produces an austenitic weld metal

which work-hardens under impact. This metal is very ductile and does not easily crack.

(b) Weldwell PH 250 and PH 400, the deposits of

which do not work-harden appreciably, but which are fairly hard and sufficiently ductile to resist cracking. They will not, however, withstand severe impact, since they tend to deform under the blows. PH 400 is better able to resist this than PH 250. The best solution to the problem of resisting very severe impact may be to employ a buffer layer of Elite RSP, followed by a layer of PH 700 or PH 600. PH 700 alone, although depositing a very hard alloy, is suitable for moderate impact conditions. For high impact loads use PH Mn.

2. Abrasion: This is caused by a grinding action of particles against the wearing surfaces, or by rubbing together of surfaces. To resist this type of wear, a relatively hard material is needed, and it often happens that this material is also somewhat brittle and unable to withstand severe impact without cracking. The PH 700 or Abrasocord 43 and Vidalloy 11 electrodes give hard deposits suitable for withstanding abrasion under various conditions.

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It is very seldom that either of these two types of wear is found alone; generally both are present in greater or lesser degree, and it is a question then of selecting an electrode that will most satisfactorily cope with both conditions. The PH 700 electrode has been designed to withstand the combined effects of impact and abrasion. Added to these types of wear it sometimes happens that the part in question is also operating under corrosive conditions, and a hardfacing alloy that is able to resist this must be used. The foregoing brief account gives some idea of the range of conditions likely to be met. For specific applications, the Weldwell Technical staff is always willing to offer advice. PRE-HEATING: There are four main reasons for preheating parts to be hardfaced:

1. To prevent underbead cracking of steels having sufficient carbon or alloys to make them very hardenable.

2. To prevent cracking of rigid, brittle components due to contraction of the weld metal.

3. To prevent cracking of large areas of the very hard types of hardfacing.

4. To minimise distortion of the part being welded. The first point is the most important to watch, since a large amount of hardfacing is done on medium-to-high carbon and alloys steels, and if underbead cracks form the weld deposit may spall off in service. The importance of the other points mentioned depends on the particular application in hand.

CUTTING WITH THE ELECTRIC ARC IN ADDITION to welding, the arc can be used for certain other operations such as cutting, piercing, chamfering and gouging of metals. There are two variations of the process C 1. the use of conventional welding electrodes at high currents, and 2. the oxy-arc process. 1. Cutting with electrodes: Whereas the gas cutting of steel is a burning action, the metal being oxidised by the oxygen stream and blown away as a molten stream, the arc cutting action depends entirely on the heat of the electric arc to melt the metal, and the force of arc to remove it from the face of the cut. For this reason the arc cutting process can be used on metals such as cast iron, stainless steel and non-ferrous metals, which are not readily oxidizable or which cannot be otherwise cut with the gas process unless the power cutting or plasma arc process is available. Higher currents are used than are needed for ordinary welding purposes. The actual current value will depend on the thickness of metal to be cut. With the electrode held vertical the arc is struck on the edge of the plate and played up and down the face of the cut with a see-saw motion. A long arc is held, which is made possible by the high current, and this causes molten metal to run down the cut. If properly used, no metal will be deposited from the electrode.

To cut a section (eg a circle) from a plate a hole is first pierced in it by concentrating the arc at one spot and pushing the electrode into the molten pool until it melts through to the other side. The hole can then be enlarged or extended into a cut as required. Back-gouging and grooving of weld joints can also be done with electrodes. As for cutting, a high current is needed. The electrode is inclined at about 5o to the plate surface and pointed in the direction in which the grooving is to be done. The molten metal is pushed ahead of the electrode tip, and periodically the electrode is run back along the groove to clean out slag. It is an advantage also if the job can be positioned so that the slope allows molten material to run ahead clear of the groove. Austarc C&G electrodes are particularly suitable for grooving and clean, neat grooves can be made. Piecing is best done, where possible, from beneath the job, the molten metal then falling clear of the hole. Chamfering is performed in a similar manner to cutting. Arc cutting is not as neat as gas cutting; it is intended for use where gas equipment is not available or where materials have to be cut for which the gas cutting process is not effective.

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Section TwoTECHNIQUES FOR SELECTED APPLICATIONS

New or Slightly Worn Grousers:Cover the working edge with one run of RSP or PH 77 to act as abuffer. Hardface with one run of PH 600. DO NOT applyhardfacing direct to grouser. Use step back sequence at 15 cmruns to reduce distortion.Badly Worn Grousers:Flame cut the tip to a straight edge and weld on build up strip ofmild steel or special carbon steel with PH 56S, PH 77 or 16TC,again using step back sequence. Allow sufficient gap forcomplete penetration.Mild steel may be hardfaced with PH 600 direct. Special steel striprequires buffer of RSP or PH 77 before hardfacing.

Track Links:Because of high carbon content of steel, it is desirable to use buffer of PH 56Sor RSP for first layer. If RSP is used no other hardfacing is necessary, since thisdeposit work-hardens to over 400 VPN.PH 400 is used to build up over PH 56S or 16TC.If it is convenient, a preheat of 150oC may be used and PH 400 applied direct tolink. In any case, it is an advantage to warm the side of the link opposite the onebeing welded to counteract the effect of contraction.A jig made up of copper bar, is of great assistance in securing desired shape ofweld deposit.

Idler Wheel:Mount the wheel on a shaft for easy manipulation. Weld diametrically opposedsegments to reduce distortion. Use PH 56S for first layer and hardface with PH250 or PH 400.

Drive Sprocket Teeth:Cut a steel template, patterned from a new wheel, covering three or four teeth.The weld deposit can then be checked to see when there is sufficient build-up.PH 56S is used for the first layer to ensure freedom from cracking, and theremaining build-up is done with PH 400.

Track Rollers:Generally made of cast steel and flame or induction hardened on the wearingsurface.Method: Mount on shaft for easy turning. Use PH 56S for first run, and PH 400for build-up.Top rollers are sometimes made of cast iron with white iron wearing surfaces,and are often considered not worthwhile reclaiming. If it is desired to build-upthese rollers, use two layers of PH 56S followed by PH 400. Preheat to 500oCbefore welding commences.

Dozer Blade Tips and Wearing Strips:These are made of high carbon steel and it is essential to use a buffer layer.Method: Preheat the blades to 150oC before welding. For blades working underheavy impact as well as abrasion, use RSP buffer on all surfaces to behardfaced, followed by a layer of PH 600 or PH 700.For abrasive wear only, in sand or clay pits, PH 56S is suitable.A layer of Vidalloy 11 on the corner of the tip greatly helps in preventing this frombecoming rounded.

Excavator Buckets:Deposit runs of PH 600 or PH 700 at distances of 25-50 mm apart on all wearingfaces. Cover all rivet heads with hardfacing otherwise they wear away veryrapidly.

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Scarifier and Ditcher Teeth:Worn Manganese Steel Teeth: Build up with RSP and hardfacewith PH 600 or PH 700. Do not allow to overheat.New Manganese Steel Teeth: One layer of PH 600 or PH 700.High Carbon Steel Teeth: PH 56S or RSP for buffer layers orbuild-up. PH 600 or PH 700 for facing layer. Vidalloy 11 prolongstooth life.

Ploughshares:It is always best to hardface ploughshares before use or when onlya little wear has taken place.(a) Cast Iron Ploughshares: Use PH 700 in short runs.(b) Cast Steel Ploughshares: Use PH 600 or PH 700.Only one face of the share requires hardfacing in order to create aself-sharpening edge.

Ripper Teeth:Generally made of manganese steel. Use PH 600 or if build-upneeded, use RSP with final layer of PH 700. Do not allowmanganese steel to overheat.Vidalloy 11 on the point will give extended life.If teeth are made of high carbon steel apply RSP buffer beforehardfacing.

Pump Impellers:Hardface with PH 600 or Abrasocord 43 as shown. Use smallelectrodes to keep heat input down. The pump casing may also behardfaced with PH 600 or Abrasocord 43 if not made of cast iron.If casings are cast iron, use Supercast Ni or Supercast NiFe forbuild-up. 16TC can be used as a buttering run if the casing iscontaminated.

Excavator and Bucket Teeth:If these are made of manganese steel, use PH 600 or PH 700.Manganese steel must not overheat or it becomes brittle; therefore,scatter the welds or quench to keep cool. If build-up needed, useRSP before hardfacing.For teeth made of high carbon steel, use RSP buffer, followed byPH 600 or PH 700. Provide a self-sharpening edge by covering theupper surface with hardfacing and depositing stringer beads on theunderside. The softer base metal wears more rapidly than thehardfacing, thus maintaining a sharp edge, but stringer beadsprevent excessive wear. (See Fig. 86b.)If teeth are badly worn, new steel tips are welded on with RSP andhardfaced, as shown in Fig. 86c.

Excavator Doors:Deposit runs of PH 600 at 25 mm intervals as shown in the sketch.

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Dredge Bucket Lips:Hardface lips with PH 600 or PH 700.

Chains (Dragline, etc):Hardface wearing areas with PH 400.

Post Hole Auger:The cutting edge gives best service if hardfaced with Vidalloy 11.Only the upper cutting surface and corners need to be hardfaced,thus providing a self-sharpening edge.The edge of the spiral may be hardfaced with Abrasocord 43 orPH 600 as shown in Fig. 90.

Drill Bits:Preheat to 200oC and apply RSP buffer. Hardface with PH 600.Alternatively use PH 700 alone. Build the corners out so that thedrill will not stick in hole.

Oil Drills (Fish Tails):Clean the surface to be welded. Apply Vidalloy 11 to the wearingedge as shown in the sketch.

Oil Drill Collars and Joints:Vidalloy 11 is deposited in bands around collars and joints asshown in Fig. 94, and built out slightly beyond the rest of themetal to give adequate protection.

Mill Hammers:Preheat to 250oC. Build up worn corners with PH 600, PH 700 orAbrasocord 43.

Conveyor Screws:Mount the screw on a shaft for easy turning. Deposit PH 600, PH700 or Abrasocord 43 on the edge and bearing surface of the screw.For cast iron screws, use RSP or PH 56S deposited in short runsfrom small gauge electrodes. Hardfacing is generally confined tothe edge of the spiral due to the brittleness of cast iron.

Crusher Jaws: Usually made of Manganese Steel. If so, butter the worn surfacewith RSP, usually two layers thick.Then build up to nearly the required dimension with PH Mn andfinish off with either PH 600 or PH 700. Note the usualprecautions are maintained, ie "Keep Cool", "Scatter the welddeposits", etc.Usually when depositing PH Mn it is desirable to peen each runthus work hardening the deposit.

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Grizzlies:Use PH Abrasocord 43, PH 700 or PH 600 along with the wearingedges of the bars. If necessary, deposit a run also in the centre ofthe bars.

Crusher Liners:May be manganese steel. If so, hardface with PH 600 observingusual cooling precautions. Deposit runs as shown in sketch.For build-up, use RSP before hardfacing.

Crusher Mantles:For build up on carbon steel, use PH 250 or PH 400, followed byPH 600. For building up on manganese steel, use RSP and hardfacewith PH 600 or PH 700.

Cyclone Fan Blades:Use PH 600. It is essential that the contact sides be completelycovered with hardfacing and that the runs be even and completelyoverlap, because abrasion will quickly enlarge any depression.After welding, balance the blades by grinding off heavy portions.

Pug Mill Knives:More economical to hardface when only a little wear has takenplace. Use Abrasocord 43 or PH 700. If building-up necessary, usePH 56S and then hardface with PH Abrasocord 43 or PH 700.

Beater Bar (Swarf Hammer)Use Abrasocord 43 or PH 700. Set face of hammer in mould,preheat to 500oC and cover with hardfacing, using weave. If madeof manganese steel do not preheat, butter with RSP then overlaywith PH 700. Must be kept cool.

Valves (Liquid):The electrode to be used depends on the material in the valve. Forbronze valves use Bronze Arc; for 18/8 stainless steel use PHRM318LC or RS309LC; for cast iron use Supercast Ni; for steel useelectrode suitable to resist corrosion being met. For mild corrosiveconditions Supercast Ni on steel is suitable; for more severecorrosion use PH RM318LC or RS309LC.After building up as shown in the sketch, machine or grind to shape.

Valves and Seats (Liquid and Steam):Machine groove in seating edge and place valve in copper chill,making sure there is sufficient build-up to allow for machining backto desired shape.Electrodes used will depend on composition of base metal (seerecommendations for Valves above).Use oxy-acetylene applied Stellite 6 for resisting attack by corrosiveliquids at high temperature, and liquids carrying abrasive material.

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Valve Seating (IC Engine):Machine out groove in valve seat to take weld deposit. A copperchill shaped as in Fig. 107 helps to prevent excessive heat meltingthe seat, and to retain shape of bead. Use small gauge SupercastNi or Supercast NiFe. Use short runs and peen.

Valves (IC Engine):Machine groove in seating edge and place valve in copper chill.(See Fig. 108.) Usually done with gas or TIG to depositBrightray alloy, use arc Hi Ten 8.

Gear Teeth:For repairing broken and chipped gear teeth, use Hi Ten 8. Onlarge gears a slight preheat is desirable. The deposit may bemachined back to the desired contour.

Chisels:Chisels may be re-tipped with PH 600 and striking end faced withRSP buffer followed by PH 400. This is very successful inovercoming "mushrooming". New chisels may be made frommild steel bar using the technique described.

Tool Tips:Very satisfactory lathe tools may be made up using mild or lowalloy steel shank with a high speed tool steel deposit for thecutting edge. The supporting parent metal beneath the bed shouldbe at least twice the thickness of the high speed tool steel depositto give adequate strength.Make a mould of copper, carbon or a suitable plastic refractorymaterial to retain the molten deposit on the tip. Puddle the weldmetal into the mould until build-up is sufficient and allow to coolin air. Deposit is self-hardening.

Shear Blades:A groove is machined on the cutting edge as shown. Blades maybe made of mild steel, or a carbon or alloy steel, in which case apreheat is needed, the amount depending on the carbon or alloycontent.

To avoid distortion in long blades either bolt blades back to backor hold in a suitable restraining jig, and use the step-backsequence of deposition.Building-up should be done with PH 400 and the final hardfacingwith PH 600.

Axles and Shafts:Butt break together and tack weld in two places. Cut one vee incrackline with Austarc C & G electrode, clean, then put threeruns in with PH 56S. Then vee the other side through to the 56Sdeposit. Weld with 56S keeping weld area hot, straighten in alathe or suitable press, let cool in vertical position.

Springs:Prepare a 70o included angle on the broken ends, line up thepieces and weld with Hi Ten 8, a 300oC preheat is desirable.Cool slowly.

28

Section Three

WELDWELL WELDING ELECTRODES

ELECTRODES FOR WELDING MILD STEEL DOWNHAND WELDING

For downhand welding of mild steels where ease of operation and weld appearance is essential the PH 46 is ideal. It has a "rutile coating" which gives a soft arc with the slag following closely to the arc. This slag is compact and has excellent self lifting properties revealing a smooth weld with a nice glossy appearance. The PH 46 has 100% efficiency of deposition and is ideal for sheet metal and general constructional work in medium-thick plate. Where higher deposition rates are desired the PH 22 or PH 7024 type with an efficiency of 140-160% is an ideal choice. They are fast running with quick release slag, very smooth appearance and with very little spatter.

ALL-POSITION WELDING

A large number of often only slightly different rutile-coated all-position electrodes are available on the market. This great variety may make selection of the proper type for the job very difficult. The WELDWELL range of all-position rutile electrodes includes the PH 68, PH 48A, PH 28 and PH 78, each of which has distinctly different properties as a result of difference in arc characteristics, protective gas stream and speed of slag solidification. The strong gas stream and the quickly setting slag makes the PH 68, in particular, suitable for overhead and vertical-down welding, and the metal transfer in the form of relatively large droplets facilitates the bridging of large gaps. The deeper cup and the somewhat finer droplet-transfer of the PH 48A allow this electrode to be welded slightly in touch with the workpiece. It is a somewhat slower setting type than the PH 68, with a rather weak gas stream yielding nice fillet welds in all positions. On account of their quickly solidifying slag the PH 68 and, to a much lesser degree, the PH 48A have a tendency to produce welds with so-called heat indentations if the heat-dissipation is not sufficient, which can be the case when welding joints in thinner plates. On the other hand, their type of slag can take more care of contamination in the form of rust or paint before becoming uncontrollable. The PH 28 is characterised by a cone-shaped cup, a finer droplet-transfer and a slower-setting type of slag. It is the virtual all-position electrode of the series. Heat build-up such as occurs in thin-plate welding, has much less effect on slag behaviour and weld appearance. Compared with PH 28, the PH 78 has a still slower-setting type of slag, which is completely insensitive to heat accumulation in the work piece; there is always sufficient time for the gases to escape from the molten pool before the slag solidifies, resulting in sound welds. Upward welding is favoured by the very nice wash of the weld metal onto the sides, and by the fact that the slag leaves the molten pool very quickly, yet gives sufficient support to the molten pool. The slag is too fluid for vertical-down welding. With this group of all-position electrodes the PH C18 should be mentioned as well. This iron-powder-containing electrode excels in vertical-down welding of fillet joints. Its good penetration properties make it also suitable for spot welding of thin plates.

29

DESCRIPTION:The WELDWELL PH 28 electrode has a medium-heavy rutilecoating and yields a fairly rapidly solidifying slag. This electrodeis the answer where a universal rod is desired for welding in allpositions.

With this electrode even not so experienced welders will obtaingood results since it is very easy to use.

The PH 28 is extremely suitable for making fillet welds.Welding is then done with a short arc. The weld surface is verysmooth and the beads are almost flat. The same applies forunprepared butt welds and for outside corner welds.

The uniform fine-droplet metal transfer and the possibility ofusing a shorter arc length without risk of short-circuiting andfreezing are very helpful in both vertical and overhead welding.

The PH 28 may be employed on either AC or DC. When it isused with DC the electrode is normally connected to thenegative pole (straight polarity).

For this electrode, use can be made of transformers with arelatively low no-load voltage.

Applications:Pipe welding on site. Pressure vessels, general construction,hydro installations, ship building. storage tanks.

Welding Positions:

F, H, V, OH

Recommended Amperages

Dia. Length Amperes Depositionmm mm Rate kg/hr*2.5 305 70-1003.2 380 85-135 1.004.0 380 130-170 1.455.0 455 190-230 2.156.0 Available on Special Order only

* Deposition rate at maximum amps.AC 50V DC -

Typical Mechanical Properties of Weld MetalTensile Strength 500 MPaYield Value 448 MPaElongation(1 = 5d) 26%Impact Value Charpy V Notch at 0oC 52 J

AWS A5.1 : E6013AS/NZS 1553.1 : E4112-0

WELDWELL

ELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR BlueFLUX MARKING PH 28 6013 E4112

Approvals:American Bureau of ShippingLloyds Register of ShippingBureau Veritas

CharacteristicsExcellent X-ray properties.Quality for wide range of work.High efficiency for vertical and overhead.Smooth arc with very little spatter.Easy to control and for slag removal.Fine for fillet welds.Welding can be done using either AC or DC-.

StorageStore electrodes in a dry place. To reconditionmoist electrodes bake for half an hour at 120oCin a vented oven.

Typical Chemical AnalysisC 0.04%Mn 0.47%Si 0.40%

28

30

DESCRIPTION:Austarc 12P is a smooth running, rutile type electrode for allpositional welding of mild steel. It is characterised by amoderately forceful and extremely stable arc, and producesexcellent penetration with low spatter losses. Features include :- Superb arc striking and restriking

on low voltage AC machines.

Low spatter levels and self-releasing slag. A stiff, fastfreezing slag for all positions (especially vertical down), filletwelding.

Applications:All positional welding of galvanised gates and fences, steelfurniture, trailers, wrought iron work.

Austarc 12P is especially recommended for the fillet weldingof pipe or rectangular framed sections using the verticaldown technique to minimise distortion and the risk of burnthrough.

Recommended AmperagesDia. Length Amperesmm mm2.0 305 40-602.5 305 60-853.2 380 90-1304.0 380 130-1805.0 455 180-230AC 45V DC + or -

AWS A5.1 : E6013AS/NZS 1553.1 : E4112-0

WIAAUSTARC 12P

ELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR RedFLUX MARKING 4112

Approvals:American Bureau of ShippingLloyds Register of ShippingDet Norske Veritas

Welding Positions:F, H, V, VD, OH

Typical Mechanical Properties of WeldMetalTensile Strength 480 MPaYield Value 447 MPaElongation(1 = 5d) 31%Impact Value Charpy V Notch at 0oC 108J Average

Typical Chemical AnalysisC 0.05%Mn 0.48%Si 0.29%

StorageStore electrodes in a dry place. To reconditionmoist electrodes bake for one hour at 110oC ina vented oven.

31

45E

DESCRIPTION:The WELDWELL PH 45E is a conventional electrode havinga very low silicon content. It was specially developed for thewelding of low silicon plate, eg "lyco" used in the fabrication ofgalvanising baths, etc.

Welding Techniques:Before welding the current should be checked for theapplication. If the current is too low the weld bead will belumpy and irregular. If too high an irregular bead with sharpripples and excess spatter will be the result. A medium arclength should be made, too short an arc will produce a highcrowned bead with little wash in.

Recommended Amperages

Dia. Length Amperesmm mm4.0 455 140-1806.0 455 200-280

AC 50V DC -

Typical Mechanical Properties of Weld Metal

Tensile Strength 507 MPaYield Value 439 MPaElongation(1 = 5d) 24%Impact Value Charpy V Notch at 0oC 73 J

AWS A5.1 : E6020AS/NZS 1553.1 : E4120-0

WELDWELL

ELECTRODESFOR WELDINGLOW SILICON

PLATE

TIP COLOUR GreenFLUX MARKING PH 45E 6020 E4120

Welding Positions:F, H, V, OH

Typical Chemical AnalysisC 0.04%Mn 0.76%Si 0.03%

StorageStore electrodes in a dry place. Torecondition moist electrodes bake for half anhour at 120oC in a vented oven.

32

46

DESCRIPTION:! Heavy rutile coating.! Metal transfers in fine spray across the arc.! Touch welding technique.! Quick flowing characteristics.! Slag self-detaching.! Smooth and steady arc.! Appearance very smooth and flat, with no undercut.! Welds can be drawn out for long small fillets.! For use where fine appearance enhances sales

appeal of weldments.

Applications:For quality welding of mild steel sheet speedily and withvery little distortion. Constructional work, also oil andwater-tight jobs. Truck and Car Body Industry, SteelFurniture, Agricultural Machinery, Motor Mower Frames,Pressure Tanks, Water or Air, etc.

Welding TechniquesTo gain the optimum results with the WELDWELL PH 46Electrode a Touch and Draw Technique is advisable, thespeed of travel depending upon the weld size desired.For economy and fine finish with some work a largegauge size is used and the weld is "stretched" out at afaster speed of travel. In some cases however, a veryshort arc can be used.

Due to the very fluid slag, care must be taken to ensurethat the work is free of rust, heavy mill scale and paint.The amperages used can be varied quite substantially tosuit different working conditions. Due to the low viscosityof the slag, it is not recommended to proceed downwardswith the work angle at a greater slope than 20o.

Recommended AmperagesDia. Length Amperes Depositionmm mm Rate kg/hr*2.0 305 40-602.5 305 60-1003.2 380 80-140 1.024.0 380 130-180 1.44

* Deposition rate at maximum amps.AC 50V DC -

AWS A5.1 : E6012AS/NZS 1553.1 : E4113-0

WELDWELL

ELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR OrangeFLUX MARKING PH 46 6012 E4113

Approvals:American Bureau of ShippingLloyds Register of ShippingBureau Veritas

Welding Positions:F, H, V, OH

Typical Mechanical Properties of Weld MetalTensile Strength 477 MPaYield Value 438 MPaElongation(1 = 5d) 34%Impact Value Charpy V Notch at 0oC 84 J

Typical Chemical AnalysisC 0.04%Mn 0.44%Si 0.25%

StorageStore electrodes in a dry place. To reconditionmoist electrodes bake for half an hour at 120oC ina vented oven.

33

48A

DESCRIPTION:The WELDWELL PH 48A is a Rutile Electrode. It is for allpositional general purpose welding of mild steel. The arcstability on low open circuit voltages makes it excellent for useon 230V single phase welding machines. The slag has quickerfreezing properties than many types of similar class electrodes,this makes it suitable for out of position welding and it offers aquite remarkable tolerance to bad fit-up. The easy starting andre-starting properties combined with quiet running make it agood electrode for welding galvanised steel and pipe.

Welding TechniquesPH 48A is used with either a short free arc or by contact ifconditions are suitable. The welding amperage can be variedconsiderably to gain ease of control when welding thick to thin,etc.When used with DC current it is normally connected to thenegative (-) pole.

Functions of the Coating of PH 48AThe function of the coating is two-fold:1. To protect the metal across the arc.2. To protect the deposited metal while it is cooling.When the arc is established, and the melting of the electrodestarts, a protruding sheath of flux forms at the electrode tip.The metal globules are transferred across the arc and thecoating melts rather more slowly than the metal, thus allowingthe coating to form a cup, which shields the weld metal as it isbeing deposited, exercises a directional control over the arc,and reduces operator fatigue.The combination of the coating produces an inert gaseousshield, or reducing atmosphere, which envelopes the arc andthe molten metal. The resultant chemical reactions produce aslag covering which rises over the deposited metal and shieldsit from the atmosphere during final cooling.This slag cover also has a beneficial annealing or refininginfluence upon the grain structure of the deposit. This influenceis well illustrated by the excellent mechanical properties shown.After the weld has been completed, the removal of the cold slagis practically automatic, and consequently, it is not necessary towaste valuable time by excessive chipping or hammering, as itis in the case with many other types of electrodes.

Recommended AmperagesDia. Length Amperes Depositionmm mm Rate kg/hr*2.5 305 70-1003.2 380 90-135 1.004.0 380 130-180 1.60

* Deposition rate at maximum amps.AC 45V DC -

AWS A5.1 : E6013AS/NZS 1553.1 : E4112-0

WELDWELL

ELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR SilverFLUX MARKING PH 48A 6013 E4112

Approvals:Lloyds Register of ShippingBureau Veritas

Welding Positions:F, H, V, VD, OH

Typical Mechanical Properties of Weld MetalTensile Strength 521 MPaYield Value 467 MPaElongation(1 = 5d) 31%Impact Value Charpy V Notch at 0oC 59 J

Typical Chemical AnalysisC 0.04%Mn 0.50%Si 0.40%

StorageStore electrodes in a dry place. Torecondition moist electrodes bake for half anhour at 120oC in a vented oven.

34

68

DESCRIPTION:The WELDWELL PH 68 is a medium-heavy-coated rutileelectrode which produces very rapidly solidifying slag. Itis an outstanding electrode for welding in all positions andat places difficult to reach. An important feature is that thesame current can be used for welding in any position.This means that welding can be done without repeatedsetting of the current, and accordingly a considerablesaving in time is obtained.

PH 68 is suitable for vertical down welding because ofthe excellent slag control.

Applications:The PH 68 is suitable for welding in sharply curved andpoorly fitting grooves, as well as inclined grooves. It meltsoff in fairly coarse droplets, for which reason it is used forbridging large gaps. The very rapidly solidifying slagprevents the liquid weld metal from flowing away whenwelding is done in difficult positions, especially pipewelding.

Welding TechniquesBefore welding commences, the current setting should bechecked to see that it is correct for the type of work. If thecurrent is too low, the metal tends to pile and the bead willbe lumpy and irregular. If the current is too high, a flatdeposit with undue spatter and wastage of the electrodewill result.

Different applications require variations within therecommended current range and with PH 68 a currentsetting is possible to allow welding in all positions withouthaving to alter it. In general, a medium arc length is usedto gain even welds but touch welding is possible atcurrents near to maximum.In vertical positions, extremely heavy deposits of mitrecontour can be made in one pass for butt and fillet weldsusing a triangular weaving motion. For second andsubsequent passes, only a simple side to side weave isrequired with a slight pause in each corner to avoidundercutting.

When used with DC it is normally connected to thenegative (-) pole.

Recommended AmperagesDia. Length Amperes Depositionmm mm Rate kg/hr*2.5 305 60-953.2 380 70-125 1.204.0 380 130-170 1.685.0 455 170-240 2.22* Deposition rate at maximum amps.AC 50V DC -

The type PH 68 is highly recommended to weldGalvanised Steel.

AWS A5.1 : E6013AS/NZS 1553.1 : E4112-A

WELDWELL

ELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR RedFLUX MARKING PH 68 6013 E4112

Approvals:American Bureau of ShippingLloyds Register of ShippingBureau Veritas

Welding Positions:F, H, V, VD, OH

Typical Mechanical Properties of Weld Metal

Tensile Strength 495 MPaYield Value 443 MPaElongation(1 = 5d) 29%Impact Value Charpy V Notch at 20oC 87 J

Typical Chemical AnalysisC 0.06%Mn 0.43%Si 0.46%

StorageStore electrodes in a dry place. To reconditionmoist electrodes bake for half an hour at 120oC ina vented oven.

35

78

DESCRIPTION:The WELDWELL PH 78 electrode deposits weld metalwhich combines the advantages of both a rutile and abasic electrode.PH 78 has a medium-heavy rutile coat which yields a fairlythin fluid type of slag and a rather strong protective gasstream. It is suitable for welding in all positions exceptvertical down and due to its remarkable arc action it isexcellent for welding pipes.

This electrode is tested for impact values at minus 20oC, thedeposited weld metal will therefore be very suitable forwelding pipe which operates at low temperatures. Whenwelding vertically-up a relatively high current is required forease of welding resulting in a high deposition rate. Due toits nature, the slag is insensitive to heat accumulation in theworkplace, which contributes towards obtaining welds ofgood X-ray quality.

Applications:General purpose mild steel welding. Pipe welding,especially on site. Pressure vessels, ship construction,tanks and body construction or repairs.

Welding TechniquesFor downhand welding the arc should be kept short. Inupward welding a medium arc length is recommended, andif beads are deposited with weaving, the weaving movementshould be carried out rather quickly.

Recommended AmperagesDia. Length Amperes Depositionmm mm Rate kg/hr *2.5 305 60-95 0.783.2 380 90-140 1.154.0 380 120-190 1.75

* Deposition rate at maximum amps.AC 50V DC -

Typical Chemical AnalysisC 0.05%Mn 0.69%Si 0.12%

AWS A5.1 : E6013AS/NZS 1553.1 : E4113-2

WELDWELL

ELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR VioletFLUX MARKING PH 78 6013E 4113

Approvals:American Bureau of ShippingBureau Veritas

Welding Positions:F, H, V, OH

Typical Mechanical Properties of Weld MetalTensile Strength 508 MPaYield Value 455 MPaElongation(1 = 5d) 27%Impact Value Charpy V Notch at -20oC 83 J

StorageStore electrodes in a dry place. To reconditionmoist electrodes bake for half an hour at 120oCin a vented oven.

36

DESCRIPTION:The WELDWELL PH C18 is a heavy coated rutile electrodewith a relatively large amount of iron powder in the coating,thus permitting a larger amount of metal to be depositedvery easily. This type is suitable for welding in ALL positionswith particularly striking results in vertical down welding. ThePH C18 has deep-penetrating properties and thanks tothe protective effect of the deep cup, the weld metal is verypure. The slag is easy to remove.

Applications:This type owes most of its field of application to the positiveroot penetration in vertical down welding. Especially inshipbuilding much use is made of this property. In a greatdeal of work with vertical fillet welds the root run is depositedwith PH C18 electrodes, followed by a second and a third, ifnecessary. When large fillets are required it is good practiceto use PH C18 for root runs, then use the vertical up methodwith PH 48A to complete.

Amongst the many attributes of PH C18 is its ability to beused as a cutting or gouging electrode. PH C18 is anexcellent means of making very strong Spot Welds in thinplate. The maximum thickness of the upper plate must notexceed 3 mm. There is, of course, no limit to the thicknessof the base plate.

Welding TechniquesFor vertical down welding the electrode is held at an angleof about 75o to the direction of travel. When metal plateunder 4 mm is welded in this manner the angle of theelectrode is adjusted to about 35o and the speed of travelincreased. The touch technique must be used. Whenwelding the heavier plate at a 75o angle the formation of atiny drop of molten iron and slag regularly appears just belowthe tip of the electrode. This drop is periodically blown awayand should instantly reappear, since it is proof of rootpenetration which is only acquired when the electrode isbeing held at the correct angle of 75o. Should thisphenomenon not appear, eg when welding at an angle ofsay 60o, slag will be included right in the corner, resulting inlack of root penetration. The function of PH C18 electrodesis influenced unfavourably by rusty, scaly or dirty platebecause of the fact that these impurities increase the fluidityof the slag. When metal has to be removed, ie tack welds,fillet welds or to vee out a crack, the PH C18 is excellent.

Recommended Amperages

Dia. Length Amperes Depositionmm mm Rate kg/hr *2.5 305 80-1203.2 380 130-160 1.554.0 380 150-210 2.225.0 450 210-300 3.60* Deposition rate at maximum Amps.AC 50V DC + Cutting AC 50V or DC -

AWS A5.1 : E7014AS/NZS 1553.1 : E4814-0

WELDWELL

C18

ELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR GreenFLUX MARKING PH C18 7014 E4814

Approvals:American Bureau of ShippingLloyds Register of ShippingBureau Veritas

Welding Positions:F, H, V, VD, OH

Typical Mechanical Properties of Weld MetalTensile Strength 494 MPaYield Value 446 MPaElongation(1 = 5d) 30%Impact Value Charpy V Notch at 0oC 66 J

Typical Chemical AnalysisC 0.075%Mn 0.56%Si 0.40%

StorageStore electrodes in a dry place. To reconditionmoist electrodes bake for half an hour at 120oCin a vented oven.

37

DESCRIPTION:The WELDWELL PH 22 is a heavy coated, rutile electrode,with a large amount of iron powder in the flux coating.

It is used for high speed contact welding of mild steel in theflat and horizontal positions.

Welding can be carried out using AC power sources with aminimum of 50 open circuit volts, or DC power sources withelectrode positive + or negative - (- preferred).

The PH 22 electrode features excellent re-strike ability, verygood slag and weld pool control and slag detaches veryeasily.

The weld appearance is smooth and flat with very goodedge tie-in, without undercut.

Because of the high iron powder content of the flux thedeposition rate is very high with a weld metal efficiency of140-160%.

Applications:Roof trusses, ship building, buckets, dozers, rolling stock,bridge girders, tank ends, beams, heavy machinery frames.

Welding TechniquesA touch weld technique is recommended, where the flux atthe end of the electrode is lightly touching the workpiece.The electrode should be angled in the direction of travel, 45o

to 65o, so as to prevent the slag touching the electrode tip.

Recommended AmperagesDia. Length Amperesmm mm3.2 380 130-1704.0 455 185-220

AC 50V DC + or - (- preferred)

AWS A5.1 : E7024AS/NZS 1553.1 : E4824-0

WELDWELL

22

IRON POWDERELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR OrangeFLUX MARKING PH 22 7024 E4824

Approvals:Lloyds Register of ShippingBureau Veritas

Welding Positions:F, H

Typical Mechanical Properties of Weld MetalTensile Strength 502 MPaYield Value 453 MPaElongation(1 = 5d) 30%Impact Value Charpy V Notch at 0oC 63 J

Typical Chemical AnalysisC 0.05%Mn 0.90%Si 0.25%

StorageStore electrodes in a dry place. To reconditionmoist electrodes bake for half an hour at 250oCin a vented oven.

38

7024

DESCRIPTION:The WELDWELL PH 7024 is a heavy coated rutile contacttype electrode developed for high speed welding of mildsteel in the downhand and horizontal positions using AC orDC current. The high iron powder content in the flux coatinggives high efficiency combined with excellent mechanicalproperties and weldability.

PH 7024 Features! Highest Deposition Rates! Ease of Welding! Excellent Appearance at all Speeds! Extremely Easy Slag Removal! Virtually No Spatter! Instant Striking and Re-Striking! Very Neat Mitre Fillets! No Undercutting! Efficiency = 140-160%

Applications:Dozers, Buckets, Ship Building, Roof Trusses, Rolling Stock,Bridge Girders, Crusher Frames, Pressure Vessels, HeavyMachinery Frames, Tank Bottom Welding, Beams andBlades.

Welding TechniquesA touch weld technique is recommended with the electrodeangle adjusted in the direction of travel so as to prevent theslag touching the electrode tip. The electrode should bisectthe angle of the joint at approximately 50o-55o for 4.0 mmand 65o for 5.0 mm, other diameters at approximately 45o.

Recommended AmperagesDia. Length Amperes Depositionmm mm Rate kg/hr *2.5 305 90-1403.2 380 130-160 1.94.0 455 180-210 3.005.0 455 260-320 5.05

* Deposition rate at maximum Amps.AC 50V DC -

AWS A5.1 : E7024AS/NZS 1553.1 : E4824-0

WELDWELL

IRON POWDERELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR WhiteFLUX MARKING PH 7024 E4824

Approvals:American Bureau of ShippingLloyds Register of ShippingBureau Veritas

Welding Positions:F, H

Typical Mechanical Properties of Weld MetalTensile Strength 507 MPaYield Value 447 MPaElongation(1 = 5d) 31%Impact Value Charpy V Notch at 0oC 71 J

Typical Chemical AnalysisC 0.05%Mn 0.59%Si 0.36%

StorageStore electrodes in a dry place. To reconditionmoist electrodes bake for half an hour at 250oCin a vented oven.

39

DESCRIPTION:The WELDWELL PH 31A is a thinly coated electrode of thecellulose type, intended for welding in all-positions. Theexcellent properties of this type show to the best advantagein downward welding, in particular the stove-pipe technique.The arc is easy to ignite, is powerful and extremely stable,giving this electrode deep-penetration properties. The thinlayer of slag being easy to remove. The PH 31A type ofelectrode has been primarily developed for weldingcircumferential seams in pipe lines in the vertical downposition; the welding time is considerably shorter than whereupward welding is done conventionally.

Welding TechniquesCircumferential pipe seams to be welded with the PH 31Atype must have an included angle of 60o and a root face of1.5mm. The root gap between pipes must be 1.5mm wide.The root pass (or stringer bead) is done by pushing theelectrode firmly into the root of the weld, so that the arcburns inside the pipe, and is carried out with a relatively highrate of travel. As the coating is fairly tough, no drawbackswill be encountered should the electrode become slightlybent by this firm pressure. The root pass is ground flat, toprevent slag inclusions when the second layer is welded.The second layer (hot-pass) is welded with a high current,a short to medium arc length and a fairly high travel speed.The subsequent layers are welded with a medium arclength. Sometimes a rapid thrusting movement is used toadvantage. To prevent porosity relatively thin layers arewelded. As desired, a slightly weaving motion can beemployed or layers can be deposited side by side.The X-ray quality of the joints welded as described satisfythe requirements to which they have to conform in practice.The PH 31A electrode can be used either with DC + or withAC where the open circuit voltage is not less than 70V.

Recommended AmperagesDia. Length Amperes Fusion Timemm mm in seconds2.5 305 60-953.2 380 90-125 524.0 380 115-175 655.0 380 160-220 79Note that fusion time rate are at maximum current values.AC 70V DC +

AWS A5.1 : E6011AS/NZS 1553.1 : E4111-3

WELDWELL

31A

ELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR BrownFLUX MARKING PH 31A 6011 E4111

Approvals:American Bureau of ShippingLloyds Register of ShippingBureau Veritas

Welding Positions:F, H, V, VD, OH

Typical Mechanical Properties of Weld Metal

Tensile Strength 510 MPaYield Value 410 MPaElongation(1 = 5d) 31%Impact Value Charpy V Notch at -30oC 89 J

Typical Chemical AnalysisC 0.12%Mn 0.60%Si 0.16%

StorageStore electrodes in a dry place. Rebaking is notrecommended.

40

DESCRIPTION:Pipemaster 60 is a quick starting, cellulosic mild steelelectrode that provides outstanding arc stability, penetrationand wash-in. Ideal for welding in all positions and producesx-ray quality welds with a light slag that is easy to remove.Pipemaster 60 can be used to weld the following API 5Lsteels: Grade A, B, X-42, X-46, X-52, X-56 and for the rootpass on material up to X-80.

Applications:Pipes, plates, construction, shipbuilding and general purposefabrication and maintenance welding.

Features:! Quick starting efficiency! All Position! Excellent vertical down! Excellent arc stability! Excellent penetration! Light slag

Welding Techniques:Arc length 3 - 6 mm. For welding in the flat position stay ahead of the puddle anduse a slight whipping motion.For vertical up and overhead, use a slight whipping orweaving technique.When welding vertical down use higher amps and a fastertravel speed, staying ahead of puddle. Vertical down weldingis commonly used when welding pipe.

Recommended AmperagesDia. Length Amperes Optimum Depositionmm mm Amperes Rate kg/hr *2.4 355 40-70 50 0.593.2 355 65-130 100 0.734.0 355 90-175 140 0.864.8 355 140-225 170 1.18

* At optimum amperes DC +

AWS A5.1 : E6010AS/NZS 1553.1 : E4110-3

HOBART

ELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR None FLUX MARKING

Approvals:Lloyds Register of ShippingAmerican Bureau of Shipping

Welding Positions:F, H, V, VD, OH

Typical Mechanical Properties of Weld MetalTensile Strength 511 MPaYield Value 436 MPaElongation(1 = 5d) 26%Impact Value Charpy V Notch at -30oC 76 J

Typical Chemical AnalysisC 0.06%Si 0.20%Mn 0.40%

StorageStore electrodes in a dry place. Rebaking is notrecommended.

41

DESCRIPTION:Pipemaster 70 is an excellent, all position, cellulosic mild steelelectrode that provides strong, dependable, x-ray quality welds. Itdelivers the arc stability and arc force you need for the bestpenetration. It is ideal for vertical-down welding, single or multi-pass on 5L, 5LX and X52 through X65 pipe.

Applications:High yield pipe steels, drill platforms, shipbuilding, storage tanks.

Features:! Quick starting efficiency! All Position! Excellent vertical down! Excellent arc stability! Excellent penetration and wash-in! Light slag

Welding Techniques:Arc length 3 - 6 mm. For welding in the flat position stay ahead of the puddle and use aslight whipping motion.For vertical up and overhead, use a slight whipping or weavingtechnique.When welding vertical down on pipes etc, use higher amps and afaster travel speed, staying ahead of the arc.

Recommended AmperagesDia. Length Amperes Optimum Depositionmm mm Amperes Rate kg/hr *3.2 355 70-140 100 0.994.0 355 80-190 160 1.224.8 355 120-230 190 1.75

* At optimum amperes DC +

AWS A5.5 : E7010-P1AS/NZS 1553.2 : E4810-P1

HOBART

ELECTRODESFOR WELDINGMILD STEEL

TIP COLOUR None FLUX MARKING

Approvals:Lloyds Register of ShippingAmerican Bureau of Shipping

Welding Positions:F, H, V, VD, OH

Typical Mechanical Properties of Weld MetalTensile Strength 625 MPaYield Value 514 MPaElongation(1 = 5d) 25%Impact Value Charpy V Notch at -30oC 60 J

Typical Chemical AnalysisC 0.10% Mn 0.85%Si 0.40% P 0.01%S 0.01% Ni 0.55%Mo 0.10% Cr 0.02%

StorageStore electrodes in a dry place. Rebaking is notrecommended.

42

WELDWELL WELDING ELECTRODES

BASIC COATED ELECTRODES FOR WELDING MILD AND MEDIUM TENSILE STEELS Since their introduction basic-coated electrodes, also called low-hydrogen electrodes, have been employed mainly where quality requirements are laid down which cannot be realised or are difficult to meet with other types. The deposited metal has a high resistance to hot and cold cracking, a high notch toughness and an excellent X-ray quality even if impurities such as sulphur are present in the material to be welded. On account of the low hydrogen content of the weld metal the risk of cracking of the weld and the heat-affected zone is extremely limited. Accordingly these electrodes are particularly suitable for the welding of heavy workpieces and of very rigid mild steel constructions. They are also recommended for welding low-alloy steel and steel of which the carbon and sulphur contents are higher than those of readily weldable mild steel. BASIC-COATED ELECTRODES FOR ALL-POSITION WELDING

Owing to the high solidification rate of the weldpool, which permits high currents for welding in difficult positions, the low-hydrogen electrode is the fastest type for those positions. On the other hand, because of its nature, the slag will not be entrapped easily. These properties, together with a good 'penetrating arc', explain the welder's liking for this electrode.

Since the optimum properties for each of the wide variety of welding-applications cannot be had in one electrode, a number of different unalloyed basic-coated Weldwell electrodes are available. The differences between these types may relate to welding-properties, deposition rate, mechanical values, kind of current, etc.

Refer to the information on each electrode to find the most suitable for any particular job.

WELDWELL PH 27 has a coating which emits a forceful arc with a slag which sets quickly, resulting in a useful type for vertical down welding.

WELDWELL PH 27P the P denotes "pipe" this type especially designed for pipe welding, particularly welding downwards and has excellent properties for bridging gaps and making tie-ins where the pipes are misaligned.

WELDWELL PH 56S These thinly-coated types of 100% efficiency produce welds in all positions with very high impact properties.

WELDWELL PH 56R - A specially designed low hydrogen electrode for rapid joining of steel with large cross sections, using the enclosed welding process.

AUSTARC 16TC is an easy to use dual coated electrode for welding in all positions with DC or AC power sources with open circuit voltages as low as 45 OCV. The weld pool is very controllable. Re-strike and slag release are very good.

WELDWELL PH 75 is designed to produce welds where high impact values are required at sub-zero temperatures and for welding in all-positions.

WELDWELL PH 77 produces good efficiency, it has a very quiet arc with low spatter levels and gives excellent results in all-positions with high impact values at -50oC.

WELDWELL PH 118. This type is designed to produce very strong welds in low alloy-high tensile steels and with excellent impact values at low temperatures,

WELDWELL PH KV3 for low alloy and medium tensile steels, especially suitable for high quality pipe welds in all positions and Cr/Mo high temperature applications.

FOR DOWNHAND WELDING

WELDWELL PH C6H has a very heavy coating containing zirconium oxide which gives welds of up to 200% efficiency and with very good mechanical properties.

43

DESCRIPTION:All gauges of this basic-coated electrode are extremely suitable forwelding in the Vertical-Down position. The instructions coveringwelding with low-hydrogen electrodes and their storage should befollowed. The weldments have a flat profile and are highlyinsensitive to cracking.

Where the WELDWELL PH 27 is employed correctly, the weldmetal has a finely ribbed appearance and an excellent wettingaction, which eliminates undercut. In most cases, the slag is self-lifting, but in all cases there is a minimum of post weld cleaning up.With the aid of the PH 27 gaps can be readily bridged in vertical-down welding. In addition, the diameters 3.2 mm and 4.0 mm arevery suitable for welding root passes of single and double-vee jointsin this position. As this electrode tolerates very high currents thePH 27 yields a con-siderable economic advantage in comparisonwith conventional low-hydrogen electrodes which have to be weldedvertically upwards with a relatively low current. The high weldingspeeds which can be obtained, as compared with vertical-upwelding, result in substantially less distortion. The PH 27 can beconsumed either on AC or with the electrode connected to thepositive pole, on DC.

Welding TechniquesHow to Weld Vertically Downwards with the Weldwell PH 27.Like all Low-Hydrogen types, the PH 27 may be used with a shortarc. Too long an arc will cause porosity. Use of Touch-Weldingtechnique is not recommended, since this adversely affects rootpenetration, and the welding action.

Welding is done with maximum current, in order that the greatestpossible benefit may be derived from the use of the PH 27. Theelectrode is held at an angle of 80o to 90o to the direction of travel.

In ship building vertical fillet joints are often limited by horizontalplates, causing a change of electrode angle to approximately 110o

in the last part of the joint. Experience has proved that the slag isstill easy to control above the arc, and in these circumstances theweld appearance is entirely accept-able. Making bead junctionslikewise presents no problems at all. Before the arc isextinguished, the electrode is removed from the crater in theupward direction. Then the next rod is started a little below thecrater, after which the latter is filled up and vertical-down weldingcontinues. The PH 27 can be used for vertical-down welding of filletjoints in multiple layers. Overlapping runs are made if more thantwo layers are deposited. Should two layers be sufficient, then thesecond layer is welded with a slightly faster weaving motion whilstthe arc is kept short. As already stated, bridging of gaps presentsno problems at all in vertical-down welding.

Recommended AmperagesDia. Length Amperes Depositionmm mm Rate kg/hr *3.2 305 150 max 1.34.0 380 200 max 1.85.0 455 270 max 2.53* Deposition rate at maximum Amps.AC 70V DC +

AWS A5.1 : E7048 H4AS/NZS 1553.1 : E4848-3 H5

WELDWELL

27

LOW HYDROGENELECTRODESFOR WELDING

MILD AND MEDIUM-TENSILE STEELS

TIP COLOUR WhiteFLUX MARKING PH 27 7048 E4848

Approvals:American Bureau of ShippingLloyds Register of ShippingBureau Veritas

Welding Positions:F, H, VD, OH

Typical Mechanical Properties of WeldMetalTensile Strength 507 MPaYield Value 439 MPaElongation(1 = 5d) 32%Impact Value Charpy V Notch at -30oC 183 J

Typical Chemical AnalysisC 0.04%Mn 1.15%Si 0.45%

Storage (See also page 88.)Once the packet has been opened, theseelectrodes should be stored in a heated cabinetat a temperature of 20oC minimum and/or atleast 10oC above ambient. Good ventilationshould be allowed.

For highest weld quality, these electrodesshould be baked before use at 280oC for onehour to achieve a maximum weldmetalhydrogen level of 10ml/100g.

Do not redry more than three times. Thesetemperatures should also be used torecondition damp electrodes.

Use from a hot box during welding.

44

27P

DESCRIPTION:The basic coated WELDWELL PH 27P electrode has beenspecially developed for welding circumferential joints using thevertical down technique ("stove-pipe welding"). It provides theanswer to the ever increasing requirements for strength andtoughness in pipe welds. The low-hydrogen content of thePH 27P electrode deposit reduces the risk of hydrogen heat-affected zone and weld metal cracking; such defects are morelikely to occur with increasing pipe steel strengths. Inparticular, its basic high purity weld metal ensures high impacttoughness, along with other improvements over cellulosicelectrodes.

Excellent Operational Characteristics PH 27P electrodehas a stable smooth arc, low spatter volume, and very goodslag control; easy deslagging properties minimise clean uptime. High productivity results from high current intensitiesused with this electrode and the increased recovery rate(120% approx.)

Applications:Applications of the PH 27P electrode are principally oil andgas pipelines requiring welds of high strength and ductility, asin the North Sea and Arctic areas. The high deposition ratemakes it a very attractive alternative for the low-hydrogenelectrodes which are presently employed uphill for valveconnections, tie-ins and main crossing welds.

Process pipe work is another area where time savings of 30to 50% are achieved. Pipe diameters which can besatisfactorily welded with the PH 27P electrode are from 200mm upwards. The minimum wall thickness is 6 mm.

Welding TechniquesBeing an electrode for pipe welding, a branch of weldingrequiring a high degree of skill, welders must necessarilybecome familiar with the welding technique developed for thePH 27P. Experience indicates that this can be achievedquicker and with higher success rate, compared with trainingwelders to use cellulose electrodes on pipe welding. Welderstrained in downhill welding with cellulose types on pipes arefavoured over others, since they are already used to hightravel speeds and continuous change of welding position withconsequent adaption of the rod to this. However, due to theirtraining with cellulosic electrodes, welders generally have tobe alerted to the following differences.* Starting porosity results from drawing a long arc after

striking. The PH 27P arc should be kept short at alltimes.

* Usually cellulosic electrodes are kept under a rather sharpangle with the direction of travel, resulting in long arclengths. The PH 27P is held almost perpendicular tothe pipe.

* A welder can be misled by the considerably loweramount of spatter from the PH 27P, so giving theimpression that current intensity is too low. Raising this togain "the required level of spatter" adversely affects slagand weld pool behaviour and promotes porosity.

* WELDWELL PH 27P slag stays at a greater distancefrom the arc than a cellulosic slag. The welder shouldavoid slowing down travel speed as a reaction to this,otherwise the slag will run through the arc or the weld poolwill be overheated.

AWS A5.5 : E8018-G H8AS/NZS 1553.2 : E5548-G H5

WELDWELL

LOW HYDROGENELECTRODESFOR WELDING

MILD AND MEDIUM-TENSILE STEELS

TIP COLOUR VioletFLUX MARKING PH 27P 8018-G E5548-G

Approvals:American Bureau of ShippingLloyds Register of ShippingBureau Veritas

Welding Positions:F, H, VD, OH

Recommended AmperagesDia. Length Amperesmm mm2.5 355 80-1003.2 355 130-1504.0 355 180-210DC +

Typical Mechanical Properties of Weld MetalTensile Strength 594 MPaYield Value 561 MPaElongation(1 = 5d) 27%Impact Value Charpy V Notch at -20oC 151 J

Typical Chemical AnalysisC 0.05%Mn 1.15%Si 0.45%

Storage (See also page 88.)Once the packet has been opened, theseelectrodes should be stored in a heatedcabinet at a temperature of 20oC minimumand/or at least 10oC above ambient. Goodventilation should be allowed.For highest weld quality, these electrodesshould be baked before use at 280oC for onehour to achieve a maximum weldmetalhydrogen level of 5ml/100g.Do not redry more than five times. Thesetemperatures should also be used torecondition damp electrodes.Use from a hot box during welding.

45

DESCRIPTION:Austarc 16TC is a smooth running, basic flux low hydrogenelectrode, developed for all positional (except vertical down)welding, using AC or DC power sources. The electrodegives exceptional stability and weldability for its class, andproduces high quality weld deposits with reliable notchtoughness to -40oC. Austarc 16TC is manufactured using aunique twin coating extrusion process, which produceselectrodes with two concentric flux coatings. Arc stabilisingelements are concentrated in the inner coating of theelectrode for significantly improved arc stability on low opencircuit AC welding machines.

Applications:Austarc 16TC is the ideal low hydrogen electrode for weldingcarbon, carbon-manganese and low alloy high strengthsteels used in a multitude of critical and non-criticalapplications. This electrode is particularly suitable forwelding heavy wall joints subject to high degrees of restraintand for structural applications where notch toughness downto -40oC is a prerequisite. Austarc 16TC is often used inmaintenance situations as a buffer or build-up layer onagricultural and earth moving equipment prior to hardsurfacing.

Welding TechniquesArc striking and re-striking is easily accomplished. Use alight dragging action on the rod end to achieve ignition.Welding is carried out with a short arc and low travelspeeds.

Recommended AmperagesDia. Length Amperesmm mm2.5 305 60-903.2 380 90-1354.0 380 140-1905.0 455 190-2406.0 455 250-310AC 45 OCV for 2.5 and 3.2 mmAC 55 OCV for 4.0, 5.0 and 6.0 mm DC +

Typical Mechanical Properties of Weld MetalTensile Strength 518 MPaYield Value 426 MPaElongation 33%Impact Value Charpy V Notch at -40oC Average 118J

AWS A5.1 : E7016 H8AS/NZS 1553.1 : E4816-4H10

WIAAUSTARC 16TC

LOW HYDROGENELECTRODES FOR

WELDING MILDAND MEDIUM TENSILE

STEELS

TIP COLOUR BronzeFLUX MARKING 4816

Approvals:Lloyds Register of ShippingAmerican Bureau of ShippingDet Norske Veritas

Welding Positions:F, H, V, OH

Typical Chemical AnalysisC 0.05%Mn 1.18%Si 0.52%

Storage (see also page 88.)Once the packet has been opened, theseelectrodes should be stored in a heated cabinetat a temperature of 20oC minimum and/or atleast 10oC above ambient. Good ventilationshould be allowed.

For highest weld quality, these electrodesshould be baked before use at 300oC for twohours to achieve a maximum weld metalhydrogen level of 10ml/100g.

Do not re-dry more than five times. Thesetemperatures should also be used to reconditiondamp electrodes. Use from a hot box duringwelding.

46

DESCRIPTION:The WELDWELL PH 56S is a basic coated C/Mn electrodeproviding excellent mechanical properties. Due to the thin coatingand concentrated arc this electrode ensures fully penetrated rootpasses even under adverse conditions, such as small gaps andnarrow joints. The strong protective gas stream is a furtheradvantage.Low moisture content of the coating and high resistance to moisturere-absorption is a major benefit long recognised by the offshore andgeneral structural steel industries, where avoidance of hydrogeninduced cracking is of crucial importance.Applications:PH 56S is widely adopted for offshore fabrication to ensureconsistent results, with the assurance of high impact values in theas-welded condition and further improved by stress relieving.COD testing confirms excellent fracture toughness after stressrelieving.Many years of successful use in offshore work provides an immenserange of approved procedures; also a workforce fully familiar with thePH 56S and well able to exploit the full potential of this electrode fornodes and other primary structural joints.Pipework PH 56S assures the full penetration demanded by theoil and gas industry for offshore and onshore process piping.Welders prefer the better manipulation of this thin coatedelectrode for handling root passes, particularly when variations ingap width occur due to field fit-up conditions.Root layers for submerged arc filling is another majorapplication area of PH 56S, confirmed by well establishedprocedures in offshore yards.Combinations with other Weldwell "offshore" electrodes.PH 56S can be used advantageously with the following, for jointsof primary structural importance.! As root pass electrode followed by filling with Weldwell PH 77

(E7018-1) for extra productivity due to the 120% recovery of thelatter. Most yards tend to avoid use of two electrodes due tothe extra supervision involved, but the practice remains soundand is often adopted for tank welding and other generalstructural work.

! For even more demanding requirements down to -60oC, theWeldwell PH 75 should substitute the Weldwell PH 56S. Forfurther information see Weldwell PH 75 data sheet.

General steel structure. PH 56S is widely adopted whereassurance of high as-welded impact values are necessary for all-position welds.Electrode performance. PH 56S gives 100% recovery, it can beused equally well for AC or DC + operation; DC - is oftenpreferred for root passes.The electrode is easily welded in thin layers, to gain maximumgrain refining from the heat of subsequent runs, and so obtain hightoughness properties.X-ray properties of the weld metal are highly regarded byinspectors working to stringent requirements.Welding TechniquesIt is important that this electrode is welded with a short arc under allconditions. The rate of travel must be slow; weaving, if carried out,must also be slow using no greater movement than three electrodewidths each way. To avoid start porosity, strike each fresh electrodeon the crater of the preceding run while it is still hot, or by restarting halfinch back on previous run and chipping off the thin bead formed there.

Recommended Amperages

Dia. Length Amperes Depositionmm mm Rate kg/hr *2.5 305 60-1003.2 380 85-140 1.144.0 380 100-180 1.625.0 455 180-230 2.526.0 455 230-300 3.36* Deposition rate at maximum Amps.AC 7O OCV DC+ or DC- for root passes if preferredTypical Mechanical Properties of Weld Metal

Tensile Strength 589 MPaYield Value 497 MPaElongation(1 = 5d) 28%Impact Value Charpy V Notch at -40oC Average 107 J

AWS A5.1 : E7016-H8AS/NZS 1553.1 : E4816-4H5

WELDWELL

LOW HYDROGENELECTRODES FOR

WELDING MILDAND MEDIUM TENSILE

STEELS

TIP COLOUR RedFLUX MARKING PH 56S 7016 E4816

Approvals:Lloyds Register of ShippingAmerican Bureau of ShippingBureau VeritasWelding Positions:F, H, V, OHTypical Chemical AnalysisC 0.05%Mn 1.11%Si 0.34%

Moisture reabsorbsion characteristics ofWeldwell 56S.

Storage (see also page 88.)Once the packet has been opened, theseelectrodes should be stored in a heated cabinet ata temperature of 20oC minimum and/or at least10oC above ambient. Good ventilation should beallowed.For highest weld quality, these electrodes shouldbe baked before use at 350oC for 1 hour toachieve a maximum weld metal hydrogen level of10ml/100g or 400oC for 1 hour to achievemaximum weld metal hydrogen of 5ml/100g. Donot re-dry more than f ive t imes. Thesetemperatures should also be used to reconditiondamp electrodes. Use from a hot box duringwelding.Typical COD test resultsType of joint and Parametersmaterial thickness

Position: : 3GPreheat temp: 100oCInterpass temp: max 140o CElectrode size: 2.5 mm

3.2 mm4.0 mm

Heat treatment: 3h, 580-620oCSteel quality: 50D

47

DESCRIPTION:The WELDWELL PH 56R is a low hydrogen electrode,specially designed for rapid joining of profiles with largecross sections, according to the enclosed-welding process.Being of the low hydrogen type the Weldwell PH 56R yieldsexcellent mechanical properties; it produces a sound X-rayquality and is very insensitive to impurities of the base metal.

The use of this electrode in combination with the enclosed-welding process has some striking advantages, which, inshort, are:C a considerable saving of time in relation to orthodox

methods used for the same applications;C more irregularly shaped profiles can be welded as

well, and, because of the great heat input in theseam, it is possible to weld steels with a relativelyhigh carbon content (up to approximately 0.60-0.65%C).

Applications:The enclosed-welding process is employed for making buttwelds in round and square bars, heavy flanges, thick plates,rails, rail crossings, rudder shafts, anchor chains, etc.

Welding TechniquesProfiles to be joined are sawn or cut off straight and placed15 to 18 mm apart. Next the gap is enclosed in coppermoulds and filled up with the Weldwell PH 56R. The weld isdeposited at a high current in one layer, without the need forintermediate chipping. Welding must be done with a veryshort arc.

A detailed brochure on the enclosed-welding process isavailable.

Recommended AmperageDia. Length Amperes Fusion Dep rate Net weightmm mm time g/min kg/hr per 1,000pcs

sec kg5.0 450 280 76 48 2.90 90.8

AC 70 OCV DC +

Typical Mechanical Properties of Weld MetalTensile Strength 530-590 MPaYield Value 470-510 MPaElongation(1 = 5d) 26-30%Impact Value Charpy V Notch at -20oC 47-78 J

AWS A5.1 : E7016AS 1553.1 : E4816

WELDWELL

LOW HYDROGENELECTRODESFOR WELDING

MILD AND MEDIUMTENSILE STEELS

TIP COLOUR NoneFLUX MARKING PH 56R

Welding Position:F

Typical Chemical AnalysisC 0.064%Mn 1.04%Si 0.66%

Storage (See also page 88.)Once the packet has been opened, theseelectrodes should be stored in a heated cabinetat a temperature of 20oC minimum and/or atleast 10oC above ambient. Good ventilationshould be allowed.For highest weld quality, these electrodesshould be baked before use at 350oC forone hour to achieve a maximum weld metalhydrogen level of 10ml/100g or 400oC forone hour to achieve maximum weld metalhydrogen of 5ml/100g. Do not re-dry more thanthree times. These temperatures should also be used torecondition damp electrodes. Use from a hot box during welding.

56R

48

DESCRIPTION:The WELDWELL PH 75 is a low hydrogen all positionelectrode depositing a nickel-alloyed weld metal. Theresult of this nickel addition is very high impact values areobtained at sub-zero temperatures. These properties aregained regardless of whether the welding is donedownhand or vertical up, etc. The PH 75 exhibits verygood weldability on both AC and DC and gives excellentresults in the welding of root runs of pipes and plates indifficult welding positions. PH 75 is ideal for welding thefine-grains steels of the 1.5% Ni steel and 3.5% Ni steel.

Applications:Pipes, vessels, containers, etc, which are designed forlow-temperature service.

Welding TechniquesAs for all low-hydrogen electrodes welding must be donewith a short arc and at a low rate of travel, should weavingbe necessary, this must likewise be carried out slowly.

Welding Positions:F, H, V, OH

Recommended AmperagesDia. Length Amperesmm mm3.2 380 85-1404.0 380 120-180

AC 70V DC +

Typical Mechanical Properties of Weld MetalTensile Strength 514 MPaYield Value 439 MPaElongation(1 = 5d) 32%Impact Value Charpy V Notch at -60oC 79 J

AWS A5.5 : E7016-C1L H8AS/NZS 1553.2 : E4816-C1L H10

WELDWELL

75

LOW HYDROGENELECTRODESFOR WELDING

LOW TEMPERATURE STEELS

TIP COLOUR AluminiumFLUX MARKING PH 75 7016-C1L E4816-C1L

Approvals:American Bureau of ShippingLloyds Register of ShippingBureau Veritas

Typical Chemical AnalysisC 0.04%Mn 0.49%Si 0.40%Ni 2.50%

Storage (See also page 88.)Once the packet has been opened, theseelectrodes should be stored in a heated cabinet ata temperature of 20oC minimum and/or at least10oC above ambient. Good ventilation should beallowed.For highest weld quality, these electrodes shouldbe baked before use at 350oC for 1 hour toachieve a maximum weld metal hydrogen level of10ml/100g or 400oC for 1 hour to achievemaximum weld metal hydrogen of 5ml/100g. Donot re-dry more than five times. These temperatures should also be used torecondition damp electrodes. Use from a hot box during welding.

49

DESCRIPTION:The WELDWELL PH 77 is a low-hydrogen electrodecontaining iron-powder in the coating. PH 77 is designed toweld in all positions except vertical down.

The welding arc of PH 77 is very quiet and with very littlespatter and the weld metal deposits exceptionally smoothlywith excellent wash to the weld sides which practicallyeliminates undercutting. The slag is easy to control and iseasy to remove after welding.

Compared to the general types of low-hydrogen electrodesthe PH 77 performs nearly like a rutile electrode with low-hydrogen results.

This Weldwell PH 77 electrode is for welding unalloyed,micro-alloyed and low-alloy steels up to medium tensilestrength. This electrode is used where the higheststandards are required, such as high ductility and X-rayqualities.

It is excellent for thick plates and highly restrained workpieces, etc. Due to its Low-Hydrogen properties it is suitableto weld sulphur-alloyed (0.2-0.3% S) steels (free cuttingsteel) and for steels with increased carbon content. PH 77may be used for cold or hot welding of cast iron but careshould be exercised because of carbon pickup which causesbrittleness. It is very suitable for most steel castings.

Applications:Penstocks, turbines, Class 1 pressure vessels, heavygirders, tanks, earthmoving plant, repair and maintenance,etc.

Welding TechniquesArc striking is easy and re-starting is simple as a slight dragbrings arc ignition.

Welding is done with a short arc and low travel speeds.

Recommended AmperagesDia. Length Amperesmm mm2.5 305 60-1053.2 380 90-1454.0 380 140-2005.0 455 180-300AC 70V DC +

AWS A5.1 : E7018-1 H8AS/NZS 1553.1 : E4818-5 H5

WELDWELL

77

LOW HYDROGENELECTRODESFOR WELDING

MILD AND MEDIUMTENSILE STEELS

TIP COLOUR BlackFLUX MARKING PH 77 7018 E4818

Approvals:American Bureau of ShippingLloyds Register of ShippingBureau Veritas

Welding PositionsF, H, V, OH

Typical Mechanical Properties of Weld MetalTensile Strength 563 MPaYield Value 483 MPaElongation(1 = 5d) 29%Impact Value Charpy V Notch at -50oC 123 J

Typical Chemical AnalysisC 0.04%Mn 1.47%Si 0.31%

Storage (See also page 88.)Once the packet has been opened, theseelectrodes should be stored in a heated cabinetat a temperature of 20oC minimum and/or atleast 10oC above ambient. Good ventilationshould be allowed.For highest weld quality, these electrodesshould be baked before use at 350oC for onehour to achieve a maximum weld metalhydrogen level of 10ml/100g; or 400oC for onehour to achieve a maximum weldmetalhydrogen of 5 ml/100g.Do not re-dry more than three times. Thesetemperatures should also be used to reconditiondamp electrodes. Use from a hot box duringwelding.

50

DESCRIPTION:WELDWELL PH C6H electrodes are intended for weldingmild and medium tensile steels and have a Zircon-basedCoating in which very large amounts of iron powder areincluded. The efficiency is approximately 195%.

The deposited metal has a smooth and flat appearancewhich favours high fatigue strengths. The weld washes orwets very nicely without undercuts.

Welds obtained with this type show very good mechanicalproperties and an excellent X-ray quality. As for all low-hydrogen electrodes the weld metal can be pushed into theform of very thick layers, in which case slag removalnevertheless remains excellent, a characteristic of zircon-based electrodes.

PH C6H is intended for Downhand Welding only. The veryheavy coating permits high welding currents, andconsequently a particularly high deposition rate is obtained.Therefore this type of electrode is eminently suitable forrapidly filling bevelled butt joints in thick and very thickplates and for making positioned fillet welds as well.

Welding TechniquesPH C6H can be used to weld either by contact with theworkpiece or by a short free arc.

AC or DC may be used, but with DC the electrode should beconnected to the positive pole.

Recommended AmperagesDia. Length Amperes Depositionmm mm Rate kg/hr*3.2 380 130-1804.0 455 200-230 4.005.0 455 260-340 6.356.0 455 360-440 8.90

* Deposition Rate at maximum amps.AC 70V DC +

AWS A5.1 : E7028 H4 AS/NZS 1553.1 : E4828-2 H5

WELDWELL

C6H

LOW HYDROGENELECTRODESFOR WELDING

MILD AND MEDIUMTENSILE STEELS

TIP COLOUR BlueFLUX MARKING PH C6H 7028 E4828

Approvals:American Bureau of ShippingLloyds Register of ShippingBureau Veritas

Welding PositionsF, H

Typical Mechanical Properties of Weld MetalTensile Strength 513 MPaYield Value 424 MPaElongation(1 = 5d) 34%Impact Value Charpy V Notch at -20oC 108 J

Typical Chemical AnalysisC 0.02%Mn 1.26%Si 0.62%

Storage (See also page 88.)Once the packet has been opened, theseelectrodes should be stored in a heated cabinetat a temperature of 20oC minimum and/or atleast 10oC above ambient. Good ventilationshould be allowed.For highest weld quality, these electrodesshould be baked before use at 280oC for onehour to achieve a maximum weld metalhydrogen level of 10ml/100g.Do not re-dry more than three times. Thesetemperatures should also be used to reconditiondamp electrodes. Use from a hot box duringwelding.

51

DESCRIPTION:Weldwell KV3 is an all position, very low hydrogen electrodefor welding a wide range of low alloy and medium tensilesteels.

Because of the stable arc and smooth weldability, KV3produces high quality welds, and is very suitable for weldingtubes and pipes in fixed positions. The chrome andmolybdenum bearing composition of KV3 produces strong,tough weld deposits which are highly resistant to weld metalcracking.

Suitable for welding 2.25 Cr, 1 Mo and 0.5 Cr, 0.5 Mo,0.25 V bearing steels in high temperature applications, andother low alloy, medium tensile steels where matching orimproved strength and toughness are desired.

Weldwell KV3 is the recommended electrode for weldingseismic reinforcing bar - Grade 500E.

Welding TechniquesWelding must be carried out with a short arc and a slowtravel rate.

Recommended AmperagesDia. Length Amperesmm mm2.5 350 65-953.2 350 75-1304.0 350 115-1655.0 455 180-240

Welding current DC + only

Typical Mechanical Properties of Weld MetalTensile Strength 726 MPaYield Value 638 MPaElongation 25%

AWS A5.5 : E8015-B3L H4AS/NZS 1553.2 : E5515-B3L H5

WELDWELL

LOW HYDROGEN ELECTRODES FOR WELDING

LOW ALLOY AND MEDIUMTENSILE STEELS

TIP COLOUR AluminiumFLUX MARKING PH KV3 8015-B3L

Welding PositionsF, H, V, OHTypical Chemical AnalysisC 0.05% Mo 0.95%Mn 0.77% P 0.03%Si 0.22% S 0.01%Cr 2.10%

ApprovalsAmerican Bureau of ShippingStorage (See also page 88.)Once the packet has been opened, theseelectrodes should be stored in a heated cabinetat a temperature of 20oC and/or at least 10oCabove ambient. Good ventilation should beallowed.For highest weld quality, these electrodesshould be baked before use at 350oC for onehour to achieve a maximum weld metalhydrogen level of 10 ml/100g or 400oC for onehour just before use for maximum weld metalhydrogen of 5 ml/100g. Do not redry more thanthree times.These temperatures should also be used torecondition damp electrodes. Use from a hotbox during welding.

52

WELDWELL WELDING ELECTRODES

ELECTRODES FOR WELDING HIGH TENSILE STEELS In the following it is assumed that all structural steels with a minimum yield point of approximately 480 MPa are among the high-tensile steels. Mostly such steel qualities are low alloyed, and as a result of their chemical composition they may be sensitive to hydrogen cracking. Sources which may produce hydrogen, such as dirt, grease, oxide scale, etc, on the plates, must therefore be carefully removed before welding. For the welding of these steel qualities low-hydrogen electrodes such as the type Weldwell PH 118 have to be used. These Weldwell electrodes are supplied in sealed packs, to prevent moisture pick-up during transport and storage. In spite of this precaution, it is recommended to dry the electrodes before use, by following the procedure as detailed in the data sheet. As soon as the electrodes have reached the temperature they may be used. It is advisable for the welder not to take more electrodes with him, in small humidity-safe or heated containers, than are necessary for about two hours of welding. Electrodes which have not been kept in humidity-safe conditions have to be rebaked at 400oC for a maximum of one hour, then they can be stored in an oven at 10oC above ambient. When high strength steels are welded the requirements with respect to design, workmanship and inspection must be more stringent than those for structural carbon steels. A design that has abrupt changes in cross sections in regions of high stress cannot be tolerated. Therefore, butt welds are to be preferred to fillet welds. The butt joints should be welded on both sides, to avoid severe stress-raisers at the root. Moreover such welds can more easily be inspected. Tack welds and the root run should be welded with an electrode type having a lower yield value than that applied for filling the joint. After filling or partial filling of one side of the joint, the reverse side can be welded after chipping or gouging the root run. Grinding is necessary after gouging with carbon electrodes, and at least 1 mm of material should be removed. It is common practice also to weld standing fillet welds with an electrode type having lower yield values than the type used for welding butt joints. In order to ensure adequate notch toughness and strength of the HAZ, the recommendations made by the steel supplier with respect to preheating, interpass temperature and heat input must be strictly adhered to. These recommendations have to be followed during tack welding and welding of the root run, as well.

53

DESCRIPTION:The WELDWELL PH 118 is a low hydrogen electrode usedfor welding low-alloy high strength steels with tensileproperties of about 120,000 psi or 750-860 N/mm2, such asBisalloy 80, Sumiten 80S, T1, AISI4140 and Welten 80-Cetc. These electrodes are supplied in a condition such thata particularly low hydrogen content of the deposited weldmetal is ensured. For this reason it is imperative to preventmoisture pick-up when using these types. It is advisable thatthe operator should not take more electrodes than he needsfor two hours welding. In unfavourable conditions of highhumidity, it is recommended that an airtight container beused on site. The welding of high-strength steel is usuallydone by following the procedures given by the steelmanufacturers and this should be carried out, if themechanical properties of the HAZ are not to be affected.

In most cases when welding root passes and first runs instanding fillets or tacking these steels, the use of WeldwellPH 56S or PH 77 is beneficial.

The efficiency of PH 118 is 110-120% and this electrode ischaracterised by a fast efficient metal-transfer with depositsof excellent quality. In addition due to the chemicalcomposition the impact properties at sub-zero temperaturesare outstanding.

Applications:Welding with PH 118 is very useful for repairing parts ofmachinery which are made of low-alloy high-strength steels,such as shafts, axles, forklift arms, etc.

Welding TechniquesWelding with PH 118 can be done in all positions. Thespeed of travel should be low and the arc kept very short. Ifweaving is necessary "do it slowly". If these conditions aremet the welds obtained will have excellent X-ray quality.

Recommended Amperages

Dia. Length Amperes Depositionmm mm Rate kg/hr*3.2 380 90-140 1.204.0 380 110-180 1.625.0 455 170-240 2.30

* Deposition Rate at maximum amps.AC 70V DC +

AWS A5.5 : E11018-G H4AS/NZS 1553.2 : E7618-G H5

WELDWELL

LOW HYDROGENELECTRODESFOR WELDING

HIGH TENSILE STEELS

TIP COLOUR VioletFLUX MARKING PH 118 11018-G E7618-G

Approvals:American Bureau of Shipping

Welding PositionsF, H,V, OH

Typical Mechanical Properties of WeldMetalTensile Strength 821 MPaYield Value 775 MPaElongation(1 = 5d) 24%Impact Value Charpy V Notch at -51oC 81 J

Typical Chemical AnalysisC 0.05%Mn 1.30%Si 0.30%Cr 0.02%Ni 1.60%Mo 0.50%

Storage (See also page 88.)Once the packet has been opened, theseelectrodes should be stored in a heated cabinetat a temperature of 20oC minimum and/or atleast 10oC above ambient. Good ventilationshould be allowed.

For highest weld quality, these electrodesshould be baked before use at 350oC for 1 hourto achieve a maximum weld metal hydrogenlevel of 10ml/100g or 400oC for 1 hour toachieve maximum weld metal hydrogen of5ml/100g. Do not re-dry more than three times.

These temperatures should also be used torecondition damp electrodes.

Use from a hot box during welding.

118

54

WELDWELL WELDING ELECTRODES

ELECTRODES FOR WELDING CREEP-RESISTING STEELS

Recommendations for welding creep-resisting steels

Type of steel Electrode Preheating and interpass Stress relieving treatmentSpecification temperatures

Temperature Plate thickness Temperature Time in minutes

1.25 Cr/0.5 Mo Weldwell 150-200oC All 680-700oC 2.5 x plate thick-KV5 ness in mm (min.

60 minutes)

2.25 Cr/1 Mo Weldwell 200-250oC All 700-740oC 5 x plate thick-KV3 ness in mm (min.

120 minutes)

0.5 Cr/0.5 Mo/ Weldwell 200-300oC All 680-720oC 2.5 x plate thick-0.25 V KV3 ness in mm (min.

180 minutes)

Recommendations for storage and re-baking of Weldwell KV electrodes

1. All basic-coated electrodes like the Weldwell KV electrodes should be stored in a dry place.

2. It is advisable for the welder not to expose to the atmosphere more electrodes than will beneeded for two hours of welding, at the same time keeping the remainder in an oven at 120 to150oC, but the preferred procedure is to store electrodes at the welding site in a hot box at 70oCminimum for a maximum of eight hours.

3. To achieve a maximum weld metal hydrogen level of 10 ml/100g these electrodes should bebaked at 350oC for one hour, just before use.

4. To achieve a maximum weld metal hydrogen level of 5 ml/100g these electrodes should be bakedat 400oC for one hour, just before use.

5. Electrodes which have been exposed to the atmosphere, and have become damp, should berebaked, as detailed above.

55

DESCRIPTION:The all-position electrode Weldwell KV3, a basic coatedtype, is used for welding creep resisting steels alloyed with2.25 Cr/1.0 Mo.

The Weldwell KV3 is also recommended for welding0.5 Cr/0.5 Mo/0.25V steel.

As a result of the stable arc and smooth weldability it is alsovery suitable for obtaining high quality welds when theWeldwell KV3 is used for welding tubes out of position. Thewelds are characterised by an excellent X-ray quality; thechemical composition of the weld metal guarantees a lowsensitivity to solidification cracking.

Welding TechniquesWelding must be carried out with a short arc and a slowtravel rate.

Recommended Heat TreatmentA preheat and interpass temperature during the welding of2.25 Cr - 1% Mo steels has to be 200 to 250oC for all platethicknesses.

Stress relieving must be carried out at 700 to 740oC, for atime in minutes equal to 5 x the plate thickness in mm for aminimum of two hours.

Recommended AmperagesDia. Length Amperesmm mm2.5 350 65-953.2 350 75-1304.0 350 115-165

DC only, positive polarity

AWS A5.5 : E8015-B3L H4AS/NZS 1553.2 : E5515-B3L H5

WELDWELL

ELECTRODES FORWELDING

CREEP-RESISTING STEEL

TIP COLOUR AluminiumFLUX MARKING PH KV3 8015-B3L

ApprovalsAmerican Bureau of Shipping

Welding PositionsF, H, V, OH

Typical Mechanical Properties of Weld MetalTensile Strength 726 MPaYield Value 638 MPaElongation 25%

Typical Chemical AnalysisC 0.05% Mo 0.95%Mn 0.77% P 0.03%Si 0.22% S 0.01%Cr 2.10%

StorageStore in a dry place. (See page 54.)

Typical Creep Properties

Temp Min. creep strength Min. stress rupture strengthF1/10,000 F1/100,000 FB/10,000 FB/100,000

MPa Kg/mm2 MPa Kg/mm2 MPa Kg/mm2 MPa Kg/mm2

500oC 147 15.0 108 11.0 207 21.0 158 16.0520oC 128 13.0 89 9.0 168 17.0 118 12.0550oC 84 8.5 59 6.0 114 11.5 79 8.0580oC 59 6.0 39.5 4.0 79 8.0 54 5.5

Yield values at elevated temperature:200oC: min. 440 MPa (45 kg/mm2)250oC: min. 410 MPa (42 kg/mm2)300oC: min. 390 MPa (40 kg/mm2)350oC: min. 380 MPa (39 kg/mm2)400oC: min. 375 MPa (38 kg/mm2)450oC: min. 360 MPa (37 kg/mm2)500oC: min. 350 MPa (36 kg/mm2)

56

DESCRIPTION:The WELDWELL KV5, a basic coated electrode, isemployed for the all-position welding of creep resistingsteels alloyed with 1.25 Cr/0.5 Mo.

It can also be used for welding of 0.9 Cr/0.5 Mo steels.Because of the excellent weldability, stable arc, the weldingof tubes in all positions does not give rise to any problems.

The weld metal of the Weldwell KV5 is insensitive tosolidification cracking.

Welding TechniquesWelding must be carried out with a short arc and a slowtravel rate.

Recommended Heat TreatmentA preheating and interpass temperature of 150 to 200oC isgenerally required in welding large plate thicknesses. Forthin plates a preheating temperature of 100 to 150oC will besufficient.

Stress relieving must be carried out at a temperature of 680to 700oC, during a time in minutes equal to 2.5 x the platethickness in mm for a minimum of one hour. Rapid coolingof the workpiece should be avoided.

Recommended AmperagesDia. Length Amperesmm mm2.5 350 65-953.2 350 75-1304.0 350 115-165

DC only, positive polarity

AWS A5.5 : E7015-B2L H4AS/NZS 1553.2 : E4815-B2L H5

WELDWELL

ELECTRODES FORWELDING

CREEP-RESISTING STEEL

TIP COLOUR GreenFLUX MARKING PH KV5 7015-B2L

ApprovalsAmerican Bureau of Shipping

Welding PositionsF, H, V, OH

Typical Mechanical Properties of Weld MetalTensile Strength 579 MPaYield Value 504 MPaElongation 30%

Typical Chemical AnalysisC 0.04% Mo 0.46%Mn 0.86% P 0.02%Si 0.23% S 0.01%Cr 1.20%

StorageStore in a dry place. (See page 54.)

Typical Creep Properties

Temp Min. creep strength Min. stress rupture strengthF1/10,000 F1/100,000 FB/10,000 F/100,000

MPa Kg/mm2 MPa Kg/mm2 MPa Kg/mm2 MPa Kg/mm2

500oC 166 17.0 118 12.0 235 24.0 166 17.0520oC 126 12.8 83 8.5 182 18.5 112 11.5550oC 78 8.0 49 5.0 108 11.0 59 6.0

Yield values at elevated temperature:200oC: min. 372 MPa (38 kg/mm2)250oC: min. 352 MPa (36 kg/mm2)300oC: min. 333 MPa (34 kg/mm2)350oC: min. 323 MPa (33 kg/mm2)400oC: min. 314 MPa (32 kg/mm2)450oC: min. 304 MPa (31 kg/mm2)500oC: min. 294 MPa (30 kg/mm2)

57

WELDWELL WELDING ELECTRODES

ELECTRODES FOR WELDING STAINLESS STEELS In the welding of stainless steel a choice can be made from the following forms of joints, depending on the thickness of the material to be welded.

SQUARE BUTT WELDS These are employed for sheets and plates with a thickness up to 4 mm (below 1 mm the TIG-welding process is used). The gap between the plates must be half the plate thickness. In connection with shrinkage the gap must be made 1 mm wider during tack welding, in order to ensure the required dimension of the root gap. The first weld is deposited on the side opposite to the one where the tack welds were made. After grinding, the side of the tack welds can be welded

SINGLE V-GROOVE Single V-grooves are used for plate thicknesses of 5 up to 12 mm. It is necessary to bevel the groove faces so that good penetration is ensured. Root face of 2 mm is necessary in order to avoid overheating of the metal due to the low rate of heat transfer in stainless steel. The included angle must be 80o for plates of 5 to 7 mm. This angle should be 70o for thicknesses of 7 to 12 mm. These greater angles permit welding with an electrode having a larger diameter than in the case of unalloyed steels, so that the joint can be filled in fewer layers, which is favourable with regard to distortion.

DOUBLE-V GROOVE For thickness over 10 mm the symmetrical double-V groove comes into consideration. A root face is not necessary here. The root run should always be ground out, in order to avoid welding-defects. Instead of the double-V grooves single U-grooves are also applied, especially for heavier plates.

TACK WELDING Distortion of the workpiece as a result of tack welding can be reduced to the minimum by a favourable distribution of heat. It is a well known fact that straightening of austenitic stainless steel is very difficult and that it may affect the corrosion resistance. The use of tacking strips is not recommended, because then local stresses are introduced (stress corrosion). The tack welds should have a length of 40 mm; the distances between them should be as follows:

Plate Thickness Distance between mm tack welds mm

1-1.5 25-40 2-3 40-70 4-6 70-100 Over 6 100-150

RECOMMENDED WELDWELL ELECTRODES FOR WELDING VARIOUS GRADES OF STAINLESS STEEL IN GENERAL USE

Parent Metals Filler Metals AISI Grades UNS (or common names) Number Electrode Recommendation 301 S30100 Weldwell PH RS308LC or RS347LC * 302 S30200 Weldwell PH RS308LC or RS347LC * 304 S30400 Weldwell PH RS308LC or RS347LC * 304L S30403 Weldwell PH RS308LC or RS347LC * 309 S30900 Weldwell PH RS309LC 310 S31000 Weldwell PH BM310 316 S31600 Weldwell PH RM316LC or RM318LC 316L S31603 Weldwell PH RM316LC or RM318LC 318 S31800 Weldwell PH RM318LC 2205 S31803 Weldwell PH 22.9.3LR 2304 S32304 Weldwell PH 22.9.3LR Stainless Steel to Carbon Steel Weldwell PH RS309LC Molybdenum Bearing Stainless Steel to Carbon Steel Weldwell PH RS309MoLC * Note: RM316LC or Staincord 316L-16 could also be used.

58

DESCRIPTION:This WELDWELL PH RS308LC electrode is used for weldingaustenitic stainless steels containing 16-20% chromium and812% nickel. The non-stabilised weld metal is ductile, has acapacity for deformation and can be polished to a mirror finish.The smooth and finely rippled welds reduce grinding andpolishing to the minimum. The electrode has good penetrationproperties and the slag is easy to control and to remove.Long welds can be made, reducing distortion to the minimum.Applications:Welding of stainless steels of similar composition in dairies,nuclear power plants, foodstuff and chemical industries,fertiliser plants, etc, when relatively mild corrosive attack can beexpected.Welding TechniquesThe electrode should preferably be held at an angle of 80o tothe direction of travel, and be welded with a SHORT ARC.Recommended AmperagesDia. Length Amperesmm mm2.5 300 40-80 3.2 350 60-1004.0 350 90-140AC or DC +For AC a minimum open circuit voltage of 70V is required.

Typical Mechanical Properties of Weld Metal

Tensile Strength 642 MPaElongation 38%Typical Ferrite 6.5%

AWS A5.4 : E308L-17AS/NZS 1553.3 : E308L-17

WELDWELL

ELECTRODESFOR WELDING

STAINLESS STEEL

TIP COLOUR BrownFLUX MARKING PH RS308LC

ApprovalsAmerican Bureau of Shipping

Welding Positions:F, H, V, OH

Typical Chemical AnalysisC 0.03% Cr 19%Mn 0.85% Ni 9.5%Si 0.70%

StorageTo recondition moist electrodes bake for one hour at 350oC in a vented oven.

DESCRIPTION:This is a heavily coated austenitic electrode for welding heat-resistant materials, such as the type of steel containing 25%chromium and 20% nickel (AISI 310). In many cases thesematerials are used at temperatures exceeding 700oC. Anotheruse is the welding of clad steels viz welding in the intermediatezone between mild steel and stainless material. Despite thefact that the weld metal mixes with ordinary mild steel, the weldmetal will still contain a sufficient percentage of chromium andnickel, which guarantees that no martensite will be formed.The same applies to welded joints between ordinary mild steeland stainless steel.Welding TechniquesThe WELDWELL PHBM310 electrode produces a homogeneousweld with very good appearance and excellent heat resistance.The electrode has very low crack-sensitivity. Since theaforementioned types of steel are poor heat-conductors, a lowcurrent must be used for welding.For welding on direct current the electrode must be connected tothe positive pole; in that case penetration is good. The arc mustbe kept short, both for downhand and for vertical position welding.

Typical Mechanical Properties of Weld MetalTensile Strength Min 550 MPaElongation Min 30%Fully austeniticRecommended AmperagesDia. Length Amperesmm mm2.5 300 50-753.2 350 70-954.0 350 90-120DC + AC 70 OCV

AWS A5.4 : E310-16AS/NZS 1553.3 : E310-16

WELDWELL

ELECTRODESFOR WELDING

STAINLESS STEEL

TIP COLOUR BlueFLUX MARKING PH BM310

Welding PositionsF, H, V, OH

Typical Chemical AnalysisC 0.10% Cr 26.3%Mn 1.76% Ni 21.1%Si 0.39%

StorageTo recondition moist electrodes bake for one hour at 280oC in a vented oven.

59

DESCRIPTION:WELDWELL PH RM316LC is an electrode for weldingaustenitic stainless steels containing 16-20% Chromium, 10-14% Nickel and 2-3% Molybdenum.Welding TechniquesRM316LC is used to weld AISI 316 and 316L types such asencountered in petrol chemical, pharmaceutical, textile andpaper industries.Like the steel to be welded, the weld metal has a superiorresistance to pitting and to most types of corrosion, especiallyin reducing and neutral solutions.The welds obtained are smooth and finely rippled, slag-controlis easy, and removal after cooling-down presents no problems.Welding should be carried out with a short arc; the electrodeshould preferably be held at an angle of 80o to the direction oftravel.Recommended AmperagesDia. Length Amperesmm mm2.5 300 40-803.2 350 60-1004.0 350 90-1405.0 350 130-180

AC 70 OCV DC +For AC a minimum open circuit voltage of 70V is required.Typical Mechanical Properties of Weld MetalTensile Strength 600 MPaElongation 41%Typical Ferrite 5.5%

AWS A5.4 : E316L-17AS/NZS 1553.3 : E316L-17

WELDWELL

ELECTRODESFOR WELDING

STAINLESS STEEL

TIP COLOUR OrangeFLUX MARKING PH RM316LCApprovalsAmerican Bureau of ShippingWelding Positions:F, H, (V, OH for 4 mm and smaller)Typical Chemical AnalysisC 0.02% Cr 17.8%Mn 0.72% Ni 11.40%Si 0.67% Mo 2.5%StorageTo recondition moist electrodes bake for one hour at 350oC in a vented oven.

DESCRIPTION:The WELDWELL PH RM318LC is an electrode designed forwelding highly-alloyed austenitic types of Stainless Steelscontaining 16-20% chromium, 10-14% nickel and 2-3%molybdenum (AISI Type 318). The deposit has a highresistance to corrosion by strong acids. Naturally, the electrodecan be used to weld steels of the AISI type 316.The presence of 3% molybdenum makes it suitable for the weldingof stainless steels containing molybdenum in small quantities.The weld metal of the RM318LC is alloyed with niobium (orcolumbium), which guarantees that in the weld metal no inter-crystalline corrosion will occur (stabilised material).Welding TechniquesThe RM318LC electrode must be connected to the positive polefor welding on direct current; when welding is done withalternating current, an open circuit voltage of at least 70V isnecessary. For welding, a short arc must be used becauseporosity may occur. The weld deposit is very smooth and finelyribbed, thus needing little finishing. Even at high currents theslag is easy to control and after welding it is very easy toremove. The angle between the electrode and the direction oftravel must be approximately 80o.

Typical Mechanical Properties of Weld MetalTensile Strength Min 550 MPaElongation Min 25%Typical Ferrite 7.2%Recommended AmperagesDia. Length Amperesmm mm2.0 300 25-602.5 300 40-803.2 350 60-1004.0 350 90-1405.0 350 110-170

AC 70 OCV DC +

AWS A5.4 : E318-16AS/NZS 1553.3 : E318-16

WELDWELL

ELECTRODESFOR WELDING

STAINLESS STEEL

TIP COLOUR YellowFLUX MARKING PH RM318LC

Welding PositionsF, H, (V, OH for 4.0 mm and smaller)

Typical Chemical AnalysisC 0.02% Cr 18.0%Mn 0.77% Ni 11.30%Si 0.72% Mo 2.50%Niobium 0.24%

StorageTo recondition moist electrodes bake forone hour at 350oC in a vented oven.

60

DESCRIPTION:Staincord 316L-16 is an extra low carbon, rutile type electrodeexhibiting superior all positional (except vertical down)performance with an improved moisture resistant "Pink" fluxcoating for weld metal of high radiographic integrity. Thesmooth arc action of Staincord 316L-16, together with lowspatter and excellent slag control/detachability, promotesexceptional weld appearance and profile. Other featuresinclude high arc stability and easy restriking on low voltage ACwelding machines.

Applications:Staincord 316L-16 deposits molybdenum bearing,19Cr/12Ni/2.5Mo filler metal to meet the requirements forwelding type 316 and 316L stainless steels in criticalapplications. Staincord 316L-16 is also recommended for thegeneral purpose welding of common 300 series stainlesssteels, such as 301, 302, 304, and 304L. It is also suitable forthe general welding of ferritic stainless steel alloys, such as409, 444 and 3Cr12. (Contact your nearest Weldwell branchor distributor for further information on these applications.)

Recommended AmperagesDia. Length Amperesmm mm2.0 300 30-502.5 300 50-753.2 350 75-1104.0 350 110-150

AC 45 OCV DC +

Typical Mechanical Properties of Weld Metal

Tensile Strength 600 MPaElongation 40%Typical Ferrite 5.5%

DESCRIPTION:The WELDWELL PH RS309LC is a rutile coated - all positionelectrode for welding stainless steel using 22-25% Cr and 12-14% Ni. AISI 309 may also be used for welding dissimilarmetals, eg stainless steel type 18/8 to mild steel. Also usedfor welding the buffer layer of 18/8 clad steels, of which thefinal run of the joint is made with PH RS308LC.

Welding TechniquesThe electrode should be held at an angle of 80o to thedirection of travel, and be welded using a short arc and atravel speed that allows good fusion of the parent metal.

Typical Mechanical Properties of Weld MetalTensile Strength Min 520 MPaElongation Min 30%Typical Ferrite 12.4%

Recommended AmperagesDia. Length Amperesmm mm2.5 300 45-703.2 350 70-1104.0 350 100-1405.0 350 110-155

AC 70 OCV DC +

AWS A5.4 : E316L-16AS/NZS 1553.3 : E316L-16

WIASTAINCORD 316L-16

ELECTRODES FORWELDING

STAINLESS STEEL

TIP COLOUR GreenFLUX COLOUR Dust PinkFLUX MARKING 316L-16

Welding Positions:F, H, V, OH

Typical Chemical Analysis

C 0.025% Cr 18.5%Mn 0.7% Ni 12.0%Si 0.7% Mo 2.4%

Storage To recondition moist electrodes bake for twohours at 200oC . Do not exceed 250oC.

AWS A5.4 : E309L-17AS/NZS 1553.3 : E309L-17

WELDWELL

ELECTRODESFOR WELDING

STAINLESS STEEL

TIP COLOUR WhiteFLUX MARKING PH RS309LC

Welding PositionsF, H, (V, OH for 4.0 mm and smaller)Typical Chemical AnalysisC 0.03% Cr 23.9%Mn 1.00% Ni 13.1%Si 0.90% Mo 0.06%

StorageStore electrodes in a dry place.To recondition moist electrodes bake for one hour at 350oC in a vented oven.

61

DESCRIPTION:The WELDWELL PH RS309MOLC is an all position, rutilecoated electrode which is extremely suitable for the welding ofMolybdenum, containing austenitic stainless steels to carbonsteels, and for the welding of buffer layers of AISI 316 cladsteels of which the final run is made with PH RM316LC.Welding TechniquesThe electrode should be held at an angle of 80o to the directionof travel, and be welded using a short arc and a travel speedthat allows good fusion of the parent metal.Typical Mechanical Properties of Weld MetalTensile Strength 787 MPaElongation 30%Typical Ferrite 18%

Recommended AmperagesDia. Length Amperesmm mm2.0 300 25-602.5 300 45-703.2 350 70-1104.0 350 100-1405.0 350 110-155AC 70 OCV DC +

Typical Chemical AnalysisC 0.03% Cr 22.20%Mn 0.81% Ni 12.60%Si 0.60% Mo 2.70%

AWS A5.4 E309MoL-17AS/NZS 1553.3 E309MoL-17

WELDWELL

ELECTRODESFOR WELDING

STAINLESS STEEL

TIP COLOUR VioletFLUX MARKING PH RS309MOLC

ApprovalsAmerican Bureau of Shipping

Welding Positions:F, H, (V, OH for 4 mm and smaller)

StorageStore electrodes in a dry place. To recondition moist electrodes bake for one hour at 350oC in a vented oven

DESCRIPTION:WELDWELL PH 22.9.3LR is an all position, rutile coatedelectrode with some basicity. It is suitable for welding Duplexgrades of stainless steel such as 2205, 2304 and 3RE60.

Weldwell PH 22.9.3LR has a ferritic-austenitic structure, with aferrite number of greater than 25 when measured with a severngauge. It is resistant to inter-granular corrosion, and has verygood resistance to pitting and stress corrosion cracking.

Welding TechniquesWelding is possible in all positions, except vertical down.Welding should be carried out using a short arc. Keepamperages as low as possible to achieve good fusion and weldpool control. The electrode has good re-ignition properties.

Typical Mechanical Properties of Weld MetalTensile Strength 882 MPaElongation 22%Typical Ferrite > 45%

Recommended AmperagesDia. Length Amperesmm mm2.5 300 50-803.2 350 70-1204.0 350 90-160

AC 50 OCV DC +

AWS A5.4 E2209-16AS/NZS 1553.3 E2209-16

WELDWELL

ELECTRODESFOR WELDING

STAINLESS STEEL

TIP COLOUR GreenFLUX MARKING PH 22.9.3LR

ApprovalsAmerican Bureau of Shipping

Welding PositionsF, H, V, OH

Typical Chemical AnalysisC 0.03% Cr 23.10%Mn 0.85% Ni 9.80%Si 0.84% Mo 3.20%N 0.17%StorageStore electrodes in a dry place. To recondition moist electrodes bake for one hour at 350oC in a vented oven.

62

WELDWELL WELDING ELECTRODES

ELECTRODES FOR WELDING PROBLEM STEEL Through the years many types of steels have been developed to suit specific kinds of work. In many cases they were not formed with the ultimate aim of weldability. The question often arises when a repair or such like is required, is what filler metal should be used, this is often difficult to answer without the material specifications. However, the so called rule of thumb can make these decisions much easier. Usually the part or body of the machine or implement etc will have been designed to suit a certain work force, ie strength in tensile or vibration, toughness and resistance to compression as in punch and die tooling. There are three types of electrodes in the ELITE range, RSP, Hi Ten 7 and Hi Ten 8. Each is listed with its own description, which in most cases will enable the end user to select a suitable welding electrode for that problem weld. Please remember that Weldwell do have technical people who can assist and we advise - IF IN DOUBT, PLEASE ASK US.

63

DESCRIPTION:ELITE RSP is a rutile-coated electrode depositing a weld metalof an austenitic-ferritic structure, which is highly crack resistant.Hence its use for welding Problem Steels where the risks ofcracking do occur. Elite RSP deposits a smooth dense weldand its slag releases very easily. It can be used to join steelswhich differ from one another, ie stainless and mild steel.The Elite RSP is also suitable to weld creep-resistant steelssuch as 5% Cr - 0.5% Mo steel, where no heat treatment canbe applied after welding. It is most appropriate for joining high-alloy and/or low-alloy steels which differ from one another.Due to the type of composition the weld metal is highlyacceptable for buffer layers prior to hard surfacing because ofits toughness and ability to absorb stresses. Although theappearance is similar to stainless steel, Elite RSP should not beused as a corrosion-resistant alloy and is not stabilised.

Recommended AmperagesDia. Length Amperesmm mm2.5 300 40-753.2 350 60-1004.0 350 90-1405.0 350 130-180

AC 75V DC +

Typical Mechanical Properties of Weld MetalTensile Strength 640-750 MPaElongation(1 = 5d) Min. 25%Deposited 200 BrinellWork Hardens to 500 BrinellTypical Ferrite 22%

WELDWELLELITE

ELECTRODESFOR WELDING

PROBLEM STEELS

TIP COLOUR GoldFLUX MARKING Weldwell RSP

Welding Positions:F, H, (V, OH for 4 mm and smaller)

Typical Chemical AnalysisC Max 0.04% Cr 17.0-20.0%Mn Max 2.50% Ni 10.0-14.0%Si Max 1.00% Mo 2.0-3.5%

StorageTo recondition moist electrodes bake for onehour at 350oC in a vented oven.

64

DESCRIPTION:ELITE HI-TEN 8 has a special coating which permits smooth,dense deposits, porosity free and with little or no spatter. Weldsare made with highest possible speed using the lowest practicalamperage, the deposit will take a high polish.

Exceptionally good where high strength, impact, heat andcorrosion resistance are required. It is very insensitive tocracking. Recommended for use when the analysis of thevarious stainless steels is unknown or doubtful, the repair of dieand tool steels. Elite Hi-Ten 8 can not be heat treated, but canbe work hardened to over 1200 MPa tensile strength.

Typical ApplicationsElite Hi-Ten 8 is used in the jet aircraft, coal mining, chemical,oil and gas industries. The general engineering industry findsit exceptional for welding spring steels, dies, gears, pumps,shafts, nickel-clad steels, tools and saltwater pumps. It will weldor overlay aluminium bronzes with very good results. Ideal torepair or overlay petrol engine exhaust valves.

Welding TechniquesEnsure that weld areas are thoroughly cleaned and follow rulesfor good joint preparation. AC or DC reverse polarity, ieelectrode positive.

When applying in some of the high alloy steels a preheat ofapproximately 200-300oC ie a "light blue colour" isrecommended.

It is good practice before commencing welding to make testruns on scrap steel to ensure that the amperage condition isideal. In most cases use stringer beads and let each pass coolprior to flux removal. A short arc is very necessary. Peeningwill remove internal stresses. When using multi-passes ensurethat the slag is completely removed with each pass.

Recommended AmperagesDia. Length Amperesmm mm2.5 300 40-753.2 350 75-1254.0 350 90-140

AC 50V DC +

WELDWELLELITE

ELECTRODESFOR WELDING

PROBLEM STEELS

TIP COLOUR Light BlueFLUX MARKING Weldwell Hi-Ten 8

Welding PositionsF, H, V, OH

Typical Mechanical Properties of Weld Metal

Tensile Strength As deposited up to 825 MPa

Tensile Strength Work hardened up to 1200 MPa

Yield Strength Up to 625 MPaElongation in 50 mm Minimum 22%Hardness 200 BrinellTypical Ferrite > 45%

StorageTo recondition moist electrodes bake for onehour at 350oC in a vented oven.

65

WELDWELL WELDING ELECTRODES

ELECTRODES FOR GOUGING AND CUTTING

There are conditions when metals need to be removed or parted and sometimes the oxygen-acetylene system is notalways suitable.

There are two types in the range which perform very well, these are the AUSTARC C&G and the WELDWELLPH C18.

With powerful arc welding machines the type AUSTARC C&G is the most efficient, with the PH C18 working verywell where the power supply is not so high.

These types will operate successfully on steels, cast irons, copper base, stainless, nickel and aluminium metals.

66

DESCRIPTION:Austarc C & G is a heavy coated electrode providing a highlymobile means of cutting, gouging and piercing most steels,using standard AC or DC arc welding equipment. Austarc C& G produces a very high arc force and can be used forgeneral cutting and grooving in joint preparation, removingdefective welds and reclaiming scrap metal, etc.

Typical ApplicationsOxy-acetylene and carbon arc-air cutting and gouging are twoprocesses available to industry capable of giving high quality,smooth preparations. Austarc C & G will not replace theseprocesses but rather provide a convenient, easy to use andmobile tool for the arc gouging and cutting of most metals. Itis particularly useful to the maintenance welder operating inawkward locations to remove welds, open up joints and trimoff bolt or rivet heads, etc.

Welding TechniquesCutting: Direct the electrode into the work in the desiredcutting direction, working from the outside edge. Use an upand down sawing motion, the “up” arc length being increasedto increase heating, the “down” arc length being decreased tocontact point to force the molten metal out of the groove.Angle of electrode should be approximately 70o to thehorizontal.

Gouging: Point the electrode in the direction of gouging atapproximately 10-20o to the plate surface. Strike the arc andmove forward rapidly. If slag and molten metal start to clogthe groove bring the electrode up to clear, and, withoutbreaking the arc, circle backwards and move forward again.This latter technique may prove more necessary than straightforward motion on lower amps or as the electrode becomeshotter. If amps are excessive, C & G will tend to “cut out” onAC and overheat, causing premature charring of the coatedand reduced arc force.

Piercing: For holes, plunge the electrode into the plate atslightly off right angles. With a small circular motion to theholder, force the electrode into the plate until full penetrationis achieved. Once the hole has been made it may be trimmedwith an up and down sawing motion.

WARNING: The fire hazard potential of arc cutting is muchgreater than for welding, therefore ensure the arc is clear of allflammable materials before proceeding. Do not cut on or nearoil drums, gas cylinders, etc.

AUSTARCC & G

ELECTRODESFOR GOUGINGAND CUTTING

TIP COLOUR PLAIN

Recommended AmperagesDia. Lengthmm mm Amperes3.2 380 170-2504.0 380 220-350

AC 70 OCV or DC +

StorageStore electrodes in a dry place.

Note:As these electrodes demand very high arcingvolts, it must be taken into account that theamperes indicated by mechanical means onwelding machines will be much lower andtherefore compensation adjustment will benecessary. In addition when comparing AC toDC in values, it is normal to add 15% to theAC range to allow for the slightly weaker ACvalue.

67

WELDWELL WELDING ELECTRODES

ELECTRODES FOR WELDINGCAST IRON

Cast iron contains 3-5% carbon and smaller quantities of silicon and manganese; phosphorus and especially sulphur areundesirable impurities. Alloyed cast irons may also have additions of nickel, molybdenum, chromium or copper. Innormal grey cast iron the carbon is present in the form of flakes of free graphite which is responsible for thecomparatively low tensile strength. With special metallurgical techniques cast irons with improved properties can beproduced, the effect being that the strength impairing flakes of graphite are replaced by nodules of graphite. Theseductile irons (nodular cast irons; spheroidal cast irons; SG irons) are more ductile and have tensile strengths two tothree times that of grey iron. Both grey cast iron and ductile iron are weldable. As may be expected, the latter is easierto weld than grey iron, which is more likely to develop fusion-line and base-metal cracks. However relatively little isdemanded of joints in this material in terms of mechanical properties, since service stresses are mainly compressive.Cast iron must be joined with adapted welding-techniques and suitable weld metal compositions. The major part ofcast-iron welding is carried out with nickel base electrodes designed for low energy input, ie "Low Heat". Low Heatinput restricts expansion and contraction stresses, which, due to the low degree of plastic deformation of the base metal,easily result in cracks. Moreover, the zone adjacent to the weld develops, under the influence of the welding-heat andthe inherently fast cooling-rates, undesirable hard and brittle structures. The depth of this zone is relative to the heatinput. Nickel-based electrodes have emerged as the most satisfactory filler metal for the welding of cast irons,generally because of their good ductility and bond strength and their ability to precipitate the carbon picked up from thebase metal in the form of free graphite.

The commonly used nickel-based electrodes are represented in the Weldwell range by the Supercast Ni containing over96% nickel and the Supercast Ni Fe, a 60/40 nickel-iron type. These electrodes operate on a low current intensity anda low arc voltage, thus ensuring minimum heat input.

The Austarc 16TC electrode is ideally suitable for the welding of dirty and heat affected cast iron, where machineability is not necessary. Also suited for buttering and sealing runs prior to using Supercast Ni.

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DESCRIPTION:Supercast Ni is a basic, graphite-coated AC/DC electrode forthe lower strength welding of cast irons. It is characterised bya soft, smooth arc with low penetration and spatter levels onboth AC and DC power sources. Ease of striking is a feature ofSupercast Ni and it also has a particularly good wetting actionresulting in well bonded welds of regular contour and attractiveappearance.

This electrode is made from a pure nickel core wire andproduces a ductile, fully machinable weld deposit. Supercast Nimay be used for the repair and reclamation of all standardgrades of grey cast iron, malleable iron, austenitic cast iron.

Recommended Amperages

Dia. Length Amperesmm mm3.2 350 50-1004.0 350 80-130

AC 45 OCV DC + or -

Typical Mechanical Properties of Weld MetalTensile Strength 400 MPaYield Value 220 MPaDeposit Hardness 150-170 HV (30)

AWS A5.15 E Ni - Cl

WELDWELL

ELECTRODESFOR WELDING

CAST IRON

TIP COLOUR PLAIN

Welding Positions:F, H (V, OH for smaller sizes)

Typical Chemical AnalysisNickel 97.0%Manganese 0.03%Silicon 0.006%

To recondition moist electrodes bake for one hour at 150o in a vented oven.

DESCRIPTION:Supercast Ni Fe is a basic, graphite-coated AC/DC electrode forthe higher strength welding of cast irons. It is characterised bya soft, smooth arc with low penetration and spatter levels onboth AC and DC power sources. Ease of striking is a feature ofSupercast Ni Fe.

This electrode is made from a nickel-iron core wire andproduces a ductile, machinable weld deposit with the extrastrength required for welding SG (spheroidal graphite) irons.Supercast Ni Fe may also be used for the repair andreclamation of all standard grades of grey cast iron, malleableiron, austenitic cast iron. It is ideally suited to the dissimilarwelding of these irons to steels.

Recommended AmperagesDia. Length Amperesmm mm3.2 350 50-1004.0 350 80-130

AC 45 OCV DC + or -

Typical Mechanical Properties of Weld MetalTensile Strength 500 MPaYield Value 300 MPaDeposit Hardness 200-220 HV (30)

AWS A5.15 E NiFe - Cl

WELDWELL

ELECTRODESFOR WELDING

CAST IRON

TIP COLOUR GREEN

Welding Positions:F, H, (V, VD, OH for smaller sizes)

Typical Chemical AnalysisNickel 57.8%Manganese 0.85%

To recondition moist electrodes bake for one hour at 150o in a vented oven.

69

WELDWELL WELDING ELECTRODES

ELECTRODES FOR HARDFACING Hardfacing is applying wear-resistant alloys on a metal surface, to improve the wear resistance of components subject to abrasion, impact, heat and corrosion, or a combination of these. The purpose of the hardfacing is primarily to increase the service time of the component, thus limiting shut-down time. In addition, and this is often overlooked, production rates and quality of the product are frequently considerably improved. The alloys used in combating wear are usually classified according to their functions as build-up alloys and hard facing alloys. In general practice badly worn components are restored to size by the softer and less wear-resistant build up alloys, which possess good deformation resistance and provide good support for the hard-surfacing alloy. The latter has been designed to give maximum resistance to a specific form of wear or to a combination of wear factors. The wear resistance of the hardfacing deposit depends on the amount of carbides (chromium, tungsten, molybdenum carbides, etc) and on the matrix, which through alloying with elements such as nickel, manganese, silicon and cobalt, can be given specific properties for optimum performance under certain service conditions. Though abrasion is involved in most cases, sometimes conditions call principally for greater toughness, and when heavy impact or metal-to-metal wear with heavy impact dominates, austenitic manganese steel is the preferred material. Surfacing electrodes yielding a 13% manganese deposit are often employed to rebuild 13% manganese steel, but also as an overlay deposited on a carbon-steel base. It is a good thing to bear in mind that the properties of the hard surfacing alloy stated by the manufacturers usually relate to those of the pure weld metal. However, hardness and structure can be appreciably affected by dilution of the deposit with the parent metal. Generally speaking little effect is apparent after the third layer. Cooling-rates can likewise modify the structure, and hence the wear resistance, of some of the hard facing alloys (air-hardening types). Selection of the hard facing alloy should be after careful analysis of the service conditions. Data relevant to mechanical and physical properties of the weld metal and base metal should be taken into consideration and a welding-procedure be established accordingly. Rather than the "try-and-see" method, this approach to wear will ultimately result in the highest savings.

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DESCRIPTION:The WELDWELL PH MN is a basic coated hard facingelectrode which deposits a 13% manganese weld metal whichis very tough and dense, with a high yield and tensile strength.The high work-hardening capacity of PH MN makes it verysuitable for withstanding heavy impact loads. It performs wellin cases of metal to metal wear. The weld metal of the PHMN is less sensitive to embrittlement due to carbideprecipitation than conventional 13% manganese electrodes,yet has the same compressive strength. The deposit can beflame-cut.

The PH MN is used as a final overlay when impact values aretoo high for hard facing, and for rebuilding austeniticmanganese base materials prior to the application of a moreabrasion-resistant overlay. Whenever unalloyed or low alloysteel must be covered with this type, it is necessary to applya buffer layer of Weldwell Elite RSP weld metal. The toughlayers then absorb the high contractional stresses caused bythe high coefficient of thermal expansion and low thermalconductivity of 13% manganese steel (Hadfields).

Welding TechniquesThe PH MN is used in the downhand position. Craters shouldbe filled up through reversal of the direction of travel.

When welding is done on the manganese steel it is essentialto prevent heat build-up in the component. Therefore weldingwith little or no weaving, while a short arc is maintained, andusing minimum current are recommended. For the samereason it is advisable to cover the surface evenly with apattern of short beads approximately 100 mm in length, eachbead at a distance of at least 150 mm from the preceding oneand to fill up the spaces in between according to the sameprocedure. Heavy peening immediately after welding isrecommended to stress-relieve the weld. Artificial cooling bya stream of water or partial immersion in water are beneficialaids for gaining high cooling rates.

ApplicationsCrusher jaws and rolls, impact bars, hammers, ball and tubemill liners, rail frogs and switch points, shovel bucket andteeth, manganese steel castings, etc.

AWS A5.13 : E Fe Mn-BAS/NZS 2576 : 1220-A4

WELDWELL

ELECTRODESFOR HARDFACING

TIP COLOUR BlueFLUX MARKING PH MN

Welding Positions:F, H

Recommended AmperagesDia. Length Amperesmm mm4.0 380 125-170

AC 60 OCV DC +

Typical Undiluted HardnessAs Welded After Work

HardeningVickers 250 HV 540 HVBrinell 250 HB 495 HBRockwell 25Rc 50Rc

Typical Chemical AnalysisC 0.6%Mn 14.8%Mo 0.9%

StorageStore electrodes in a dry place. To reconditionmoist electrodes bake for one hour at 350oC ina vented oven.

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DESCRIPTION:The WELDWELL PH 250 is an electrode which deposits strong,tough and machineable weld material.

The application of this electrode is specially suited to thereinforcing of tram and railway rails by depositing a toughsurface on rails and crossings. It is also used for theresurfacing of axles, lightly-alloyed steels, and the edges ofdies.

The composition of the weld deposit corresponds, with respectto carbon and manganese contents, to that of the steel used formodern rails.

The hardness of the deposited metal depends upon the numberof layers, upon the speed with which the material cools, andupon the temperature of the work-piece. By quenching thedeposited metal at a temperature of 816-904oC in water, aBrinell hardness of about 400 can be obtained.

By quenching at a temperature of 954oC in oil, a Brinellhardness of about 350 is achieved. Grinding tends to increasethe surface hardness of the deposit.

Due to the fairly heavy iron powdered coating the PH 250electrode can take higher currents which increase thedeposition rates to approximately 120% efficiency.

The hardness of PH 250 weld metal is low enough to make iteasy to machine, so that it finds use for facing componentswhich require only moderate wear resistance, and which haveto be machined after building up, as often as necessary onshafts, axles and other machinery parts.

The weld deposit is readily carburised for case hardening.

PH 250 can be applied as a build up prior to using higherhardness electrode weld metal deposits

Applications:Tractor sprockets - Idler shafts - Carbon steel rails - Wheelassembly shafts - building up of parts which require subsequentmachining.

Welding TechniquesNo special precautions are necessary when overlaying mild ormedium tensile steels. A preheat is desirable when dealing withthe hardenable carbon or alloy steels, this is to avoid hard zonecracking beneath the weld deposit.

If the type of steel is not known a preheat of 150o-205oC and theuse of a buffer layer of PH 77 or PH 56S weld metal ensures aresult which is safer with most types of hardenable steels whichcould be encountered.

AS/NZS 2576 : 1120-A4

WELDWELL

ELECTRODESFOR HARDFACING

TIP COLOUR GreenFLUX MARKING PH 250

Welding Positions:F, H

Recommended AmperagesDia. Length Amperesmm mm3.2 380 95-1454.0 450 125-180

AC 50 OCV DC + or -

Typical Undiluted HardnessVickers 250 HV)Brinell 250 HB) Refer to text aboveRockwell 24RC)

Typical Chemical AnalysisC 0.1%Mn 0.83%Si 0.4%

StorageStore electrodes in a dry place. Torecondition moist electrodes bake for half anhour at 120oC in a vented oven.

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DESCRIPTION:The WELDWELL PH 250 is an electrode which deposits strong,tough and machineable weld material.

The application of this electrode is specially suited to thereinforcing of tram and railway rails by depositing a toughsurface on rails and crossings. It is also used for theresurfacing of axles, lightly-alloyed steels, and the edges ofdies.

The composition of the weld deposit corresponds, with respectto carbon and manganese contents, to that of the steel used formodern rails.

The hardness of the deposited metal depends upon the numberof layers, upon the speed with which the material cools, andupon the temperature of the work-piece. By quenching thedeposited metal at a temperature of 816-904oC in water, aBrinell hardness of about 400 can be obtained.

By quenching at a temperature of 954oC in oil, a Brinellhardness of about 350 is achieved. Grinding tends to increasethe surface hardness of the deposit.

Due to the fairly heavy iron powdered coating the PH 250electrode can take higher currents which increase thedeposition rates to approximately 120% efficiency.

The hardness of PH 250 weld metal is low enough to make iteasy to machine, so that it finds use for facing componentswhich require only moderate wear resistance, and which haveto be machined after building up, as often as necessary onshafts, axles and other machinery parts.

The weld deposit is readily carburised for case hardening.

PH 250 can be applied as a build up prior to using higherhardness electrode weld metal deposits

Applications:Tractor sprockets - Idler shafts - Carbon steel rails - Wheelassembly shafts - building up of parts which require subsequentmachining.

Welding TechniquesNo special precautions are necessary when overlaying mild ormedium tensile steels. A preheat is desirable when dealing withthe hardenable carbon or alloy steels, this is to avoid hard zonecracking beneath the weld deposit.

If the type of steel is not known a preheat of 150o-205oC and theuse of a buffer layer of PH 77 or PH 56S weld metal ensures aresult which is safer with most types of hardenable steels whichcould be encountered.

AWS A5.13 E Fe2AS/NZS 2576 : 1120-A4

WELDWELL

ELECTRODESFOR HARDFACING

TIP COLOUR GreenFLUX MARKING PH 250

Welding Positions:F, H

Recommended AmperagesDia. Length Amperesmm mm3.2 380 95-1454.0 450 125-1805.0 455 190-280

AC 50 OCV DC + or -

Typical Undiluted HardnessVickers 250 HV)Brinell 250 HB) Refer to text aboveRockwell 24RC)

Typical Chemical AnalysisC 0.1%Mn 0.83%Si 0.4%

StorageStore electrodes in a dry place. Torecondition moist electrodes bake for half anhour at 120oC in a vented oven.

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DESCRIPTION:The WELDWELL PH 600 is a heavy coated iron powderelectrode which deposits a weld metal containing carbonchromium and manganese. This resultant deposit ismartensitic, containing finely divided chromium carbides whichare highly resistant to abrasive wear, and also have verygood properties against sliding and rolling friction.

PH 600 is not recommended for loads encountering highimpact.

The deposit is malleable when hot and therefore is forgeable.

When applied as a deposit without dilution PH 600 exhibits aBrinell hardness of approximately 600. This hardness can bevaried if slow cooling is used or by quenching in water. Theweld metal will not stand large shrinkage stresses, therefore insome cases where the deposits are heavy, a preheat may bedesirable.

Machining of the deposit is not recommended, and grinding isthe usual method.

Often, intermediate layers made with "softer" electrodes areemployed; a layer of PH 600 can be preceded by a layer of, forinstance, WELDWELL PH 77 or PH 250 or PH 400. Thesetougher deposits will then absorb the stress resulting from thePH 600 deposit.

There is another group of electrodes of the austenitic type whichare sometimes employed for this use, namely Weldwell EliteRSP. These are deposited in alternate beads with PH 600. Asa result the resistance to impact loads increases largely whilstthe hardness decreases very little.

ApplicationsPH 600 electrodes may be used to reclaim tips of excavatortools, dredging bucket rims, hammers of hammer mills, etc.New manganese steel which is soft before work hardening isoften overlayed with PH 600 to counter the initial rapid wearperiod whilst work hardening occurs.

Some Typical Applications areBulldozer blades Harrow tynesSwing hammers PloughsharesCrusher jaws Shear bladesCultivator blades Ripper teethPicks and mattocks Bucket teeth and lipsDies Cutter headsExcavator teeth Mover shoesTrack pads Post hole diggersChutes Chisels and anvils

Welding TechniquesThe welding characteristics of PH 600 are similar toWELDWELL PH 250, therefore please refer to the PH 250description.

AWS A5.13 : E Fe 3AS/NZS 2576 : 1855-A4

WELDWELL

ELECTRODESFOR HARDFACING

TIP COLOUR PinkFLUX MARKING PH 600

Welding Positions:F, H, (V, OH for 2.50 mm)

Recommended AmperagesDia. Length Amperesmm mm3.2 380 95-1454.0 455 125-1805.0 455 190-280

AC 50 OCV DC + or -

Typical Undiluted HardnessVickers 741 HV)Brinell 614 HB) Refer to text aboveRockwell 59RC)

Typical Chemical AnalysisC 0.40%Mn 0.74%Si 0.41%Cr 5.30%

StorageStore electrodes in a dry place. Torecondition moist electrodes bake for half anhour at 120oC in a vented oven.

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DESCRIPTION:The WELDWELL PH 700 electrodes when welded, deposit aHigh Chromium, High Carbon type alloy commonly knownas Chromium Carbide. A mild steel core wire with a high alloycontent and heavy coating permits the use of fairly highcurrents and fast deposition rates.The PH 700 alloy is designed to combat the effects of bothabrasion and impact, because the micro-structure of thedeposit consists of very hard chromium carbide particles (upto 1700 VPN) imbedded in a tough matrix of austenite(approximately 400 VPN).The high chromium content allows the weld deposit very goodresistance to corrosion and scaling at high temperatures (upto 980oC).Due to the fact that the coefficient of thermal expansion of30% Cr steel is about 50% higher than carbon steel, smallcracks can be expected in the deposited weld metal. Thesewill have no adverse influence on the wear-resistance,because stresses will be eliminated, thus reducing the risk ofcrumbling of the weld metal.PH 700 can only be sized by grinding because the depositcannot be softened by annealing.

Welding TechniquesPH 700 electrodes can be used over a wide current range andhave a very stable arc with low open circuit voltage ACmachines. When first striking, a medium to long arc is heldfor a few seconds to create a hot pool which allows a flatdeposit to form, but a short arc should be held during weldingso as to reduce chromium loss due to oxidation.Either stringer bead or a weaving technique may be employed.A weave three or four times the electrode diameter allows theshape of the deposit to be controlled for smoothness andflatness.As with general practice the PH 700 can be hardnesscontrolled by the use of higher currents for greater welddeposit dilution, which allows for better impact properties.When low currents are used, then the weld deposit reaches itshighest hardness for superior abrasion resistance.In general, a single layer deposit is recommended, but multilayers may be used to combat high abrasion in service.The deposit hardness of PH 700 on austenitic manganesesteel is reduced, but this condition is excellent for heavierimpact loads.

ApplicationsFurnace parts Bucket lipsRolling mill guides ChutesConveyor screws PloughsharesBrick machines Drag chain linksFeed spouts Pins and rider blocksMuller tyres Wire straightening rollersDozer blades Cement mill mixers,Ripper teeth chutes, etc.

AS/NZS 2576 : 2360-A4

WELDWELL

ELECTRODESFOR HARDFACING

TIP COLOUR RedFLUX MARKING PH 700

Welding Positions:F, H

Recommended AmperagesDia. Length Amperesmm mm3.2 380 110-1304.0 380 130-1805.0 380 150-220

AC 50 OCV DC + or -

Typical Undiluted HardnessVickers 820 HV)Brinell 653 HB) Refer to text aboveRockwell 62RC)

Typical Chemical AnalysisC Minimum 3%Cr Minimum 18%

StorageStore electrodes in a dry place. Torecondition moist electrodes bake for half anhour at 150oC in a vented oven.

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DESCRIPTION:Abrasocord 43 is a heavy coated, hard surfacing electrodedepositing a complex, extremely hard, abrasion resistantchromium/niobium carbide in an austenitic matrix. It is ideal forhard surfacing applications where resistance to extremeabrasion and moderate to heavy impact are required. Due tothe nodular shape of the complex carbides, Abrasocord 43deposits are capable of withstanding heavier impact levels thanstandard chromium grades.

Welding TechniquesAbrasocord 43 deposits are non-machinable, grindable, proneto fine relief checking and should be restricted to three layershigh.

While two layers of Abrasocord 43 may be required formaximum wear resistance, this complex carbide alloy has lowerdilution sensitivity than straight chromium carbide deposits.

ApplicationsTypical applications include bucket teeth/lips, grizzlies, pressscrews, crusher hammers and ripper teeth to name but a few.

Recommended AmperagesDia. Length Amperesmm mm3.2 380 115-1404.0 380 140-185AC 55 OCV DC +

Typical Mechanical Properties - HardnessSingle layer onto Mild steel 60-65 HRcMulti-layer 64-69 HRc

AS/NZS 2576 : 2465-A4

WELDWELL

ELECTRODESFOR HARDFACING

TIP COLOUR PLAIN

Welding Positions:F, H

Typical Chemical AnalysisCarbon 5.0%Manganese 0.7%Chromium 22%Niobium 7%

StorageStore electrodes in a dry place. Torecondition moist electrodes bake for twohours at 200oC in a vented oven.

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DESCRIPTION:Vidalloy 11 contains a minimum of 60% Tungsten Carbideclassified as a diamond substitute and has the highestresistance to abrasion of any commercially produced product.The electrode body consists of a thin walled tube denselypacked with coarse mesh cast tungsten carbide particles.When welded the rough shaped tungsten carbide particles areembedded in a tough alloy steel matrix and impart excellentcutting efficiency.Hardness RatingSingle layer deposits on mild steel give a carbide hardness of1800 VPN.If a finish is required then grind using special wheels.Welding Position Where necessary 6.3 mm Vidalloy 11 can be used in thevertical and overhead position.No Special StorageThe electrodes are completely moisture resistant because ofthe non-hygroscopic flux coating.Relief checks are normal. Fluidity is very good. Fume factorlow.DepositsMay be made on cast iron, mild steel, low alloy steels,stainless steels and austenitic manganese steels withoutpreheat. High carbon steels should be preheated to 500oCbefore welding and allowed to cool slowly.

AS/NZS 2576 : 3360-A1

VIDALLOY

ELECTRODESFOR HARDFACING

TIP COLOUR GoldWelding Positions:F, H, V, OH

Typical Undiluted HardnessVickers 1800 HVMOH Scale 9.9

Applications:Bucket teeth, Bulldozer end tips, Trencherteeth, Oil drill collars, Reamers, Postholeauger blades, Churn drills, Raymond millploughs, Bituminous mixer blades, Coalcutter bits, Diamond core drills

Recommended Amperages Approx area Dia Approx No covered per kg Approx depositionmm Amperes per kg 3.25 mm thick = CM2 rate Kg per hour6.3 90-145 9.26 274-284 1.5 - 2

AC 50 OCV DC + or -

DESCRIPTION:Vidalloy 30 deposits an alloy known as Chromium CarbideAustenitic Iron and when applied to a mild steel base the nominalcomposition is Carbon 5%, Chromium 35%, Manganese 3.5%,balance Iron.

Hardness FiguresSingle layer deposit 500-600 Brinell. Multi layer deposit630-675 Brinell.

No Special StorageThe electrodes are completely moisture resistant because of thenon-hygroscopic flux coating.The stub end allows even the 11 mm diameter electrode to fitmost conventional electrode holders.Vidalloy has very little spatter and a low fume factor. Reliefchecks are normal. Finish by grinding only. The high alloycontent in the deposited metal is the main reason for superiorservice life results. Vidalloy contains the highest amount ofdeposited metal per kg of electrodes. Contains the highest andbest balanced proportions of alloying elements which meanslongest life for the lowest cost outlay.

Typical Undiluted HardnessSingle Layer Multi Layer

Vickers 567 HV 717 HVBrinell 514 HB 601 HBRockwell 52Rc 58Rc

AS/NZS 2576 : 2355-A1VIDALLOY

ELECTRODESFOR HARDFACING

TIP COLOUR RedWelding Positions:F, H, (V, OH for 6.3 mm)Applications:Parts subject to severe abrasion and goodimpact resistance. The deposited alloy gainsa high polish in wear and has a high erosionfactor. Examples are: Swing hammers, fixedhammers, blow bars, shovel buckets, draglinebuckets, bucket teeth, lips, crusher rolls (rockand shale), gums and bottoms, Cement ballmill, Liner plates (dry), Augers, Scraper blades,Brickpan tyres.Note: Excessively high amperages result ingreater dilution with base metal.

Recommended Amperages Approx area Dia Approx No covered per kg Approx depositionmm Amperes per kg 3.25 mm thick = CM2 rate Kg per hour6.3 80-125 12.4 144-155 1.65 - 2.508.0 140-190 5.4 155-180 2.50 - 2.7511.0 190-250 4.0 180-206 3.00 - 4.00The 6.3 mm diameter is designed for all positional welding.

AC 50 OCV DC + or -

77

WELDWELL WELDING ELECTRODES

ELECTRODES FOR SPECIAL METALS These types are for the brass and bronzes and for aluminium. BRONZE ARC is a general purpose phosphor bronze electrode. ALLY-ARC is for welding aluminium castings and extrusions.

78

DESCRIPTION:BRONZE-ARC is a phosphor bronze alloy with an extrudedcoating which gives exceptional arc stability. With thisversatile electrode you can "arc braze" the same as you"arc weld" using a DC arc welding machine.

The Bronze-Arc alloy has good saltwater and generalcorrosion resistance and colour match comparable to redbronzes. Bronze-Arc may be used to fabricate and joinphosphor bronzes, copper alloys and some iron basemetals. It has a relatively high strength, ductility, freeflowing and crack resistant characteristics. It is particularlysuited for surfaces exposed to corrosion.

Copper alloys of high lead content will require two or threepasses of Bronze-Arc to produce porosity free welds.Brasses of high zinc content should be welded with verylittle fusion.Certain variations will occur due to the welding conditions.

Typical ApplicationsBronze-Arc may be used to weld or overlay cast ormalleable irons which are oil soaked, extremely dirty, rustyor burned. It will give excellent results where many othersfail. In addition, it will braze cast iron or steel, bronzes orbrasses, etc. Very useful for some of the many problemsinvolved in maintenance welding shops.

Welding TechniquesClean all joint areas by removal of scale, dirt, grease andsoft solder which may be there. Materials over 5 mm thickshould be bevelled, a double-vee if possible.Because copper and its alloys conduct heat rapidly, apreheat is essential to avoid non bonding, non flowout andporosity. With sufficient preheating the alloy from Bronze-Arc will flow readily, using low amperages.

Multiple passes will add extra heating making for easierwelding or brazing. Each pass should be thoroughlycleaned, whilst peening will increase the strength andtoughness. Preheat thick sections to 200oC.

Weld, using a medium to long arc length. Carry arc on tothe leading edge of the weld pool and do not weave widerthan four times the electrode diameter. Avoid deeppenetration and over heating because cracking andporosity may result.

AWS A5.6 : E CuSn-C (Closest)

WELDWELL

ELECTRODESFOR WELDING

SPECIAL METALS

TIP COLOUR Green

Recommended AmperagesDia. Amperesmm 3.2 100-1504.0 125-190

DC +

Typical Mechanical Properties of Weld MetalTensile Strength Up to 414 MPaYield Point Up to 240Brinzell Hardness 85-100 HB

StorageStore electrodes in a dry place. To reconditionmoist electrodes bake for one hour at 95oC in avented oven.

79

DESCRIPTION:ALLY-ARC is an aluminium electrode with an extrudedcovering. It operates smoothly, with an easy to control quietarc, and provides a dense spatter-free deposit. Corrosionresistance is good, together with good colour match. It ischaracterised by low amperage application and easy slagremoval. Tensile strength is up to 28,000 psi or 193 MPa.

Typical ApplicationsRecommended for use on aluminium plates, sheets andcastings. Ideal for tanks, railings, pipe, truck and automotiveconstruction and repairs. Outstanding for repairing cracks,build-up of missing sections, cladding and reinforcing.

Welding TechniquesAfter cleaning weld area it is advisable to preheat to 204o-315oC before welding commences. A short-arc should bemaintained, tilting the electrode slightly in the direction oftravel. Either stringer or weaving technique, as used inwelding steel, is suitable except that the rate of welding speedmust be considerably greater. As with all aluminium welding,the flux must be removed and this can be done with a wirebrush and hot water solution containing 5% nitric or 10%sulphuric acid. Rinse with clean hot water. Can only be usedon DC + current.

AWS A5.3 : E4043

WELDWELL

ELECTRODESFOR WELDING

ALUMINIUM

Recommended AmperagesDia. Amperes Voltagemm 3.2 85-135 18-22

DC +

StorageStore electrodes in a dry place. To reconditionmoist electrodes bake for one hour at 95oC ina vented oven.

80

To convert ksi to MPa multiply ksi x 6.895eg 20 ksi = 137.9 MPa

Section Four

Miscellaneous

81

PHYSICAL PROPERTIES OF METALS AND ALLOYS

MeltingPoint deg. C

Densitygm/cc

Coeff. ofExpansion

x 10 - 6

ThermalConductivity

CGS units

Electrical Resistance

Microhms/cm3

AluminiumCadmiumChromiumCobaltCopperGoldIronLeadMagnesiumManganeseMercuryNickelPlatinumSilverTinTitaniumTungstenZinc

Cast iron-low Phos0.5% Carbon Steel12% Chromium steel27% Chromium steel18/8 Cr-Ni stainless80/20 Ni-CrMonelBrass 70/30 copper/zincBronze 7.5% tin

0.06% Phos.Aluminium Bronze 93/7Everdur AAluminium silicon 13%Aluminium magnesium 7%

659.7320.9

18901495108310631535327.3651

1260-38.87

14551773.5960.8231.9

18003370419.5

1240-11201500-14201530-15101510-14901420-13951420-14001350-1300 950-925

1030-8501042-10401050-1000 -577 620-550

2.708.647.18.718.96

19.37.87

11.341.747.4

13.558.9

21.4510.57.34.5

19.37.14

-7.857.70-7.928.408.808.53

8.737.68.542.662.63

23.5316.5

12.517.014.112.129.026.023.06113.39.0

19.123.58.84.5

31

11.613.311.410.918.113.915.019.8

18.217.818.021.024

0.570.200.1650.1659.940.700.170.0820.40-0.0220.210.171.000.1550.0360.3940.265

0.1480.1000.0460.050.0330.0380.060.290

0.1480.1920.1120.350.31

2.697.4

216.241.6732.39.71

20.64.4

16095.86.84

10.61.6

12.855.05.55.9

--

55.067.073.0

108.042.56.9

10.512.126.05.45.7

CONVERSION CHART - INCH/MILLIMETRE

1 INCH = 25.399978 MILLIMETRES 1 MILLIMETRE = .039370113 INCH

Inches m/m Inches m/m Inches m/m Inches m/m

1/64

1/32

3/64

1/16 5/64

3/32

7/64

1/8

9/64 5/32

11/64

3/16

13/64

7/3215/64

1/4

.0156

.0197

.0313

.0394

.0469

.0591

.0625

.0781

.0787

.0938

.0984

.1094

.1181

.125

.1378

.1406

.1563

.1575

.1719

.1772

.1875

.1969

.2031

.2165

.2188

.2344

.2362

.25

.3969

.5

.793711.19061.51.58751.984422.38122.52.778133.1753.53.57193.968744.36564.54.762555.15945.55.55625.953166.35

17/64

9/32

19/645/16

21/64

11/32

23/64

3/8 25/64

13/32

27/64

7/16

29/6415/32

31/64

1/2

.2559

.2656

.2756

.2813

.2953

.2969

.3125

.3150

.3281

.3346

.3438

.3543

.3594

.3740

.375

.3906

.3937

.4063

.4134

.4219

.4331

.4375

.4528

.4531

.4688

.4724

.4844

.4921

.5

6.56.746977.14377.57.54067.937588.33448.58.731299.12819.59.52509.92191010.318710.510.71561111.112511.511.509411.90621212.303112.512.7

33/6417/32

35/64

9/16

37/64

19/3239/64

5/8

41/64

21/32

43/6411/16

45/64

23/32

47/64

3/4

.5118

.5156

.5313

.5315

.5469

.5512

.5625

.5709

.5781

.5906

.5938

.6094

.6102

.625

.6299

.6406

.6496

.6363

.6693

.6719

.6875

.6890

.7031

.7087

.7188

.7283

.7344

.7480

.75

1313.096913.493713.513.89061414.287514.514.68441515.081215.478115.515.8751616.271916.516.66871717.065617.462517.517.85941818.256218.518.65311919.05

49/64

25/32

51/64

13/16

53/6427/32

55/64

7/8

57/64

29/3259/64

15/16

61/64

31/32

63/64

.7656

.7677

.7813

.7874

.7969

.8071

.8125

.8268

.8281

.8438

.8465

.8594

.8661

.875

.8858

.8906

.9055

.9063

.9219

.9252

.9375

.9449

.9531

.9646

.9688

.9843

.98441.0

19.446919.519.84372020.240620.520.63752121.034421.431221.521.82812222.22522.522.62192323.018723.415623.523.81252424.209424.524.60622525.003125.4

82

WORK, ENERGY: FOOT POUNDS - FORCE TO JOULESBasis: 1 ft = 30.48 cm 1 kgf = 980 665 dyn

= 107 dyn cm

ft lbf 0 1 2 3 4 5 6 7 8 9

joules

203040

5060708090

100

27.1164 40.6745 54.2327

67.7909 81.3491 94.9073108.465122.024

135.582

28.4722 42.0304 55.5885

69.1467 82.7049 96.2631109.821123.379

136.938

29.8280 43.3862 56.9444

70.5025 84.0607 97.6189111.177124.735

138.293

31.1838 44.7420 58.3002

71.8583 85.4165 98.9747112.533126.091

139.649

32.5396 46.0978 59.6560

73.2142 86.7723100.331113.889127.447

141.005

33.8954 47.4536 61.0118

74.5700 88.1282101.686115.245128.803

142.361

35.2513 48.8094 62.3676

75.9258 89.4840103.042116.600130.159

143.717

36.6071 50.1653 63.7234

77.2816 90.8398104.398117.956131.514

145.073

37.9629 51.5211 65.0793

78.6374 92.1956105.754119.312132.870

146.428

39.3187 52.8769 66.4351

79.9933 93.5514107.110120.668134.226

147.784

STEEL TESTING BY SPARK METHOD

Wrought Iron Mild SteelCast Steel

High-CarbonSteel

Stainless SteelAlloy Steel

Colour -Straw Yellow

Averagestream lengthwith power grinder 65 in.

Volume-large

Long shaftsending in forksand arrowlikeappendages

Colour - White

Colour - white

Average length of stream with power grinder - 70 in.

Volume - moderately large

Shafts shorter than wrought iron and in forks and appendages

Forks become moremore numerous andsprigs appear as carbon content increases

Colour - white

Average streamlength with powergrinder - 55 in.

Volume - large

Numerous small andrepeating sprigs

Colour - straw yellow

Stream lengthvaries with types andamount of alloycontent

Shafts may end in forks, buds or arrows,frequently with break betweenshaft and arrow.Few, if any, sprigs

Colour - White

White Cast Iron Grey Cast Iron Malleable Iron Nickel and Monel

Colour - Red

Colour -straw yellow

Average stream length withpower grinder - 20 in.

Volume - very small

Sprigs - finer than gray iron, small and repeating

Colour - red

Colour -straw yellow

Average streamlength with powergrinder - 25in

Volume - small

Many sprigs small and repeating

Colour -straw yellow

Average streamlength with powergrinder - 30in

Volume - moderate

Longer shafts thangray iron endingin numerous small,repeating sprigs

Colour - orange

Average stream length withpower grinder - 10in

Short shafts with no forks or sprigs

The Welder is often at a loss to determine the exact quality of a piece of metal, and if a successfulweld is to be secured this forehand knowledge is necessary.An easy and useful method is to touch the metal against a high-speed emery wheel and observe thesparks against a black background and compare against the chart.While this is only a guide, practice will assist the operator to select steels by comparison.

83

AWS A2.4.93 AMERICAN WELDING SOCIETY STANDARD WELDING SYMBOLS

84

85

Volume =4

Br3 =Bd3

3 6

Volume = B r 2 h3

(B = 3•1416 = 22 approx)7

MENSURATION

PARALLELOGRAM

Area = b x h

TRAPEZOID

Area = 1/2 (a + b) x h

TRIANGLE

Area =b x h____ 2

ELLIPSE

Area = Bab

Circumference = 2Br a2 + b2

2

CIRCLE

Bd 2 11 Area = Br 2 or — (or — x d 2 )

4 14

Circumference = 2Br = Bd

SECTOR

Br 2 x 0o s x r Area = or 360 2

ANNULUS

Area = B (r1 + r2) (r1 - r2)(Circles need not beconcentric for this rule toapply.)

SPHERE

Area = 4Br 2 = Bd 2

CONE

Area of curved surface

= Br √ r 2 + h 2

CYLINDER

Area of curved surface= 2Brh

Volume = Br 2 h

86

COMPARATIVE HARDNESS SCALES ANDWELDWELL ELECTRODE DEPOSIT HARDNESS

VPN or DPN ApproxTensileN/mm2

WeldwellElectrodesSingle layer

on M/SBrinell Pyramid No Rockwell

C B

780755725712699685653627601578555534514495477461444424415401388375363341321302285262248235223212202192187174166156149146143

115010801000

960900885820765717675633598567540515494472456437420404389375350327305287263248235223212202192187174166156149146143

7068676665646260585755535250494746454442414038363432302624222017151210

741---

120119119117117116115115113112112110110109108107105103102

9997969492918886838180

7

2640

2500

2250

2000

1500

10751000

900870835800760750650630615600585575525510500

Abrasocord 32

PH 700

PH 600

RSP (work hardened)

PH 400

PH 250RSP as depositedPH 118

PH 56S PH 27 PH C6H

PH 46 PH 48A

ARC WELDING LENSESWelding Operation Electrode Size Approx Amps Shade Number

Shielded Metallic Arc(stick)

2.0 mm : 2.5 mm3.2 mm : 4.0 mm4.0 mm : 5.0 mm5.0 mm : 6.0 mm

Up to 100100 and over200 and over300 and over

9101112

Gas Tungsten Arc(TIG)Non FerrousFerrous

1112

Gas metallic Arc(MIG-MAG)Non Ferrous

Ferrous

0.6 mm0.8 mm : 0.9 mm1.2 mm : 1.6 mm

0.8 mm : 0.9 mm1.2 mm : 1.6 mm

91011

1112

87

CARE AND STORAGE OF ELECTRODES Careless treatment of electrodes, particularly in on-site and outdoor work, can seriously affect the quality of welded joints. It is therefore essential that every welder, storekeeper and foreman should have some elementary knowledge of the correct methods for maintenance and storage. Welders must treat electrodes with the care that every craftsman should take in looking after his materials and tools; for example, no carpenter of repute would leave his chisels to rust in the rain. The coatings of welding electrodes can be damaged by:-

1. Mechanical force 2. Absorption of moisture 3. Deterioration through age

There are other factors which will also produce damaged coatings, but these are rare and beyond the scope of this elementary survey. The three main sources of damage are detailed as follows :- Mechanical Force: Coatings are generally robust (except for some low hydrogen types) and can only be damaged by violent handling; by this it is meant treading on them, bending them, or in general treating them roughly. Damage from such treatment is always so obvious that no welder would consider using the electrodes. Moisture Absorption: Too high a percentage of moisture in an electrode can be dangerous, in that it will seriously affect the quality of the weld. In many cases, a welder will not be aware that an electrode is unserviceable, and even if he is, he may not realise the effects of excessive moisture. He may not be able to see the porosity or piping forming in the weld though it can be detected immediately by X-rays. When leaving the manufacturer all electrodes contain a percentage of moisture, the amount has been determined after much research work, and is carefully controlled, but varies with different types of electrodes. The basic electrode E xx 16, E xx 18, E xx 28 class are dried by a special process and contain practically no moisture. Acid or Organic Rutile types, class E xx 12, E xx 13, E xx 27 are less affected by moisture than the basic types and the Cellulosic type E xx 10 and E xx 11 class will absorb a considerable amount of moisture before causing piping or porosity. The equilibrium moisture content of the coating of an electrode varies with the relative humidity of the atmosphere, and it rises rapidly when the relative humidity exceeds 70%. The relative humidity is the percentage of moisture in the air compared with the quantity required to saturate it at the same temperature. The quantity of moisture that the air can hold rises as its temperature rises, so that if there is no change in the total moisture content of the air, the relative humidity falls as the temperature rises, and increases as the temperature falls. When the temperature falls below the point where the relative humidity becomes 100%, moisture is deposited. The temperature at which this happens is known as the dew point temperature. The relative humidity of the air in this country is often of the order of 60 to 80%, and to reduce this to a reasonable value, heating of an electrode store is desirable. The importance of maintaining the heat during the nights and weekends may be illustrated by the following example.

Air at 15oC and relative humidity 70% will deposit moist-ure if it is cooled to 10oC. Alternatively, if its temperature is raised to 21oC, its relative humidity falls to 50%. The rate at which equilibrium is reached depends on the degree of porosity of the coating. A relatively impervious coating would seem desirable, but in practice this is not found to be the case. As soon as welding with the electrode is started, the electrode becomes heated by the passage of the welding current and any moisture in the coating is soon converted into steam. If the coating is impervious this vapour cannot escape, and the coating may burst. For example, it is possible for the coating of some electrodes to burst when the moisture content is less than 0.5%; yet others will weld satisfactorily with more than 6% of moisture in the coating. The heating of a coating by passing a current through the electrode is therefore not a good method of judging its moisture content. An impervious coating can be applied to the surface of electrodes after they have been manufactured and dried; to prevent the ingress of moisture, but the materials suitable for this purpose are expensive, and generally produce objectionable fumes during the welding operation. Their use is therefore confined to underwater welding electrodes. In general, basic coated low hydrogen electrodes require protection against the absorption of moisture and are specially packed to ensure that the electrodes will remain factory fresh until opened for use. These remarks on the moisture absorption of electrodes are intended as general guidance only and because there may be exceptions to these rules, it is usually indicated by the manufacturer on the electrode packet label. Damp electrodes are usually indicated by a fierce arc action during welding and an undue amount of spatter. Also the slag is sometimes difficult to remove from the weld bead. Deterioration through age: Another form of attack which can take place on electrode coatings in storage for long periods produces more obvious results in the form of a white or crystalline fur on the surface of the coating. This fur is produced by a chemical reaction between the carbon dioxide in the atmosphere and the sodium silicate of the binder, producing crystals of sodium carbonate and silica powder. The rate of reaction appears to be extremely slow in the absence of water and is favoured by conditions of fluctuating humidity. When moisture is deposited, sodium carbonate and silica will be formed and as the reaction is irreversible under these conditions, will remain. Further additions to the deposit will be made every time moisture is deposited. Conditions favouring such deposition can occur in a store or workshop that is heated during working hours but allowed to cool excessively during the night or weekend. The crystals formed do not appear to have any serious effect on the welding quality of most electrodes, but their presence in excess may lead to the disruption of the coating as a result of rusting of the core wire. Their presence may, however, be taken as an indication of old electrodes and unsatisfactory storage conditions.

88

RECOMMENDATIONS FOR STORAGE AND DRYING OF ELECTRODES. Storage: For bulk storage of unopened electrodes, the temperature of the storage room should be maintained at not less than 20oC. If the humidity in the room does not exceed 50% the electrodes should be maintained in a suitable condition. When stored in this manner, electrodes may be used direct from a previously unopened packet. This includes low hydrogen types, however, more specific storage is then required for low hydrogen electrodes (see below). Once the electrode packet has been opened, unused electrodes should be stored in a heated, but ventilated cabinet, on perforated shelves. The temperature should be maintained at a minimum of 20oC or at least 10oC above ambient. The electrodes should not be over-stacked, thus restricting ventilation. Storage for Low Hydrogen Electrodes: For highest weld quality and to obtain specific low hydrogen weld metal levels low hydrogen electrodes should be baked before use (see individual data sheets). For intermediate storage (after baking, but before being used on site) the electrodes should be stored in a holding oven at 120-150oC. Electrodes can be held in the holding oven for a maximum period of six weeks. For site welding the electrodes should be held in a hot box at a minimum temperature of 70oC, for no more than eight hours. Unused electrodes should be returned to the holding oven.

Re-Drying: When re-drying it is advisable to bring the oven up gradually to the required temperature. Placing damp electrodes in an already hot oven may cause cracking of the flux coating.

Rutile Electrodes: ie Weldwell PH 28, 46, 48A, 68, 78, C18, WIA Austarc 12P. - Rutile type electrodes require a small amount of moisture for best running characteristics. Therefore it is essential that this small amount of moisture is not dried out when drying these types. If electrodes become damp, re-dry at 120oC for 30 minutes. It will be necessary to test weld the electrodes running characteristics to ensure no other drying takes place. Cellulose Electrodes ie Weldwell PH 31A, Pipemaster 60, Pipemaster 70. These electrodes require a fairly high percentage of moisture for optimum running characteristics, and if dried will lose arc voltage. Redrying is not recommended for these electrode types. Iron Powder Electrodes ie Weldwell PH 22, 7024 As with rutile types, iron powder electrodes require a small amount of moisture for best running characteristics, but the re-drying temperatures are much higher. If electrodes become damp re-dry at 250oC for 30 minutes. Low Hydrogen Electrodes ie Weldwell PH 27, 27P, 56S, 56R, 75, 77, C6H, 118, KV range, WIA Austarc 16TC. If electrodes become damp they must be re-dried for one hour at the recommended temperatures (two hours for Austarc 16TC). These temperatures can also be used to obtain low or very low weld metal hydrogen levels (refer to individual data sheets). Do not stack more than four layers deep. Stainless Steel electrodes ie Weldwell PH RS308LC, RM318LC, BM310, RM316LC, RS309LC, RS309MoLC, 22.9.3LR, 22.12HTR, WIA Staincord 316L-16. Stainless steel electrodes also require re-drying if they become damp. Re-dry for one hour at 350oC except BM310 which should be re-dried for one hour at 280oC and Staincord 316L-16 which should be redried for two hours at 200oC. Do not re-dry more than five times otherwise flux deterioration could occur.

89

ELECTRODES AGENCY APPROVAL GRADES Electrodes Lloyds Register American Bureau Bureau Det Norske of Shipping of Shipping Veritas Veritas

PH 28 2 2 2

PH 31A 3 3 3

PH 46 2 2 2

PH 48A 2, 2Y 2

PH 68 1 1 1

PH 78 3 3

PH C18 2 2 2

PH 7024 2, 2Y 2 2

PH 27 3, 3YH15 3H5, 3Y 3, 3Y HH

PH 27P 3, 3YH5 3H5, 3Y 3, 3YHH

PH 22 2, 2Y 2, 2Y

PH 56S 3, 4YH5 3H5, 3Y 3, 3YHH

PH 75 5Y40H10 3H10, 3Y 3, 3YHH

PH 77 3, 4YH5 3H5, 3Y 3HH

PH C6H 3, 3YH5 3H5, 3Y 3, 3YHH

PH 118 E11018-G

PH KV3 E8015-B3L

PH KV5 E7015-B2L

PH RS308LC E308L-17

PH RM316LC E316L-17

PH RS309MoLC E309MoL-17

PH22-9-3LR E2209-16

Austarc 12P 2, 2Y 2 2

Austarc 16TC 3, 4YH10 3H10 3YH10

90

TYPE MM APPROXRODS

PER PKT

KG

PH 28 2.53.24.05.0

15916410453

2.5555

Austarc 12P

2.02.53.24.05.0

250160159105

56

2.52.5555

PH 45E 4.0 94 5

PH 46 2.02.53.24.0

201144142

80

2.52.555

PH 48A 2.53.24.0

158158105

2.555

PH 68 2.53.24.05.0

172163109

72

2.5555

PH 78 2.53.24.0

148148

99

2.555

PH C18 3.24.0

12685

55

PH 22 3.24.0

9052

55

PH 7024 2.53.24.05.0

97915432

2.5555

PH 31A 2.53.24.05.0

166166107

73

2.5555

Pipemaster60

2.43.24.04.8

1500850600400

22.7

Pipemaster70

3.24.04.8

850600400

22.7

TYPE MM APPROXRODS

PER PKT

KG

PH 27 3.24.05.0

148103

55

555

PH 27P 2.53.24.0

1299060

2.25.05.0

Austarc16TC

2.53.24.05.06.0

147148

904935

2.55555

PH 56S 2.53.24.05.06.0

131151

995638

2.25555

PH 56R 5.0 55 5

PH 75 3.24.0

13895

55

PH 77 2.53.24.05.0

107126

8747

2.2555

PH C6H 3.24.05.06.0

75422820

5555

PH 118 3.24.05.0

1228645

555

PH KV3 2.53.24.0

115131

91

2.255

PHRS308LC

2.53.24.0

1437750

2.52.52.5

PH BM310 2.53.24.0

1407248

2.52.52.5

PHRM316LC 2.5

3.24.0

1417651

2.52.52.5

TYPE MM APPROXRODS

PER PKT

KG

PH RM318LC 2.02.53.24.0

228138

7850

2.52.52.52.5

AustarcStaincord316L-16

2.02.53.24.0

210137

7147

2.52.52.52.5

PH RS309LC 2.53.24.0

1307851

2.52.52.5

PH RS309MoLC 2.53.24.0

1187650

2.52.52.5

PH 22.9.3LR 2.53.24.0

1398155

2.52.52.5

ELITE RSP 2.53.24.0

1437851

2.52.52.5

ELITE HI TEN 8 2.53.24.0

1517451

2.52.52.5

Austarc C&G 3.24.0

8369

44

Supercast Ni 2.53.24.0

1548356

2.52.52.5

Supercast NiFe 3.24.0

8957

2.52.5

PH MN 4.0 78 5

PH 250 3.24.0

12668

55

PH 400 3.24.05.0

1276846

555

PH 600 3.24.05.0

1336745

555

PH 700 3.24.05.0

865736

55

Abrasocord 43 3.24.0

8756

55

91

WELD DEPOSITION AND COSTING DATA FIGURE 10 Tables 1.0 - 1.5 of this section are a convenient means of determining the mass of weld metal per unit length of joint for each of the simple joint cross-sections described. Simply look up the appropriate dimensions of the shape in question, and the weld metal mass, in kilograms per metre (kg/m), is calculated for you. By referring to GUIDE 1, shown in the following pages, a practical example is given illustrating the correct usage of tables 1.0 - 1.5. Where ready made Tables are not available or greater accuracy is required, the weld cross-section may be drawn on graph paper to a suitable scale; millimetres being ideal. By converting the curves to stepped straight lines and counting the small triangles and squares enclosed by the profile, the cross-sectional area can be accurately determined. Given the length of the required weld, the volume of weld metal can be calculated and converted to the mass of weld metal, using an appropriate density figure. For example, 1 mm2 cross-sectional area of steel weld metal by 1000 mm (1 metre) long has a mass of .00785 kg. Therefore, finding the cross-sectional area, in mm2, and multiplying by .00785 will give the mass of weld metal per metre of joint, in kg/m. GUIDE 1 - A GUIDE TO USING TABLES 1.0 - 1.5 (a) FILLET WELDS

For fillet welds the user is directed to Table 1.5. Select the desired leg length (L) with the likely degree of convexity (h) given the electrode size/type used, the welding position and process etc, and read off the mass of weld metal per metre of joint (kg/m). For acute angle or obtuse angle fillets or fillets of unequal leg length, treat as for a butt weld and refer to (b).

(b) BUTT WELDS For butt welds, first sketch the joint cross-section under consideration, breaking it down into fundamental shapes such as rectangles, triangles and reinforcement and radius sections as shown in Figure 10.

Dimension the shapes, from available information, by calculation or by "intelligent guessing". Using these dimensions, the mass of weld metal per metre of joint can be arrived at for each shape segment using the data from Tables 1.0-1.4. From here, the total mass of weld metal required per metre of joint can be simply calculated by adding the figures obtained for each shape segment. Practical Example 1 For the U-joint illustrated in Figure 10, assume the following dimensions. T (plate thickness) = 60 mm

= 100 (therefore, included angle is 20o) r (root radius) = 10 mm d2 (root face) = 8 mm Side A Rectangular, Triangular and Radius Cross-Sections With a root face (d2) of 8 mm and a root radius (r) of 10 mm, the depth of the rectangular and triangular sections (d) will be, d = T, - (d2 + r) = 60 - 18 = 42 mm. The width of the rectangle (w) is of course equal to 2r - 20 mm. From Table 1.0, the mass of weld metal per metre of joint required for a rectangle of area, 20 x 42 mm = 840 mm2, is approximately ........................... 6.59 kg/m (A) From Table 1.1, two triangles with an included angle of 200 and a depth of 42 mm will need a mass of weld metal per metre of joint of approximately ........................... 2.50 kg/m (B) From Table 1.3, a semi-circular section of radius 10 mm will require a mass of weld metal per metre of joint of approximately Side A Reinforcement Cross-Section The reinforcement width of Side A (fA) will be the addition of 2r (20 mm) and L (15 mm, taken from Table 1.1) plus whatever overlap onto the parent metal is considered desirable practice. For this example, assume an average overlap of 3 mm on each side of the joint which gives fA = 6 + 20 + 15 = 41 mm. Also let us assume a reinforcement height on Side A (hA) of 3 mm. From Table 1.2, the mass of weld metal required per metre of joint for the reinforcement section of Side A of f = 41 mm and h = 3 mm is approximately 0.75 kg/m (C1) Side B Back Gouged Cross-Section Here the user will be guided by such factors as, the welding process used for the root pass, to determine resultant root penetration, the fracture toughness requirements of the root and established workshop practices, etc, to determine the extent of back gouging required. For this example, we will assume a carbon-arc gouge carried out with a 10 mm carbon to produce a groove 14 mm wide and 10 mm deep. From Table 1.4, the mass of weld metal required per metre of joint to fill a groove of these dimensions is approximately

0.86 kg/m (E) Side B Reinforcement Cross-Section With a gouge width of 14 mm (allow a little more for uneven gouging) and estimating a 3 mm overlap onto each side of the joint gives a reinforcement width for Side B (fB) of 21 mm. From Table 1.2, the mass of weld metal required per metre of joint for a reinforcement section of f = 21 mm and an assumed height of h = 1.5 mm is approximately ....... 0.19 kg/m (C2) Therefore, A + B + D + C1 + E + C2 gives the total mass of weld metal required per metre of joint 6.59 + 2.50 + 1.23 + 0.75 + 0.86 + 0.19 = 12.12 kg/m.

92

WELD DEPOSITION AND COSTING DATA (contd)

Mass of Weld Metal in Joint

Table 1.0 RECTANGULAR WELD CROSS-SECTIONS

This table provides the mass of steel weld metal per metre of joint (kg/m) for known cross-sectional areas.

Simply, multiply “d” x “w” for cross-sectional area (mm2) and read directly from the table. Where a sectionalor total joint area is already known in square inches, multiply by 645.2 for mm2 and use this table.

Area(mm2) 0 10 20 30 40 50 60 70 80 90

0 - 0.08 0.16 0.24 0.31 0.39 0.47 0.55 0.63 0.71

100 0.79 0.86 0.94 1.02 1.10 1.18 1.26 1.33 1.41 1.49

200 1.57 1.65 1.73 1.81 1.88 1.96 2.04 2.12 2.20 2.28

300 2.36 2.43 2.51 2.59 2.67 2.75 2.83 2.90 2.98 3.06

400 3.14 3.22 3.30 3.38 3.45 3.53 3.61 3.69 3.77 3.85

500 3.93 4.00 4.08 4.16 4.24 4.32 4.40 4.47 4.55 4.63

600 4.71 4.79 4.87 4.95 5.02 5.10 5.18 5.26 5.34 5.42

700 5.50 5.57 5.65 5.73 5.81 5.89 5.97 6.04 6.12 6.20

800 6.28 6.36 6.44 6.52 6.59 6.67 6.75 6.83 6.91 6.99

900 7.07 7.14 7.22 7.30 7.38 7.46 7.54 7.61 7.69 7.77

1000 7.85 7.93 8.01 8.09 8.16 8.24 8.32 8.40 8.48 8.56

Where increments of less than 10mm2 are considered necessary, add to the above, on the basis of .008 kg/mfor every 1 mm2.

93

WELD DEPOSITION AND COSTING DATA (contd)

Mass of Weld Metal in Joint

Table 1.1 TRIANGULAR WELD CROSS SECTIONS

Table 1.TRIANGULAR WELD CROSS SECTIONS

Mass of Steel Weld Metal per Metre of Joint (kg/m)

Depthd

(mm)

WidthL

(mm)kg/m

WidthL

(mm)kg/m

WidthL

(mm)kg/m

WidthL

(mm)kg/m

6 3.5 0.08 6.0 0.14 2.1 0.05 3.2 0.08

8 4.6 0.14 8.0 0.25 2.8 0.09 4.3 0.14

10 5.8 0.23 10.0 0.39 3.5 0.14 5.4 0.21

12 6.9 0.32 12.0 0.57 4.2 0.20 6.4 0.30

14 8.1 0.45 14.0 0.77 4.9 0.27 7.5 0.41

16 9.2 0.58 16.0 1.00 5.6 0.35 8.6 0.54

18 10.4 0.73 18.0 1.27 6.3 0.45 9.6 0.68

20 11.5 0.90 20.0 1.57 7.1 0.56 10.7 0.84

22 12.7 1.10 22.0 1.90 7.8 0.67 11.8 1.02

24 13.9 1.31 24.0 2.26 8.5 0.80 12.9 1.22

26 15.0 1.53 26.0 2.65 9.2 0.94 13.9 1.42

28 16.2 1.78 28.0 3.08 9.9 1.09 15.0 1.65

30 17.3 2.04 30.0 3.53 10.6 1.25 16.1 1.90

35 20.2 2.77 35.0 4.81 12.3 1.69 18.8 2.58

40 23.1 3.63 40.0 6.28 14.1 2.21 21.4 3.36

45 26.0 4.59 45.0 7.95 15.9 2.81 24.1 4.26

50 28.9 5.67 50.0 9.81 17.6 3.45 26.8 5.26

55 31.8 6.86 55.0 11.87 19.4 4.19 29.5 6.37

60 34.6 8.15 60.0 14.13 21.2 4.99 32.2 7.58

65 37.5 9.57 65.0 16.58 22.9 5.84 34.8 8.88

70 40.4 11.10 70.0 19.23 24.7 6.79 37.5 10.30

75 43.3 12.75 75.0 22.08 26.4 7.77 40.2 11.83

80 46.2 14.51 80.0 25.12 28.2 8.85 42.9 13.47

Table 1.TRIANGULAR WELD CROSS SECTIONS Contd

Mass of Steel Weld Metal per Metre of Joint (kg/m)

Depthd

(mm)

WidthL

(mm)kg/m

WidthL

(mm)kg/m

WidthL

(mm)kg/m

WidthL

(mm)kg/m

6 5.6 0.13 6.9 0.16 8.4 0.20 12.0 0.28

8 7.5 0.24 9.2 0.29 11.2 0.35 16.0 0.50

10 9.3 0.37 11.5 0.45 14.0 0.55 20.0 0.79

12 11.2 0.53 13.9 0.65 16.8 0.79 24.0 1.13

14 13.1 0.72 16.2 0.89 19.6 1.08 28.0 1.54

16 14.9 0.94 18.5 1.16 22.4 1.41 32.0 2.01

18 16.8 1.19 20.8 1.47 25.2 1.78 36.0 2.54

20 18.7 1.47 23.1 1.81 28.0 2.20 40.0 3.14

22 20.5 1.77 25.4 2.19 30.8 2.66 44.0 3.80

24 22.4 2.11 27.7 2.61 33.6 3.17 48.0 4.52

26 24.2 2.47 30.0 3.06 36.4 3.71 52.0 5.31

28 26.1 2.87 32.3 3.55 39.2 4.31 56.0 6.15

30 28.0 3.30 34.6 4.07 42.0 4.95 60.0 7.07

35 32.6 4.48 40.4 5.55 49.0 6.73 70.0 9.62

40 37.3 5.86 46.2 7.25 56.0 8.79 80.0 12.56

45 42.0 7.42 52.0 9.18 63.0 11.13 90.0 15.90

50 46.6 9.15 57.7 11.32 70.0 13.74 100.0 19.63

55 51.3 11.07 63.5 13.71 77.0 16.62 110.0 23.75

60 56.0 13.19 69.3 16.32 84.0 19.78 120.0 28.26

65 60.6 15.46 75.1 19.16 91.0 23.22 130.0 33.17

70 65.3 17.94 80.8 22.20 98.0 26.93 140.0 38.47

75 69.9 20.58 86.6 25.49 105.0 30.91 150.0 44.16

80 74.6 23.42 92.4 29.01 112.0 35.17 160.0 50.24

94

Radius,r

(mm)

Mass of WeldMetal

Per Metre ofJoint

(kg/m)"U" "J"

3 0.11 0.064 0.20 0.105 0.31 0.156 0.44 0.227 0.60 0.308 0.79 0.399 1.00 0.50

10 1.23 0.6211 1.49 0.7512 1.78 0.8913 2.08 1.0414 2.42 1.2115 2.77 1.39

Depth(mm)

Width(mm)

Area(mm2)

Mass ofWeld

Metal perMetre of

Joint (kg/m)1.5 6 7.07 0.062.5 8 15.71 0.123.5 7 19.24 0.154 12 37.70 0.305 10 39.27 0.317 12 65.97 0.528 19 119.38 0.94

10 14 109.96 0.8610 22 172.79 1.3612 20 188.50 1.4815 30 353.43 2.77

WELD DEPOSITION AND COSTING DATA (contd)

Mass of Weld Metal in Joint

Table 1.2 WELD REINFORCEMENT CROSS-SECTIONS

FaceWidth

(f)(mm)

Mass of Weld Metal per Metre of Reinforcement (kg/m)

REINFORCEMENT HEIGHT, H

h = 1.0mm

h = 1.5mm

h = 3.0mm

h = 4.5mm

h = 6.0mm

6 0.04 0.06

8 0.05 0.07

10 0.06 0.09 0.18 0.28

12 0.07 0.11 0.22 0.33

14 0.09 0.13 0.26 0.39

16 0.10 0.15 0.30 0.44

18 0.11 0.17 0.33 0.50 0.67

20 0.12 0.18 0.37 0.55 0.74

22 0.14 0.20 0.41 0.61 0.81

24 0.15 0.22 0.44 0.67 0.89

26 0.16 0.24 0.48 0.72 0.96

28 0.17 0.26 0.52 0.78 1.04

30 0.18 0.28 0.55 0.83 1.11

35 0.22 0.32 0.65 0.97 1.29

40 0.25 0.37 0.74 1.11 1.48

45 0.28 0.42 0.83 1.25 1.66

50 0.31 0.46 0.92 1.39 1.85

Note: For face widths in excess of 50 mm, estimate averageheight of reinforcement and calculate as for a rectangle,referring to Table 1.0

Table 1.3 RADIUS WELD CROSS-SECTIONS

Table 1.4 BACK GOUGED WELD CROSS-SECTIONS

Note: Appropriate reinforcement additions, selected fromTable 1.2, will generally be required to be added to theabove figures.

95

WELD DEPOSITION AND COSTING DATA (contd)

Mass of Weld Metal in Joint

Table 1.5 FILLET WELDS

The table shows the mass of steel weld metal per metre of joint(kg/m) for fillet welds of varying degrees of convexity and atypical concave profile. The figures are based on actual leglength being maintained. Note that the leg lengths shown arenot applicable to the concave welds which are designated in thistable by throat thickness.Note: For Aluminium weld metal divide the steel weld metalmass per metre by 2.9.

Weld SizeCross-

sectionalArea

(mm2)

MASS OF WELD METAL PER METRE (kg/m)Leg Length, L Throat

ThicknessT (mm)

Flat and Convex Welds Concave Welds

(mm) (inch) h = 0(Theor.)

h =1.0 mm

h =1.5 mm

h = 2.5 mm

ThroatThickness

T (mm)

TypicalConcave

Weld3.2 1/8 2.3 5.1 .04 .07 .08 - 2.3 0.053.5 2.5 6.1 .05 .08 .10 - 2.5 0.064.0 5/32 2.8 8.0 .06 .09 .11 - 2.8 0.074.8 3/16 3.4 11.5 .09 .13 .15 - 3.4 0.105.0 3.5 12.5 .10 .14 .17 - 3.5 0.115.6 7/32 4.0 15.7 .12 .17 .19 - 4.0 0.136.0 4.2 18.0 .14 .19 .22 - 4.2 0.156.4 1/4 4.5 20.5 .16 .22 .24 - 4.5 0.177.0 4.9 24.5 .19 .25 .28 - 4.9 0.218.0 ~5/16 5.7 32.0 .25 .32 .35 - 5.7 0.279.5 3/8 6.7 45.1 .36 .44 .48 .57 6.7 0.39

10.0 7.1 50.0 .39 .48 .52 .61 7.1 0.4212.7 1/2 9.0 80.6 .63 .74 .80 .91 9.0 0.6815.9 5/8 11.2 126.4 .99 1.13 1.20 1.34 11.2 1.0619.0 ~3/4 13.4 180.5 1.42 1.59 1.67 1.84 13.4 1.5222.2 7/8 15.7 246.4 1.93 2.13 2.23 2.42 15.7 2.0625.4 1.0 18.0 322.6 2.53 2.75 2.86 3.08 18.0 2.70

Quantity of Consumables RequiredGiven the mass of weld metal required to "fill" a metre of joint, the next step is to determine the mass of consumable(s)required. The weld metal yield achieved from welding with a consumable electrode largely depends on the efficiency of thewelding process and the consumable in question.

The "QUANTITY OF CONSUMABLE"figures listed in Table 2.0 are for aweld metal yield of 1 kg and take intoaccount inherent wastage losses suchas weld metal spatter, slag coverage,stub ends, etc. An additionalpercentage (listed in the "EXTRA FORWASTAGE" column) is usually added toallow for typical shop wastage.

TO OBTAIN THE QUANTITY OFCONSUMABLE REQUIRED TO YIELD 1 KGOF WELD METAL READ DIRECTLY FROMTABLE 2.0 FOR THE APPROPRIATEELECTRODE.

CONSUMABLE TYPEELECTROD

ELENGTH

(MM)

QUANTITY OFCONSUMABLE EXTRA

FORWASTAGE50mm STUB

LENGTH75mmSTUB

LENGTH

High Efficiency (150%), Iron Powder TypeElectrodesPH 22, PH 7024

455380

1.621.63

1.681.75

10%10%

Conventional, Low Iron Powder or Basic-Hydrogen Controlled ElectrodesPH 28, PH 48A, PH 77, PH 56S, PH C18

455380

1.651.66

1.751.77

10%10%

Cellulose Type ElectrodesPH 31A, Pipemaster 60

380 1.73 1.87 10%

Table 2.0 Manual Metal-Arc Welding (MMAW)

96

WELD DEPOSITION AND COSTING DATA (contd)

Electrode Consumption for some Common Butt JointsThe following tables provide useful data on the mass of weld metal and MMAW electrodes required to complete somecommon butt joints. Electrode consumption is calculated using the following simple equation:

M = ________ D

1 - Pwhere M = Mass of electrodes required per metre of joint

D = Mass of weld metal deposited per metre of joint.P** = Proportion of electrode lost, due to spatter, slag loss, stub end etc.

Square Groove Butt Joint - welded both sides

reinforcement height, r = 2 mm

Joint Dimensions Mass of steel weld metaldeposited per metre (D)

(kg/m)

Mass of MMAW**electrodes required per

metre (M) (kg/m)T R W

3366

011.53

77

1010

0.170.200.320.39

0.280.330.530.64

Single-V Butt Joints

reinforcement height, r = 2 mm

Joint Dimensions Mass of steel weld metaldeposited per metre (D)

(kg/m)

Mass of MMAW**electrodes required per

metre (M) (kg/m)T R L W

68

10121620

3.53.53.53.03.03.0

1.51.51.53.03.03.0

10.013.015.015.019.023.0

0.260.570.790.831.382.06

0.430.951.311.392.293.43

Double-V Butt Joints

reinforcement height, r = 2 mm

Joint Dimensions Mass of steel weld metaldeposited per metre (D)

(kg/m)

Mass of MMAW**electrodes required per

metre (M) (kg/m)T R L W

1216202550

3.03.03.03.03.0

3.03.03.03.03.0

10.012.015.018.032.0

0.711.061.502.136.97

1.181.752.483.53

11.58

** For 380 mm long EXX12, 13, 14, 16 & 18 type MMAW electrodes to AS 1553.1, P is typically 0.4. This figure assumesa stub end length of 50 mm (See Table 2.0 for further details.)

97

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