The Australian Welding Guide 2012

THE AUSTRALIAN
WELDING GUIDE
The Ultimate Welding Reference Guide 2012
welding.com.au
FOR OVER 50 YEARS

With a proven history of over 50 years in the Australian market, WIA has built a reputation for delivering high quality filler metal products for the industrial user. Known for their quality, consistency and performance, WIA filler metal products are preferred by operators across a wide range of industry sectors. WIA offers an extensive range of consumables for various welding processes and applications. Choose from mild steel and low hydrogen electrodes to specialised flux cored wires and hardfacing products. Backed by a team of technical professionals who understand our customers needs, we are committed to delivering welding products that offer peak performance in operability, mechanical properties and productivity, and backed by the delivery of technical expertise and support. WIA is ISO 9001 certified. Its your guarantee of the highest levels of quality, satisfaction and efficiency when you choose WIA products.
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WELDING INDUSTRIES OF AUSTRALIA

AN ITW COMPANY
USING THIS GUIDE
PRODUCT SECTION The front section of this guide contains comprehensive product information on the range of WIA consumables. Access the latest information on WIA filler metal products, including technical data sheets at welding.com.au. TECHNICAL REFERENCE SECTION Designed as a portable reference tool for welding engineers, design and costing personnel, workshop supervisors, welding specialists and students, the Technical Reference Section incorporates the information welding professionals need to have on hand. VIEWING THIS GUIDE AS AN INTERACTIVE PDF Depending on the device or computer you are viewing this PDF in, all CONTENTS pages contain clickable links to help you navigate easily through the document.
DISCLAIMER - Welding Industries of Australia (WIA) is a supplier of welding products, and does not operate as a provider of consultancy or other technical services or advice related to welding. The information provided in this document is offered as a guide only. Every effort has been made to ensure the information contained in this booklet was correct at the time of printing. WIA does not accept responsibility for errors or information which is found to be misleading. Prior to using WIA products, it is the purchasers responsibility to ensure the products selected are suitable for the application.
CONTENTS Introduction
1 5
ELECTRODES
General Purpose Electrodes - Mild Steel Hydrogen Controlled Electrodes Iron Powder Electrodes Cellulose Electrodes Stainless Steel Electrodes Cast Iron Electrodes Gouging and Cutting Electrodes Solid MIG Wires Mild Steel Solid MIG Wires Low Alloy Steel Solid MIG Wires Aluminium Metal Cored Gas Shielded Wires Flux Cored Gas Shielded Wires Flux Cored Self Shielded Wires Hardfacing Electrodes Hardfacing Solid MIG Wires Hardfacing Self Shielded Flux Cored Wires
WIRES
33
HARDFACING PRODUCTS
65
Hardfacing Gas Shielded Flux Cored Wires
TECHNICAL INFORMATION
86
CONTENTS
ELECTRODES
Austarc 12P................................................................. 6-7 Austarc 13S................................................................. 8-9 HYdrogen Controlled Electrodes Austarc 16TC............................................................10-11 General Purpose Electrodes - Mild Steel Austarc 18TC........................................................... 12-13 Austarc 77................................................................ 14-15 Iron Powder Electrodes Cellulose Electrodes Austarc 24................................................................ 16-17 Austarc 11................................................................ 18-19 Stainless Steel Electrodes Staincord 309Mo-16................................................. 20-21 Staincord 316L-16.................................................... 22-23 Unicord 312............................................................. 24-25 Cast Iron Electrodes Supercast Ni............................................................ 26-27 Suercast Ni/Fe......................................................... 28-29 GOUGING AND CUTTING ELECTRODES Austarc C&G............................................................ 30-31
5
CONTENTS
AUSTARC 12P
SUMMARY
General Purpose Rutile Type Electrode Versatile/All Positional Capabilities Including Vertical Down Smooth Performance on Low OCV AC Welding Machines Coating - Brown Tip - Red Imprint - WIA 4313A
CLASSIFICATION IDENTIFICATION
AS/NZS 4855-B - E43 13 A AWS A5.1: E6013

DESCRIPTION AND APPLICATION
Austarc 12P is a smooth running, rutile type electrode for all positional welding of mild steel. It is characterised by a moderately forceful and extremely stable arc. Superb arc starting and restriking on low voltage AC welding machines. A stiff fast freezing slag for all positional (especially vertical down) fillet welding capabilities. Typical applications include, the all positional welding of galvanised gates/fences, steel furniture, trailers and wrought iron.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 2.0 2.5 3.2 4.0 5.0 300 300 380 380 450 40-60 60-85 90-130 130-180 180-230 ARC VOLTAGE RANGE **(V) 19 20 21 22 23
*Recommended for DC +/- or AC (minimum 45 OCV) operation. **Voltage is determined by arc current and electrode arc length. Arc voltage shown is typical and is only to be used as a guide.
6
CONTENTS
1G
2G
3G 3G
ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL
4G
1F
2F
4F
SHIPPING APPROVALS LR 2Ym ABS 2 DNV 2 TYPICAL ALL WELD METAL CHEMICAL ANALYSIS
0.07 C Mn 0.5 0.3 Si Bal Fe
TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

Yield Stress Tensile Strength Elongation CVN Impact Values 450 MPa 500 MPa 26% 70J @ 0C
In as welded condition.
PACKAGING DATA
ELECTRODE SIZE (mm) 2.0 2.5 3.2 4.0 5.0
PACKAGING (KG) Packet 2.5 2.5 5.0 5.0 5.0 Carton 12.5 12.5 15 15 15
APPROX NO. OF RODS PER KG 103 67 31 20 11
PART NUMBER 12P20 12P25 12P32 12P40 12P50
7
CONTENTS
AUSTARC 13S
SUMMARY
General Purpose/Rutile Type Electrode Versatile/All Positional (especially vertical up) Capabilities Ideal for Down Hand Fillet Welding of Mild Steel Smooth Performance on Low OCV AC Welding Machines
Coating - Blue/White Stripe Tip - Plain Imprint - WIA 4313A

CLASSIFICATION
IDENTIFICATION
AS/NZS 4855-B - E43 13 A AWS A5.1: E6013

Austarc 13S is the popular blue and white striped general purpose electrode for smooth mitre fillet welding applications. 13S has a soft and stable arc and produces flat, uniform fillet welds with ease and a self peeling slag action. Austarc 13S is formulated primarily for fillet welding in all down hand positions. It is ideal for the general purpose and structural welding of sheet and plate steels (galvanised or otherwise) and tubular components, including trailers, duct work, hoppers and storage tanks, etc.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 2.0 2.5 3.2 4.0 5.0 6.0 300 300 380 380 450 450 40-60 60-85 100-130 140-180 180-230 230-290 ARC VOLTAGE RANGE **(V) 19 20 21 22 23 24
8
CONTENTS
1G
2G
3G
ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL
4G
1F
2F
4F
SHIPPING APPROVALS LR 2m ABS 2 DNV 2 TYPICAL ALL WELD METAL CHEMICAL ANALYSIS
0.07 C 0.55 Mn 0.45 Si Bal Fe

PACKAGING DATA
ELECTRODE SIZE (mm) 2.0 2.5 3.2 4.0 5.0 6.0
PACKAGING (KG) Packet 2.5 2.5 5.0 5.0 5.0 5.0 Carton 12.5 12.5 15 15 15 15
APPROX NO. OF RODS PER KG 99 63 29 10 6 6
PART NUMBER 13S20 13S25 13S32 13S40 13S50 13S60
9
CONTENTS
AUSTARC 16TC

SUMMARY
Basic/Twin Coated (TC) Manual Arc Electrode Low Hydrogen, H10 Status Versatile/All Positional (Especially Vertical Up) Capabilities Reliable, Low Temperature Impact Toughness Easy to Strike and Re-Strike Smooth Performance on Low OCV AC Welding Machines
Coating - Light Grey Tip - Bronze Imprint - WIA 4916A

CLASSIFICATION
IDENTIFICATION
AS/NZS 4855-B - E49 16-A U H10 AWS A5.1: E7116-1 H8

Austarc 16TC is a smooth running, basic low hydrogen electrode, developed for all positional (except vertical down) welding, using AC or DC power sources. The electrode gives exceptional arc stability and weldability for its class and produces high quality weld deposits with reliable notch toughness to -40C. Austarc 16TC is manufactured using a unique twin coating extrusion process, which produces electrodes with two concentric flux coatings. Arc stabilising elements are concentrated in the inner coating of the electrode for significantly improved arc stability on AC welding machines. Other features of 16TC include, a smooth rippled weld profile with excellent edge wetting and a fluid, easily removed glassy slag. Austarc 16TC deposits X-ray quality weld metal with typical diffusible hydrogen levels of 5-8 mls of hydrogen per 100 gms of deposited weld metal, for as manufactured product, thus satisfying the H10 low hydrogen category of AS/NZS 4855 and H8 of AWS A5.1.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT *Please note, 2.5 and 3.2 Austarc 16TC are SIZE (mm) LENGTH (mm) RANGE *(A) recommended for 2.5 300 60-90 DC+ or AC (minimum 45 OCV) operation, 3.2 380 90-135 whereas 4.0, 5.0 and 4.0 380 140-190 6.0mm sizes require a 5.0 450 190-240 minimum of 55 OCV for stable AC operation. 6.0 450 250-310
10
CONTENTS
1G
2G
3G
ELECTRODES - HYDROGEN CONTROLLED ELECTRODES
4G
1F
2F
4F
LRS 4Ym H10

C
SHIPPING APPROVALS
ABS 3 H10
Si P
DNV 3Y H10
S Fe
TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

0.06 Mn 1.2 0.4 0.015 0.010 Bal

Yield Stress Tensile Strength Elongation CVN Impact Values 460 MPa 560 MPa 28% 130J @ -20C 110J @ -40C
PACKAGING DATA
ELECTRODE SIZE (mm) 2.5 3.2 4.0 5.0 6.0 PACKAGING (KG) Packet 2.5 5.0 5.0 5.0 5.0 Carton 12.5 15 15 15 15 APPROX NO. OF RODS PER KG 61 29 19 10 7 PART NUMBER 16TC25 16TC32 16TC40 16TC50 16TC60
MATERIALS TO BE WELDED
AS 1163 CODE C250, C350, C450 TYPE
Structural Steel
Pressure Equipment Steel Fine Grain Steel Cast Steel Pipe Material
AS 1397 AS 1450 AS/NZS 3679.1 AS/NZS 3678.1 AS/NZS 3679.2 AS 1548 AS/NZS 1594 AS2074 API 5LX
G250, G300, G350, G450 C/H200, C/H250, C/H350, C/H450, 250, 300, 350, 400 200, 250, 300, 350, 400, 450, A1006, XK1016, WR350 7-430, 7-460, 5-590, 7-490 HAI, HA3, HA4N, HA200, HA250, HA300, HA1006, HA1010, HA1016, HA350, HA400 C2, C3, C7A-1, C1, C4-1, C4-2, C7A-2 X42, X46, X52, X60
11
CONTENTS
AUSTARC 18TC

SUMMARY
Basic Twin-Coated (TC) Iron Powder Electrode Very Low Hydrogen H5 Status Suitable for all Positional Welding Except Vertical Down Excellent Low Temperature Fracture Toughness Easy to Strike and Re-Strike Smooth Performance on Low OCV AC Welding Machines
Coating - Light Grey Tip - Blue Imprint - WIA 4918-1A

CLASSIFICATION
IDENTIFICATION
AS/NZS 4855-B - E49 18-A U H5 AWS A5. 1: E7018-1

Austarc 18TC is a basic iron powder electrode used primarily on C-Mn and low alloy structural steels. The unique twin-coat design for 18 type low hydrogen electrode offers excellent AC arc stability and superb DC+ arc transfer, excellent re-strike, reduced spatter level and extraordinary ease of use for out-of-position welding. Typical applications include oil and gas, pipe welding, structural steel construction, off-shore where Ni-alloying is prohibited, mining equipment, heavy girders and earth moving plant repair and maintenance.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 2.5 3.2 4.0 300 380 380 60-90 90-135 140-190
*Please note, the recommended welding polarity for Austarc 18TC is DC + or AC (Min. 50 OCV).
LRS/Pending
SHIPPING APPROVALS
DNV/Pending
12
CONTENTS
1G
2G
3G
4G
1F
2F
4F

0.06 C 1.55 Mn 0.54 Si 0.010 P 0.02 S Bal Fe

Yield Stress Tensile Strength Elongation CVN Impact Values 530 MPa 602 MPa 24% 87J @ -50C
PACKAGING DATA
ELECTRODE SIZE (mm) 2.5 3.2 4.0 PACKAGING (KG) Packet 2.5 5.0 5.0 Carton 12.5 15 15 APPROX NO. OF RODS PER KG 45 26 17 PART NUMBER 18TC25 18TC32 18TC40
MATERIALS TO BE WELDED
AS 1163 CODE C250, C350, C450 TYPE
Structural Steel
AS 1397 AS 1450 AS 1450 C/H200, C/ H250, AS/NZS 3679.1 AS/NZS 3678.1 AS/NZS 3679.2 AS 1548 AS/NZS 1594 AS2074 API 5LX
G250, G300, G350, G450 C/H200, C/H250, C/H350, C450 250, 300, 350, 400 200, 250, 300, 350, 400, 450, A1006, XK1016, WR350 250, 300, 350, 400 200, 250, 300, 350, 400, 450, A1006, XK1016, WR350 7-430, 7-460, 5-590, 7-490 HA1, HA3, HA4N, HA200, HA250, HA300, HA1006, HA1010, HA1016, HA350, HA400 C2, C3, C7A-1, C1, C4-1, C4-2, C7A-2 X42, X46, X52, X60
Pressure Equipment Steel Fine Grain Steel Cast Steel Pipe Material
13
CONTENTS
AUSTARC 77
SUMMARY
Basic Coated Iron Powder Electrode Low Hydrogen Status Suitable for All Positional Welding Except Vertical Down Excellent Low Temperature Fracture Toughness
Coating - Light Grey Tip - Black Imprint - WIA 4918-1A

CLASSIFICATION
IDENTIFICATION
AS/NZS 4855-B - E49 18-1 U H5 AWS A5.1: E7018-1

The Austarc is a smooth running basic type of low hydrogen iron powder electrode used for all positional welding except vertical down. The arc is very quiet with little spatter and the welds are exceptionally smooth with excellent wash in at the toes of the weld, thus giving minimum undercut. This electrode is used where the highest restrained work pieces are fabricated for mining equipment, pressure vessels, heavy girders, earth moving plant, repair and maintenance etc. For the highest weld quality with low hydrogen levels, Austarc 77 electrodes should be baked at 400C for one hour to obtain <5mL/100g weld metal. After baking, the electrodes should be used from a hot box set at 100 -150 C.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 2.5 3.2 4.0 5.0 305 380 380 455 60-105 90-145 140-200 180-300 ARC VOLTAGE RANGE **(V) 20 22 24 26
14
CONTENTS
1G
2G
3G
4G
1F
2F
4F
SHIPPING APPROVALS LR 4Ym H5 ABS 3Y H5 TYPICAL ALL WELD METAL CHEMICAL ANALYSIS
0.05 C 0.011 S 1.28 Mn 0.022 P 0.30 Si Bal Fe

PACKAGING DATA
ELECTRODE SIZE (mm) 2.5 3.2 4.0 5.0
PACKAGING (KG) Packet 2.2 5.0 5.0 5.0 Carton 11 15 15 15
APPROX NO. OF RODS PER KG 45 26 17 9
PART NUMBER 7725 7732 7740 7750
15
CONTENTS
AUSTARC 24
SUMMARY
High Iron Powder, Rutile Type Electrode High Deposition Rates and Efficiencies Suitable for Fast Downhand Fillet and Butt Welding Coating - Brown Tip - Yellow Imprint - WIA 4924A
AS/NZS 4855-B - E49 24 A AWS A5.1: E7024

Austarc 24 is a high iron powder, rutile type electrode designed for the fast down hand welding of mild steel using AC or DC power sources. Features include high deposition rates/efficiencies and flat to slightly concave fillet welds with excellent edge wash and slag detachability. With its smooth running, positive re strike and high current carrying capacity, Austarc 24 is the ideal fillet welding electrode for down hand positions aimed at higher productivity. Austarc 24 is suited to long, heavy fillet and butt welding applications using a touch welding or `short arc technique. Such applications include the production welding of tanks, structural members/frames and truck and tractor bodies etc.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 3.2 4.0 5.0 380 450 450 120-170 200-240 270-320 ARC VOLTAGE RANGE **(V) 24 25 26
16
CONTENTS
ELECTRODES - IRON POWDER ELECTRODES
1G
1F
2F
SHIPPING APPROVALS LR 2Ym ABS 2 DNV 2 TYPICAL ALL WELD METAL CHEMICAL ANALYSIS
0.06 C Mn 0.7 0.4 Si Bal Fe

In as welded condition
PACKAGING DATA
ELECTRODE SIZE (mm) 3.2 4.0 5.0
PACKAGING (KG) Packet 5.0 5.0 5.0 Carton 15 15 15
APPROX NO. OF RODS PER KG 18 12 6
PART NUMBER 2432 2440 2450
17
CONTENTS
AUSTARC 11
SUMMARY
High Cellulose Coating All Positional/High Penetration Ideal for Site Welding Coating - White Tip - Brown Imprint - WIA 4311A
AS/NZS 4855-B - E4311A AWS A5.1: E6011

Austarc 11 is a high cellulose electrode developed for all positional welding on both AC and DC power supplies. Features include: Forceful, deep penetrating arc with fast freezing slag. Particularly suited for vertical and incline pipe welding where complete root penetration is required. The thin brittle slag is easily removed. Austarc 11 is recommended for specific applications including pipeline welding and storage tank construction where either the Stove Pipe or Flick techniques can be used to obtain full root penetration in critical structural joints.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 2.5 3.2 4.0 5.0 300 380 380 450 60-95 90-125 115-175 160-220 ARC VOLTAGE RANGE **(V) 20 21 22 23
18
CONTENTS
1G
2G
3G 3G
ELECTRODES - CELLULOSE ELECTRODES
4G
1F
2F
4F
LR 3M
SHIPPING APPROVALS
ABS 3

0.13 C Mn 0.5 0.1 Si Bal Fe

PACKAGING DATA
ELECTRODE SIZE (mm) 2.5 3.2 4.0 5.0
PACKAGING (KG) Packet 2.5 5.0 5.0 5.0 Carton 12.5 15 15 15
APPROX NO. OF RODS PER KG 66 33 21 14
PART NUMBER 1125 1132 1140 1150
19
CONTENTS
STAINCORD 309Mo-16
SUMMARY
All Positional, Rutile Type Stainless Steel Electrode Moisture Resistant Flux Coating/Extra Low Carbon Deposit Suitable for the Dissimilar Welding of Stainless Steel to Mild/Low Alloy Steels.
Coating - Grey Tip - Black Imprint - WIA 309MO-16

CLASSIFICATION
IDENTIFICATION
AS/NZS 4854-B - E309LMo-16 AWS A5.4: E309MoL-16

Staincord 309Mo-16 is an extra low carbon, rutile type electrode exhibiting superior all positional (except vertical down performance with an improved moisture resistant coating for weld metal of high radiographic integrity. The smooth arc action of Staincord 309Mo-16, together with low spatter and excellent slag control/ detachability, promotes exceptional weld appearance and profile. Staincord 309Mo-16 is a Molybdenum bearing, highly alloyed 23Cr/12Ni/2.5Mo stainless steel electrode for welding matching 309 and 309Mo base metals. Major applications of Staincord 309 Mo-16 also involve the welding of a wide range of 300 and 400 series stainless steels to mild/low alloy steels. 309M is also suitable for general welding applications with alloyed and non-alloyed dissimilar ferrous metal combinations.
OPERATIONAL DATA
20
CONTENTS
1G
2G
3G 3G
ELECTRODES - STAINLESS STEEL ELECTRODES
4G
1F
2F
4F

0.025 C Mn 0.8 0.7 Si 23.5 Cr 13.0 Ni Mo 2.4 Bal Fe

Yield Stress Tensile Strength Elongation 400 MPa 670 MPa 38%
PACKAGING DATA
ELECTRODE SIZE (mm) 2.5 3.2
PACKAGING (KG) Packet 2.5 2.5 Carton 12.5 12.5
APPROX NO. OF RODS PER KG 86 55
PART NUMBER SC309MO25 SC309MO32
21
CONTENTS
STAINCORD 316L-16
SUMMARY
All Positional, Rutile Type Stainless Steel Electrode Moisture Resistant Colour Coated Flux Coating Extra Low Carbon Weld Deposit For the Critical Welding of Matching Type 316 and 316L Steels
Coating - Pink Tip - Green Imprint - WIA 316L-16

CLASSIFICATION
IDENTIFICATION
AS/NZS 4854-B - ES316L-16 AWS A5.4: E316L-16

New generation Staincord 316L-16 is an extra low carbon, rutile type electrode exhibiting superior all positional (except vertical down) performance with an improved moisture resistant Pink flux coating for weld metal of high radiographic integrity. The smooth arc action of Staincord 316L-16, together with low spatter and excellent slag control/detachability, promotes exceptional weld appearance and profile. Other features include high arc stability and easy restriking on low voltage AC welding machines. Staincord 316L-16 deposits Molybdenum bearing, 19Cr/12Ni/2.5Mo filler metal to meet the requirements for welding type 316 and 316L stainless steels in critical applications. Staincord 316L-16 is also recommended for the general purpose welding of common 300 series stainless steels, such as 301, 302, 304 and 304L. It is also suitable for the general welding of ferritic stainless steel alloys, such as 409, 444 and 3Cr12.
22
CONTENTS
1G
2G
3G
4G
1F
2F
4F
OPERATIONAL DATA

0.025 C Mn 0.7 0.7 Si 18.5 Cr 12.0 Ni Mo 2.4 Bal Fe

Yield Stress Tensile Strength Elongation 380 MPa 600 MPa 40%
PACKAGING DATA
ELECTRODE SIZE (mm) 2.0 2.5 3.2
PACKAGING (KG) Packet 2.5 2.5 2.5 Carton 12.5 12.5 12.5
APPROX NO. OF RODS PER KG 86 55 27
PART NUMBER SC31620 SC31625 SC31632
23
CONTENTS
UNICORD 312
SUMMARY
Universal AC/DC Maintenance Electrode for Welding Ferrous Metals Ideal for Joining Dissimilar Steel Components Suitable as a Buffer Layer Prior to Hard Surfacing Stable Performance on Low OCV Welders
Coating - Grey Tip - Red Imprint - Unicord 312

CLASSIFICATION
IDENTIFICATION
AS/NZS 4854-B - ES312-16 AWS A5.4: E312-16

Unicord 312 is a basic, rutile type electrode depositing a 29%Cr/9%Ni stainless steel weld metal for the high strength welding of a wide range of alloy steels and dissimilar ferrous metals. The high ferrite, austenitic stainless steel deposit has excellent resistance to hot cracking, even under dilution by high carbon, alloy and tool steels. Unicord 312 is a universal maintenance electrode combining high strength, toughness, wear and corrosion resistance with compatibility to most ferrous metals. Unicord 312 is suitable for many repair and maintenance applications on steels of unknown composition. It is an ideal electrode for welding medium to high carbon steels, low alloy steels and dissimilar ferrous metal combinations. Unicord 312 is also suitable as a buffer or intermediate layer prior to the application of hard surfacing.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 2.5 3.2 300 350 50-75 75-110 ARC VOLTAGE RANGE **(V) 22 26
24
CONTENTS
*Recommended for DC +/- or AV (minimum 45 OCV) operation. **Voltage is determined by arc current and electrode arc length. Arc voltage shown is typical and is only to be used as a guide.
1G
2G
3G
4G
1F
2F
4F

0.04 C Mn 0.9 0.85 Si 30.0 Cr 9.0 Ni Bal Fe

Yield Stress Tensile Strength Elongation Deposit Hardness 500 MPa 770 MPa 45% 28-35 HRc
PACKAGING DATA
ELECTRODE SIZE (mm) 2.5 3.2
PACKAGING (KG) Packet 2.5 2.5 Carton 12.5 12.5
APPROX NO. OF RODS PER KG 52 27
PART NUMBER UC31225 UC31232
25
CONTENTS
SUPERCAST Ni
SUMMARY
Pure Nickel Core Wire/Basic, Graphite Coating Soft Machineable Nickel Deposit for the Lower Strength Welding of Cast Irons Coating - Black Tip - Plain Imprint - WIA SC Ni
AWS A5.15: ENi-Cl

Supercast Ni is a basic, graphite coated AC/DC electrode for the lower strength welding of cast irons. It is characterised by a soft, smooth arc with low penetration and spatter levels on both AC and DC power sources. Ease of striking is a feature of Supercast Ni and it also has a particularly good wetting action resulting in well bonded welds of regular contour and attractive appearance. This electrode is made from a pure nickel core wire and produces a ductile, fully machineable weld deposit. Supercast Ni may be used for the repair and reclamation of all standard grades of grey cast iron, malleable iron, austenitic cast iron and some grades of mechanite cast iron.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 3.2 350 50-100 ARC VOLTAGE RANGE **(V) 23
26
CONTENTS
1G
1F
2G
3G
ELECTRODES - CAST IRON ELECTRODES
4G

Mn 0.3 97.0 Ni 0.006 S Bal Fe

Yield Stress Tensile Strength Deposit Hardness 220 MPa 400 MPa 150-170 HV (30)
PACKAGING DATA
ELECTRODE SIZE (mm) 3.2 PACKAGING (KG) Packet 2.5 Carton 12.5 APPROX NO. OF RODS PER KG 37 PART NUMBER SNI32
27
CONTENTS
SUPERCAST Ni/Fe
SUMMARY
Nickel -Iron Core Wire/Basic, Graphite Coating Machineable Nickel-Iron Deposit for the Higher Strength Welding of Cast Irons, Particularly SG Irons Coating - Black Tip - Green Imprint - WIA SC NiFe
AWS A5.15: ENiFe-Cl

Supercast Ni/Fe is a basic, graphite coated AC/DC electrode for the higher strength welding of cast irons. It is characterised by a soft, smooth arc with low penetration and spatter levels on both AC and DC power sources. Ease of striking is a feature of Supercast Ni/Fe. This electrode is made from a Nickel-Iron core wire and produces a ductile, machineable weld deposit with the extra strength required for welding SG (Spheroidal Graphite) irons. Supercast Ni/Fe may also be used for the repair and reclamation of all standard grades of grey cast iron, malleable iron, austenitic cast iron and some grades of mechanite cast iron. It is ideally suited to the dissimilar welding of these irons to steels.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 3.2 350 50-100 ARC VOLTAGE RANGE **(V) 23
28
CONTENTS
1G
1F
2G
3G
ELECTRODES - CAST IRON ELECTRODES
4G

0.85 Mn 57.8 Ni 0.007 S Bal Fe

Yield Stress Tensile Strength Deposit Hardness 300 MPa 500 MPa 200-220 HV (30)
PACKAGING DATA
ELECTRODE SIZE (mm) 3.2 PACKAGING (KG) Packet 2.5 Carton 12.5 APPROX NO. OF RODS PER KG 39 PART NUMBER SNIFE32
29
CONTENTS
AUSTARC C&G
SUMMARY
Heavy Coated Manual Electrode for Cutting, Gouging or Piercing Steels Coating - Black End Tip - Plain
DESCRIPTION AND APPLICATION IDENTIFICATION
Austarc C&G is a heavy coated electrode providing a highly mobile 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 for general cutting and grooving in joint preparation, removing defective welds and reclaiming scrap metal, etc. Oxy-acetylene and carbon arc-air cutting and gouging are two processes available to industry capable of giving high quality, smooth preparations. Austarc C&G will not replace these processes but rather provide a convenient, easy to use and mobile tool for the arc gouging and cutting of most metals. It is particularly useful to the maintenance welder operating in awkward locations to remove welds, open up joints and trim off bolt or rivet heads, etc. Similarly, the rural welder will find C&G handy in repairing or preparing joints when operating away from (or without) oxy-acetylene equipment. Cutting - Direct the electrode into the work in the desired cutting direction, working from the outside edge. Use an up and down sawing motion, the up arc length being increased to increase heating, the down arc length being decreased to contact point to force the molten metal out of the groove. Angle of electrode should be approx 70 to the horizontal.
30
CONTENTS
ELECTRODES - GOUGING AND CUTTING ELECTRODES
Gouging - Point the electrode in the direction of gouging at approx 10-20 to the plate surface. Strike the arc and move forward rapidly. If slag and molten metal start to clog the groove bring the electrode up to clear and, without breaking the arc, circle backwards and move forward again. This latter technique may prove more necessary than straight forward motion on lower amps or as the electrode becomes hotter. If amps are excessive, C&G will tend to cut out on AC and overheat, causing premature charring of the coating and reduced arc force. Piercing - For holes, plunge the electrode into the plate at slightly off right angles. With a small circular motion to the holder, force the electrode into the plate until full penetration is achieved. Once the hole has been made it may be trimmed with an up and down sawing motion.
OPERATIONAL DATA
ELECTRODE ELECTRODE SIZE (mm) LENGTH (mm) 3.2 4.0 380 380 PACKAGING (KG) Packet 4 4 Carton 12 12 WELDING CURRENT RANGE *(A) 170-250 220-350
31
CONTENTS
32
CONTENTS
WIRES
solid mig wires
Austmig ES6....................................................................... 34-35

solid mig wires - low alloY steel Austmig ESD2 ........................................................ 36-37 Austmig NiCrMo ...................................................... 38-39 solid mig wires - Aluminium Austmig 5183........................................................... 40-41 Austmig 5356 .......................................................... 42-43 METAL CORED GAS SHIELDED WIRES flux cored gas shielded wires Austfil 70C-6M......................................................... 44-45 Austfil 71T................................................................ 46-47
Austfil 71T-1M.......................................................... 48-49 Hobart XL-525......................................................... 50-51 TM-71HYD............................................................... 52-53 TM-811N2................................................................ 54-55 flux cored SELF shielded wires Fabshield 4.............................................................. 56-57 Fabshield 21B.......................................................... 60-61 Fabshield XLR-8...................................................... 62-63 Fabshield 23............................................................ 58-59
33
CONTENTS
AUSTMIG ES6
SUMMARY
Electrostatically Copper Coated Gas Metal Arc (MIG) Wire All Positional Welding of Mild and Medium Strength Steels Precision Layer Wound, Very Low Diffusable Hydrogen Suitable for all Transfer Modes Designed for use with Argon/CO and CO Shielding Gases
CLASSIFICATION
AS/NZS 2717.1: ES6-GC-W503AH AS/NZS 2717.1: ES6-GM-W503AH AWS A5.18: ER70S-6

Austmig ES6 is a copper coated, low carbon steel GMAW wire, formulated for optimum performance under Argon/CO mixed gases and welding grade CO. Arc transfer characteristics are excellent with Argon based gas mixtures, particularly in spray and pulsed transfer modes. Austmig ES6 is an electrostatically copper coated wire providing excellent wire feeding and electrical conductivity and reducing contact tip wear. The higher manganese and silicon content of Austmig ES6 provides effective weld metal deoxidation for resistance to porosity. Austmig ES6 is suitable for a wide range of welding applications on mild and medium strength steels providing consistently very low H5 weld metal diffusible hydrogen levels when used with suitable shielding gases.
OPERATIONAL DATA
WIRE SIZE (mm) 0.6 0.8 0.9 1.0 1.2 1.6 WELDING CURRENT RANGE (A) 40-100 60-180 70-230 100-290 120-350 160-390 ARC VOLTAGE RANGE *(V) 12-16 14-22 15-26 16-29 18-32 18.34
34
CONTENTS
Welding Current DC + *Voltage is determined by arc current and electrode arc length. Welding currents and voltage shown are operational guides only.
1G
2G
3G
WIRES - SOLID MIG WIRES - MILD STEEL
4G
1F
2F
4F
SHIPPING APPROVALS LR 3S, 3YS TYPICAL ALL WELD METAL CHEMICAL ANALYSIS
0.1 C 1.45 Mn 0.88 Si 0.02 S 0.022 P Bal Fe

Gas Type Yield Stress Tensile Stress Elongation CVN Impact Values CO 460 MPa 560 MPa 28% 80J @ -20C Ar+18% CO 480 MPa 580 MPa 26% 70J @ -30C
PACKAGING DATA
WIRE SIZE (mm) 0.6 0.8 0.9 1.0 1.2 1.6 PACK SIZE AND TYPE 5kg spool 15kg spool 5kg spool 15kg spool 5kg spool 15kg spool 15kg spool 15kg spool 15kg spool PART NUMBER ES606M5KG ES606S ES608M5KG ES608S ES609M5KG ES609S ES610S ES612S ES616S
35
CONTENTS
AUSTMIG ESD2
SUMMARY
Copper Coated, High Manganese-Molybdenum Gas Metal Arc (MIG) Welding Wire For the all Positional Welding of Medium to Higher Strength Steels
CLASSIFICATION
AS/NZS 2717.1: ESD2-GC-W559AH AS/NZS 2717.1: ESD2-GM-W559AH AWS A5.18: ER80S-D2

Austmig ESD2 is a copper coated, low alloy steel wire used for welding medium to higher strength steels, particularly where service temperatures up to 500C are encountered. ESD2 gives excellent resistance to porosity using CO or Argon based gas mixtures (i.e. Ar/CO, Ar/O, Ar/CO/O). When porosity is a potential problem due to dirty or rusty surfaces or higher than normal sulphur contents, Austmig ESD2 will provide a consistently sound weld deposit. Austmig ESD2 is also suitable for out-of-position welding due to its quick freezing weld pool. ESD2 produces high quality welds on plain carbon and C-Mn steels, low alloy steels and higher strength used in pressure vessels and boilers, such as petrochemical and power generation industries, operating at elevated temperatures. Austmig ESD2 may also be used for the fillet welding of higher tensile, quenched and tempered steels, such as Bisalloy 70 and 80 where the lower strength weld metal may be compensated by larger fillet sizes. When used with suitable shielding gases, Austmig ESD2 will consistently produce very low H5, weld metal diffusible hydrogen levels, for excellent resistance to HAZ or hydrogen induced cracking.
36
CONTENTS
1G
2G
3G
WIRES - SOLID MIG WIRES - LOW ALLOY STEEL
4G
1F
2F
4F
OPERATIONAL DATA
WIRE SIZE (mm) 0.9 1.2 WELDING CURRENT RANGE (A) 70-230 120-350 ARC VOLTAGE RANGE *(V) 15-26 18-32

0.1 C 1.95 Mn 0.75 Si Mo 0.5 Bal Fe

Gas Type Yield Stress Tensile Stress Elongation CVN Impact Values CO 560 MPa 645 MPa 19% 35J @ -20C Ar+18% CO 570 MPa 660 MPa 20% 50J @ -30C
NOTE: The use of less oxidizing Argon based gas mixtures will result in higher manganese and silicon weld metal recovery, leading to higher tensile properties, particularly in heavy multi pass butt welds.
PACKAGING DATA
WIRE SIZE (mm) 0.9 1.2 PACK SIZE AND TYPE 15kg spool 15kg spool PART NUMBER ESD209S ESD209S
37
CONTENTS
AUSTMIG NiCrMo
SUMMARY
Copper Coated, Low Allloy Gas Metal Arc (MIG) Welding Wire All Positional Welding of Medium and High Strength Steels Welded Strength 760 MPa Tensile Class
CLASSIFICATION
AS/NZS 2717.1: ESMG-GM-W769AH-G AWS A5.28: ER110S-G

Austmig NiCrMo is a copper coated, low alloy solid wire suitable for the all positional welding of high strength steels using Argon + CO gas mixtures. Austmig NiCrMo is ideal for the full strength welding of quenched and tempered structural steels, of the 760 MPa tensile class, such as USS-T1, CcMo Pipe, Welten 80, Weldox 700, X80, N-A-XTRA and Bisplate 80.
OPERATIONAL DATA
Welding Current DC + *Voltage is determined by arc current and electrode arc length. Welding currents and voltage shown are operational guides only. NOTE: Austmig NiCrMo is NOT to be used in weldments which are to be stress relieved.
38
CONTENTS
1G
2G
3G
WIRES - SOLID MIG WIRES - LOW ALLOY STEEL
4G
1F
2F
4F

0.07 C 1.22 Mn 0.37 Si 1.42 Ni 0.29 Cr 0.24 Mo 0.07 V Bal Fe

Gas Type Yield Stress Tensile Stress Elongation CVN Impact Values Ar+18% CO 732 MPa 799 MPa 18% 78J @ -30C
NOTE: The use of less oxidizing argon based gas mixtures (ie Ar/O, Ar/CO, Ar/CO/O), will result in higher alloy recovery in the weld metal, leading to higher tensile properties.
PACKAGING DATA
WIRE SIZE (mm) 0.9 1.2 PACK SIZE AND TYPE 15kg spool 15kg spool PART NUMBER MNICRMO09S MNICRMO12S
39
CONTENTS
AUSTMIG 5183
SUMMARY
Aluminium-Magnesium-Manganese, Metal Inert Gas (MIG) Welding Wire Precision Layer Wound and Double Shaved for Superb Feedability For Welding of Alloys of the same Composition
CLASSIFICATION
AS/NZS ISO 18273 - S AI 5183 AWS A5.10: E5183

Austmig 5183 is a precision layer wound aluminium wire alloyed with Mg, Mn and Cr. It is recommended for welding Al/Mg material of the 5083 type in the annealed condition, particularly for low temperature applications where good ductility and toughness are required, ie cryogenic plant. It may also be used for welding medium strength Al/Zn/Mg alloys of the 7020 type and joining 5083 alloy to 5456 alloy. Welding grade Argon or Argon/Helium shielding gas combinations are recommended with flow rates of 10-20 litres/minute.
OPERATIONAL DATA
40
CONTENTS
1G
2G
3G
WIRES - SOLID MIG WIRES - ALUMINIUM
4G
1F
2F
4F
SHIPPING APPROVALS LR WC/1-1S ABS AWS A5. 10-92/ER5183 DNV 5183 TYPICAL ALL WELD METAL CHEMICAL ANALYSIS
0.4 Si 0.4 Fe 0.1 Cu 0.5-1.0 Mn 4.3-5.2 Mg 0.05-0.25 Cr 0.25 Zn 0.15 Ti Bal AI

Gas Type Yield Stress Tensile Stress Elongation Ar 110 MPa 240 MPa 17%
PACKAGING DATA
WIRE SIZE (mm) 1.2 1.6 PACK SIZE AND TYPE 6kg spool 6kg spool PART NUMBER M518312S M518316S
41
CONTENTS
AUSTMIG 5356
SUMMARY
Aluminium - 5% Magnesium Alloy, Metal Inert Gas (MIG) Welding Wire Double Shaved and Precision Layer Wound for Superb Feedability For Welding Cast and Wrought Aluminium Alloys Containing Magnesium
CLASSIFICATION
AS/NZS ISO 18273 - S AI 5356 AWS A5.10: ER5356

Austmig 5356 is a precision layer wound Aluminium - 5% Magnesium wire suitable for a wide range of gas metal arc welding applications on wrought or cast aluminium alloys containing magnesium as a major alloying element. Some grades of wrought aluminium - magnesium alloys which can be welded with Austmig 5356 are, 5083, 5086, 5454 and 5456.
OPERATIONAL DATA
WIRE SIZE (mm) 0.9 1.0 1.2 1.6 WELDING CURRENT RANGE (A) 80-190 100-230 150-250 200-330 ARC VOLTAGE RANGE *(V) 16-22 18-22 20-27 23-30
42
CONTENTS
1G
2G
3G
WIRES - SOLID MIG WIRES - ALUMINIUM
4G
1F
2F
4F
SHIPPING APPROVALS LR WC/I-1,S; ABS AWS A5. 10-92/ER 5356;
DNV 5356

0.1 Zn Mg 5.2 0.15 Mn 0.1 Cr 0.25 Si 0.4 Fe 0.15 Ti Bal AI

Gas Type Yield Stress Tensile Stress Elongation Ar 125 MPa 275 MPa 17%
PACKAGING DATA
WIRE SIZE (mm) 0.9 1.0 1.2 1.6 PACK SIZE AND TYPE 2kg spool 6kg spool 2kg spool 6kg spool 2kg spool 6kg spool 6kg spool PART NUMBER M5356092KG M535609S M5356102KG M535610S M5356122KG M535612S M535616S
43
CONTENTS
AUSTFIL 70C-6M
SUMMARY
Gas Shielded, Metal-Cored Wire Slag-Free Weld Bead Higher Deposition Rates Low Spatter/Smooth Appearance Better Fusion Profile
CLASSIFICATION
AS/NZS ISO 17632-B - T 492T15 0MA-UH5 AWS A5.18: E70C-6M

Austfil 70C-6M is a metal-cored wire designed for high speed fillet and butt welding in the downhand position using Argon + 18-25% CO shielding gas mixture. Weld beads are almost completely slag free with only minimal silicon islands, reducing the time and effort spent between runs and on cleanup prior to surface finishing. Austfil 70C-6M is recommended for single and multi pass welding in both flat and horizontal positions for mild steel, carbon and maganese carbon steels with minimum clean up and where high deposition rates and efficiencies are required in high productivity, semi automatic and fully automatic welding installations. Suitable applications include mining buckets, structural fabrication and tank construction where high speed welding is required.
OPERATIONAL DATA
Welding Current DC + *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.
44
CONTENTS
1G
2G
WIRES - METAL CORED GAS SHIELDED WIRES
1F
2F
0.038 C 1.46 Mn 0.68 Si 0.009 S 0.012 P 0.02 Cu Bal Fe

Gas Type Yield Stress Tensile Stress Elongation CVN Impact Values Ar+25%CO 628 MPa 587 MPa 29% 51J @ -20C
PACKAGING DATA
WIRE SIZE (mm) 1.2 1.6 1.2 PACK SIZE AND TYPE 15kg spool 15kg spool 250kg drum PART NUMBER 70C6M12S 70C6M16S 70C6M12D
45
CONTENTS
AUSTFIL 71T
SUMMARY
All Purpose Rutile Flux Cored Wire For Both Single or Multiple Pass Welds All Positional Wire Formulated Exclusively For CO Gas
CLASSIFICATION
AS/NZS ISO 17632-B - T492T1-1CA-UH10 AWS A5.20: E71T-1 H8

Austfil 71T is a rutile flux cored wire designed for excellent performance in all positional fillet and butt-welding applications. Austfil 71T is formulated exclusively for use with cost effective CO shielding gas. Austfil 71T is recommended for general purpose all positional welding of mild, carbon and carbon-manganese steels where excellent weld profile and penetration is required. Suitable for applications such as storage tanks, structural fabrication, bridge construction, machinery and earthmoving equipment. Suitable for AS/NZS 1554.5 of the structural code; Part 5: Welding of the steel structures subject to high levels of fatigue loading.
OPERATIONAL DATA
Welding Current DC + Welding parameters shown above are for DC electrode positive using 100% CO shielding gas at a flow rate of 15-20 litres/minute. *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.
46
CONTENTS
1G
2G
3G
WIRES - FLUX CORED GAS SHIELDED WIRES
4G
1F
2F
4F
0.03 C 1.28 Mn 0.44 Si 0.01 S 0.013 P Bal Fe

Gas Type Yield Stress Tensile Stress Elongation CVN Impact Values CO 531 MPa 580 MPa 26% 93J @ -20C
PACKAGING DATA
WIRE SIZE (mm) 1.2 1.6 PACK SIZE AND TYPE 15kg spool 15kg spool PART NUMBER 71T112S 71T116S
47
CONTENTS
AUSTFIL 71T-1M
SUMMARY
Rutile Type Flux Cored Joining Wire, Micro Alloyed Formulated Exclusively for use with Ar/CO Shielding Gas Mixtures Excellent Operator Appeal Smooth Spray Arc Transfer Versatile all Positional Capabilities Grade 3 Weld Metal Impact Properties
CLASSIFICATION
AS/NZS ISO 17632-B - T492T1-1MA-UH10 AWS A5.20: E71T-1M

An all positional rutile micro alloyed type flux cored welding wire specifically formulated for optimum performance using Ar/CO shielding gas mixtures. The exceptionally smooth arc performance produces a superb weld for single or multipass welding with low spatter losses in all positions and applications (except vertical down). Austfil 71T-1M is recommended for the welding of mild, carbon and carbon-manganese medium steels where good impact properties at -20C are required. This high deposition wire offers excellent operator appeal for general steel fabrications and constructions such as plate sections, beams, girders, truck chassis/bodies, shipbuilding, earth moving equipment, storage tanks, bridge construction etc. Recommended shielding gases are: Argon + 18-25%CO
48
CONTENTS
1G
2G
3G
4G
1F
2F
4F
OPERATIONAL DATA
WIRE SIZE (mm) 1.2 1.6 WELD POSITION WELDING CURRENT RANGE (A) 250-300 230-280 170-220 300-350 200-350 200-250 ARC VOLTAGE RANGE *(V) 29-35 28-30 24-28 28-34 24-34 26-28
Flat Flat Fillet Vertical - up Flat Flat Fillet Vertical - up
Recommended electrical stick out is 15-20mm. Welding Current DC + *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.
0.04 C 1.20 Mn 0.42 Si 0.012 S 0.013 P 0.001 B Bal Fe

PACKAGING DATA
WIRE SIZE (mm) 1.2 1.6
PACK SIZE AND TYPE 15kg spool 15kg spool
PALLET SIZE (KG) 1080 1080
PART NUMBER 71T1M12S 71T1M16S
49
CONTENTS
HOBART XL-525
SUMMARY
Low Diffusible Hydrogen Excellent Toughness at Low Temperatures Outstanding Weldability Exceeds 27J CVN @ -40
CLASSIFICATION
AS/NZS ISO 17632-B - T494T1-1MA-UH5 AWS A5.20: E71T-1M, E71T-12MJ H8

A rutile flux cored all position wire designed for welding mild and carbon steels, especially when good impact toughness is required at sub zero temperatures. Ideal for single and multi-pass applications, it delivers outstanding welding performance and produces high quality X-ray clear weld deposit with a bead contour that is flat to slightly convex. It can be used over rust, mill scale and some primers with no pre-cleaning of the steel necessary. Formula XL-525 has outstanding mechanical properties that resemble those of E7018 MMAW (SMAW) electrodes, plus high operator appeal with low fume levels, low spatter and easy slag removal. Recommended for ship building, storage vessels, off-shore structures, earth moving equipment and pipe welding.
50
CONTENTS
1G
2G
3G
4G
1F
2F
4F
OPERATIONAL DATA
SHIPPING APPROVALS LR 3S, 3YS; ABS 3SA, 3YSA Impact @ -40C 34 ft, lbs DNV Y40MS BV 3YM; CWB E491T-12MJ-H4; TYPICAL ALL WELD METAL CHEMICAL ANALYSIS
0.04 C 1.24 Mn 0.29 Si 0.37 Ni Bal Fe

PACKAGING DATA
WIRE SIZE (mm) 1.2 1.6
PACK SIZE AND TYPE 15kg spool 15kg spool
PART NUMBER S283212-029 S283219-029
51
CONTENTS
TM- 71HYD
SUMMARY
Low Diffusible Hydrogen Exceeds 27J CVN @ -40 Outstanding Weldability in all Positions Actual Certification to AWS A5.01 Lot Class: T3
CLASSIFICATION
AS/NZS ISO 17632-B - T494T1-1CA-UH5 1.2mm, AWS E71T-1C, E71T-12CJ H4 1.6mm, AWS E71T-1C, E71T-12CJ H8
Formulated to provide extremely low hydrogen levels. This outstanding all positional wire produces a high quality X-ray clear weld deposit with high impact values at low temperature. Every batch of the TM-71HYD is actual tested to certify the quoted mechanical property, and the vacuum sealed packaging further ensures the product integrity upon delivery. Applications include ship building and repair, earth moving equipment, structures, pressure vessel and storage vessels.
OPERATIONAL DATA
52
CONTENTS
1G
2G
3G
4G
1F
2F
4F
SHIPPING APPROVALS MIL-71T-1-HYD TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

C 0.05 Mn 1.17 Si 0.25 S 0.014 P 0.12 Ni 0.5 Fe Bal

Gas Type Yield Stress Tensile Stress Elongation CVN Impact Values Aged 48 hours @ 104C 100% CO 533 MPa 585 MPa 26.6% 150J @ -18C
137J @ -40C
PACKAGING DATA
WIRE SIZE (mm) 1.2 1.6 PACK SIZE AND TYPE 15kg spool 15kg spool PART NUMBER S245112-K53 S245019-K53
53
CONTENTS
TM-811N2
SUMMARY
Fast-Freezing Slag Low Spatter Excellent Arc Characteristics High Impact Strengths at Low Temperatures
CLASSIFICATION
AS/NZS ISO 17632-B - T555T1-1C/MA-2Ni-UH5 AWS A5.29: E81T1-Ni2C/MJ H8

Offers excellent arc stability and low spatter using either CO or Ar/CO mixtures with up to 80% Argon. These weldability features, combined with low diffusible hydrogen levels and good impact values makes the wire a good choice for single and multiple pass welding in all positions. Applications include ship building, offshore drilling rigs, HSLA steels and weathering steels with no colour match requirement..
OPERATIONAL DATA
WIRE SIZE (mm) 1.2 WELDING CURRENT RANGE (A) 100-350 ARC VOLTAGE RANGE *(V) 22.34
54
CONTENTS
1G
2G
3G
4G
1F
2F
4F
SHIPPING APPROVALS ABS 3YSA; DNV Y40MS;
LR 3Ys

Shielding Gas 100% CO C 0.04 0.05 Mn 1.02 1.26 Si 0.29 0.44 P 0.010 0.010 S 0.007 0.007 Ni 2.09 2.07
75% Ar/25% CO

Gas Type Yield Stress Tensile Stress Elongation CVN Impact Values 100% CO 535 MPa 600 MPa 27.5% 95J @ -51C 126J @ -40C 75% Ar/25% CO 579 MPa 662 MPa 26% 104J @ -40C 71J @ -51C
PACKAGING DATA
WIRE SIZE (mm) 1.2 PACK SIZE AND TYPE 15kg spool PART NUMBER S283712-K29
55
CONTENTS
FABSHIELD 4
SUMMARY
Self Shielded or Gasless Flux Cored Joining Wires For Fast Downhand Fillet and Butt Welding Applications Excellent Bead Appearance/Low Spatter Levels Crack Resistant Weld Deposits/Tolerant to Poor Joint Fit-up
CLASSIFICATION
AS/NZS ISO 17632-B - T49ZT4-0NA-H15 AWS A5.20: E70T-4

Fabshield 4 is an outstanding, high deposition rate, (up to 12.7kg/ hr using 2.4mm size wire) self-shielded or gasless flux cored wire for downhand single or multi-pass welding applications. It is specifically designed to de-sulphurise the weld deposit and thereby resist cracking. Fabshield 4 is particularly suited to the fast fillet welding of mild and medium strength steels. Typical applications include the welding of structural members and machinery. Due to its self shielding arc, Fabshield 4 is ideal for on site field construction and repair applications.
OPERATIONAL DATA
Welding Current DC *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.
56
CONTENTS
WIRES - FLUX CORED SELF SHIELDED WIRES
1G
1F
2F

0.27 C 0.73 Mn 0.30 Si 0.11 P 0.005 S 1.42 AI Bal Fe

Yield Stress Tensile Stress Elongation CVN Impact Values 432 MPa 652 MPa 25% Not Required
PACKAGING DATA
WIRE SIZE (mm) 2.4 3.0 PACK SIZE AND TYPE PART NUMBER S224529-014 S224541-014
22.7kg spool 22.7kg spool
57
CONTENTS
FABSHIELD 23
SUMMARY
Self Shielded or Gasless Flux Cored Joining Wires All Positional Welding Capabilities Suitable for Single-Pass Applications only Ideal for Mild and Galvanized Steels
CLASSIFICATION
AS/NZS ISO 17632-B - T49ZTG-1SNA AWS A5.20: E70T-GS

Fabshield 23 is a general-purpose self-shielded tubular wire that is designed for welding thin gauge mild or galvanized steel. Suitable for single-pass applications, especially for fillet lap welds, you will get outstanding welding performance as Fabshield 23 produces a smooth spray arc type of transfer with goods wetting action. Great for welding outdoors in draughty conditions, this all-positional wire also provides very low splatter levels, resulting in a weld bead that is excellent in appearance. Perfect for on site applications such as welding mild steel/ galvanized gates, fences, frames, sheds, prefab building fabrications, ornamental ironwork, general fabrication, etc.
OPERATIONAL DATA
WIRE SIZE (mm) 0.8 0.9 WELDING CURRENT RANGE (A) 25-125 55-120 ARC VOLTAGE RANGE *(V) 14-16 17-20 TYPICAL STICKOUT (mm) 12 12
58
CONTENTS
1G
2G
3G
4G
1F
2F
4F

0.18 C 0.65 Mn 0.40 Si 0.01 S 0.01 P 1.30 AI Bal Fe

Tensile Stress 572 MPa NOTE: Yield Stress and impact values not applicable.
PACKAGING DATA
WIRE SIZE (mm) 0.8 0.9 0.9 PACK SIZE AND TYPE 4.5kg spool 4.5kg spool 15kg spool PART NUMBER S222306-022 S222308-022 S222308-029
59
CONTENTS
FABSHIELD 21B
SUMMARY
Self Shielded or Gasless Flux Cored Joining Wires All Positional Welding Capabilities Suitable For Single Pass/Multi-pass Applications Suitable for Mild/Galvanised Steels
CLASSIFICATION
AS/NZS ISO 17632-B - T49ZT11-1NA-H15 AWS A5.20: E71T-11

Fabshield 21B is a general purpose self-shielded tubular wire that is designed for single and multi-pass welding of thin gauge to 20mm thick mild or galvanized steels. Great for welding fillet or lap welds, you will find that this all-position wire has high operator appeal, producing a smooth spray-like transfer with low spatter levels, excellent weld appearance and easy to remove slag. Perfect for on-site applications such as the welding of machine parts, galvanized steels tanks, gates, frames, sheds, prefab construction, light structures, general fabrication etc. Welding parameters shown below are for DC Electrode negative only.
WIRE SIZE (mm) 0.9 1.2 1.6 2.0 WELDING CURRENT RANGE (A) 55-120 130-160 150-250 200-300 ARC VOLTAGE RANGE *(V) 17-20 15-18 18-20 16-23 TYPICAL STICKOUT (mm) 12 12 19 19
OPERATIONAL DATA
60
CONTENTS
1G
2G
3G
4G
1F
2F

0.28 C 0.34 Mn 0.15 Si 0.008 S 0.003 P 1.04 AI Bal Fe

Yield Stress Tensile Stress Elongation CVN Impact Values 427 MPa 627 MPa 22% Not Required
PACKAGING DATA
WIRE SIZE (mm) 0.9 1.2 1.2 1.6 2.0 PACK SIZE AND TYPE 4.5kg spool 4.5kg spool 15kg spool 15kg spool 15kg spool PART NUMBER S222108-022 S222112-022 S222112-029 S222119-029 S222125-029
61
CONTENTS
HOBART XLR-8
SUMMARY
Welds Out of Position at High Currents Low Hydrogen Weld Deposit Excellent Slag Removal No Shielding Gas Required High Impact Strength at Low Temperatures Excellent Mechanical Properties Under a Wide Range of Heat Input
CLASSIFICATION
AS/NZS ISO 17632-B - T494T8-1NP-H10 AWS A5.20: E71T-8JD H8

Low hydrogen T-8 self-shielded, all positional flux cored wire, producing a stable arc and flat bead profile, especially suited for vertical-up welds at high currents with excellent mechanical properties and a tensile strength of 490 MPa. Capable of depositing X-ray quality welds, making it highly suitable for critical welding applications requiring a high degree of crack resistance due to its low diffusible hydrogen levels, less than 6.7ml per 100g of weld metal deposited. XLR-8 has been designed for single and multi-pass welding applications with improved productivity in out-of-position welding, offering high impact strength of (42J) at sub zero temperatures to -40C. Specifically designed for increased productivity and high deposition rates on challenging structural steel erection, heavy equipment repair, mining equipment, bucket repairs, storage tanks, pipe spooling, ship construction and site work applications.
OPERATIONAL DATA
WIRE SIZE (mm) 1.6 1.8 2.0 WELDING CURRENT RANGE (A) 180-300 170-330 200-360 ARC VOLTAGE RANGE *(V) 18-25 18-25 18-26
62
CONTENTS
Recommended electrical stick out is 25-35mm. Welding Current DC *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.
1G
2G
3G
WIRES - FLUX CORED SELF SHIELDED WIRES
4G
1F
2F
4F
SHIPPING APPROVALS ABS 3YSA; AWS D1.8 Conformance TYPICAL ALL WELD METAL CHEMICAL ANALYSIS
C 0.19 Mn 0.51 Si 0.17 P 0.009 S 0.006 AI 1.51 Fe Bal

Yield Stress Tensile Stress Elongation CVN Impact Values Diffusible Hydrogen 470 MPa 580 MPa 25% 42J @ -40C 6.7ml/100g of weld deposited
PACKAGING DATA
WIRE SIZE (mm) 1.6 1.8 2.0 2.0 PACK SIZE AND TYPE 15kg spool 15kg spool 15kg spool 22.7kg coil PART NUMBER S225719-053 S225724-053 S225725-053 S225725-014
63
CONTENTS
64
CONTENTS
HARDFACING PRODUCTS
hardfacing electrodes Abrasocord 43......................................................... 66-67 Abrasocord 350....................................................... 68-69 Abrasocord 700....................................................... 70-71 Tubecord D - 2355................................................... 72-73 Tubecord E - 2460................................................... 74-75 Hardfacing Solid mig wires Austmig TD-600 ...................................................... 76-77 Hardfacing self shielded flux cored wires Mckay Tube-Alloy 240-0.......................................... 78-79 Mckay Tube-Alloy 258-0.......................................... 80-81 Mckay Tube-Alloy A43-0.......................................... 82-83 Hardfacing GAS shielded flux cored wires Mckay Vertiwear-600............................................... 84-85
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CONTENTS
ABRASOCORD 43
SUMMARY
Tough, Wear Resistant Complex Carbide Type Deposit For Hard Surfacing Components Subjected to Extreme Abrasion and Moderate to Heavy Impact Similar Deposit Type to Tubecord E-2460
Coating - Black Tip - Plain Imprint - WIA AC 43

CLASSIFICATION
IDENTIFICATION
AS/NZS 2576: 2465-A4

Abrasocord 43 is a heavy coated, hard surfacing electrode depositing extremely hard, abrasion resistant Chromium/ Niobium carbides in an austenitic matrix. It is ideal for hard surfacing applications where resistance to extreme abrasion (in particular sliding abrasion) and moderate to heavy impact are required. Due to the nodular shape of the complex carbides, Abrasocord 43 deposits are capable of withstanding heavier impact levels than standard chromium carbide grades. Typical applications include bucket teeth/lips, grizzlies, press screws, crusher hammers and ripper teeth to name but a few. Abrasocord 43 deposits are non-machineable, grindable, prone to fine relief checking and should be restricted to 3 layers high. While two layers of Abrasocord 43 may be required for maximum wear resistance, this complex carbide alloy has lower dilution sensitivity than straight chromium carbide deposits.
OPERATIONAL DATA
66
CONTENTS
1G
2G
HARDFACING PRODUCTS - HARDFACING ELECTRODES

5.0 C Mn 0.7 22.0 Cr 7.0 Nb Bal Fe

Single Layer onto Mild Steel Multi-Layer Typical Hardness 60-65 HRc Typical Hardness 64-69 HRc
Single layer deposit hardness may vary depending on base metal type and degree of dilution
PACKAGING DATA
ELECTRODE SIZE (mm) 3.2 4.0 5.0 PACKAGING (KG) Packet 5 5 5 Carton 15 15 15 APPROX NO. OF RODS PER KG 16 11 6
PART NUMBER AC4332 AC4340 AC4350
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CONTENTS
ABRASOCORD 350
SUMMARY
Tough, Machineable, Wear Resistant Martensitic Steel Deposit For Hard Surfacing Steels Subjected to Metal-to-Metal Wear Under Compressive Loading Coating - Brown Tip - Yellow Imprint - WIA AC 350
AS/NZS 2576: 1435-A4

Abrasocord 350 is a smooth running, AC/DC electrode which deposits a tough wear resistant low carbon martensitic steel alloy. It is suitable for the heavy build-up and surfacing of steel components subjected to metal-to-metal wear and compressive loading such as, track components, gears and shafts, etc. Abrasocord 350 deposits an air hardening C-Mn-Cr steel alloy which is machineable and can be readily hot forged. It offers high compressive strength and excellent resistance to impact for all types of metal-to-metal wear.
OPERATIONAL DATA
68
CONTENTS
1G
2G

0.2 C Mn 0.4 0.3 Si 2.8 Cr Bal Fe

PACKAGING DATA
PART NUMBER HF35032 HF35040 HF35050
69
CONTENTS
ABRASOCORD 700
SUMMARY
Wear Resistant, High Carbon Martensitic Steel Deposit For a Wide Range of General Hard Surfacing Applications, Such as Points, Tynes, Lips, Blades and Augers, ect. Coating - Grey Tip - Orange Imprint - WIA AC 700
AS/NZS 2576: 1855-A4

Abrasocord 700 is a smooth running, AC/DC electrode which deposits an air hardening martensitic Cr-Mo-V steel alloy. Abrasocord 700 deposits one of the hardest steel alloys available and is free from relief checks. Applications include the surfacing of post hole augers, agricultural points, shares and tynes, grader and cultivator blades and other components subject to fatigue or flexing during service. Abrasocord 700 deposits an air hardening steel alloy which can be readily hot forged and offers good resistance to all types of abrasion under low to moderate impact conditions. In the as welded condition Abrasocord 700 weld metal cannot be machined without prior heat treatment.
OPERATIONAL DATA
70
CONTENTS
1G
2G

0.7 C Mn 0.3 0.5 Si 8.5 Cr Mo 0.3 0.5 V Bal Fe

PACKAGING DATA
PART NUMBER HF70032 HF70040 HF70050
71
CONTENTS
TUBECORD D - 2355
SUMMARY
High Chrome Carbide Improved Abrasion Resistance Welds can be Shaped by Grinding Coating - Black Tip - Light Green
AS/NZS 2576: 2355-A1* * Nearest Classification

DESCRIPTION
Tubecord D - 2355 deposits are high in carbon and chromium resulting in improved abrasion resistance. Tubecord D - 2355 is ideal for hard surfacing components subjected to heavy abrasion and moderate impact loading. No preheat is required for direct application onto grey cast iron, low carbon or manganese steels. Applications include the hard surfacing of dredge bucket lips, shovel buckets, scraper and dozer sides, cone crushers and mill hammers, etc. Deposits are grindable, subject to relief checking and may be multi-layered up to 3 layers. Features include, controlled fume levels, minimal spatter, easy bead deposition and low penetration. Tubecord D - 2355 is suitable for AC or DC applications.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE (A) 6.3 450 85-135 ARC VOLTAGE RANGE *(V) 25
*Voltage is determined by arc current and electrode arc length. Arc voltage shown is typical and is only to be used as a guide.
72
CONTENTS
1G
2G
3G
4G

5.5 C Mn 1.5 40.0 Cr Bal Fe

Single Layer Typical Hardness 55-60 HRc
PACKAGING DATA
ELECTRODE SIZE (mm) 6.3 PACKAGING (KG) PART NUMBER TUBD60
Packet 5
Carton 15
APPLICATIONS
Dredge Bucket Lips Shovel Buckets Cone Crusher
73
CONTENTS
TUBECORD E - 2460
SUMMARY
All Tubecord Electrodes are 450mm Long. 6.3mm Tubecord E - 2460 is also Suitable for Vertical Up and Overhead Welding Positions. All Tubecore Electrodes are Coated with a Moisture Resistant, Non Alloying, Black Flux Coating, Resulting in Infinate Storage life!
Coating - Black Tip - Blue

CLASSIFICATION
IDENTIFICATION
AS/NZS 2576: 2460-A1

DESCRIPTION
Tubecord E - 2460 deposits contain carbon, chromium, niobium and molybdenum alloys for good resistance to both impact and abrasion: Tubecord E - 2460 produces a similar complex carbide iron deposit to the popular Abrasocord 43 electrode. No preheat is required for direct application onto grey cast iron, low carbon or manganese steels. Applications include the hard surfacing of grizzly bars, bucket teeth, crusher hammers, rail ballast tampers, dredger and ripper teeth, etc. Deposits are grindable, subject to relief checking and should be restricted to 3 layers high. Features include, controlled fume levels, minimal spatter, easy bead deposition and low penetration. Tubecord E - 2460 is suitable for AC or DC applications.
74
CONTENTS
**
3G
**
4G
1F
2G
OPERATIONAL DATA
ELECTRODE WELDING CURRENT SIZE (mm) RANGE (A) 6.3 8.0 90-130 135-185 ARC VOLTAGE RANGE *(V) 25 29
*Voltage is determined by arc current and electrode arc length. Arc voltage shown is typical and is only to be used as a guide. **6.3mm only

4.0 C 26.5 Cr Mo 0.9 7.9 Nb 0.4 V Mn 0.8 1.5 Si Bal Fe

Single Layer Typical Hardness 58-61 HRc
PACKAGING DATA
ELECTRODE SIZE (mm) 6.3 8.0 PACKAGING (KG) PART NUMBER TUBE60 TUBE80
Packet 5 5
Carton 15 15
TYPICAL APPLICATIONS
Grily Bars Bucket Teeth Crusher Hammers
75
CONTENTS
AUSTMIG TD - 600
SUMMARY
Copper Coated, Chromium Alloy Gas Metal Arc (MIG) Welding Wire For Hard Surfacing Components Subjected to Severe Abrasion and Heavy Impact CLASSIFICATION AS/NZS 2576: 1855-B6
DESCRIPTION
Austmig TD - 600 is a copper coated, chromium alloy welding wire depositing weld metal with a hardness of 55-60 HRc which has a high resistance against severe abrasion and impact. The deposit is non-machineable but can be shaped by grinding Typical applications include: excavator blades, bucket lips, bucket teeth, screw conveyors, crushing mills, shear blades.
OPERATIONAL DATA
WIRE SIZE (mm) 1.2 WELDING CURRENT RANGE (A) 120-340 ARC VOLTAGE RANGE *(V) 18-32
76
CONTENTS
1G
2G
3G
HARDFACING PRODUCTS - HARDFACING SOLID MIG WIRES
4G

0.45 C 3.00 Si 0.40 Mn 0.025 P 0.020 S 9.00 Cr Bal Fe
Recommended Shielding Gases: Argon/18 - 25% CO, Ar/CO or 100% CO

APPLICATIONS Excavator Blades Screw Conveyors Sheer Blades PACKAGING DATA
WIRE SIZE (mm) 1.2 PACK SIZE AND TYPE 15kg
As Welded - Two Layers
55-60 HRc
Bucket Teeth Crushing Mills
PART NUMBER MTD60012S
77
CONTENTS
McKAY TUBE-ALLOY 240-O

SUMMARY
Self Shielded Hard Surfacing Flux Cored Wire General Purpose Alloy with Good Abrasion and Impact Resistance Chromium Carbide - Alloy Steel Non Machinable, Difficult to Grind
CLASSIFICATION
AS/NZS 2576: 2155-B7

DESCRIPTION
McKAY Tube-Alloy 240-O is a self shielded, flux cored hard surfacing wire that deposits a chromium carbide alloy steel. It is an excellent general purpose alloy due to a combination of good abrasion and impact resistance. McKAY Tube-Alloy 240-O is designed for overlaying carbon, low alloy or austenitic manganese base metals. The smooth globular type arc transfer gives minimal spatter and the minimum slag cover allows the wire to operate well without de-slagging between weld passes in automatic applications. Some relief check cracking will occur however it is not detrimental to the wear properties of the deposit and provides some degree of stress relief for the weld metal.
OPERATIONAL DATA
The recommended operating parameters are for DC positive with an electrode stick out of 16-25mm for the 1.2mm size, 25-35mm for 1.6mm. Out-of-position welding is limited to a horizontal shelf technique.
78
CONTENTS
HARDFACING PRODUCTS - HARDFACING SELF SHIELDED FLUX CORED WIRES
1G

3.20 C 1.80 Mn 1.90 Si 15.50 Cr Bal Fe
TYPICAL MECHANICAL PROPERTIES (AS WELDED):

Number of Layers Hardness 1 2 3-5 As-deposited on 1020 Steel 40 Rc 48 Rc 52 Rc Mn Steel 35 Rc 42 Rc 50 Rc
Abrasion Resistance: Very Good Impact Resistance: Fair Non-Machinable: Grinding is difficult Cannot be Flame Cut Deposit will Relief check Cracks Thickness should be Limited to Five Layers Maximum
APPLICATIONS
Ammonia Knives Augers Bucket Teeth and Lips Bulldozer End Bits & Blades Conveyer Screws Crusher Jaws and Cones Crusher Rolls Cultivator Chisels & Sweeps Dragline Buckets Sheepsfoot Tampers Dredge Pump Impellers and Side Plates
Hammer Mill Hammers Impactor Crusher Bars Manganese Pump Shells Mill Guides Muller Tires Pipeline Ball Joints Pulverizer Hammers Scraper Blades Screw Conveyors Sizing Screens
PACKAGING DATA
WIRE SIZE (mm) 1.2 1.6 PACK SIZE (KG) 11.3 11.3 PART NUMBER S604012-029 S604019-029
79
CONTENTS
McKAY TUBE-ALLOY 258-O

SUMMARY
Self Shielded or Open Arc Hard Surfacing Flux Cored Wire Hard Wearing Martensitic Steel Alloy Deposit Tough, Hard Tool Steel Weld Metal Composition Good Impact and Abrasion Resistance Excellent Resistance to Metal-to-Metal Wear Weld Deposits Grindable Only
CLASSIFICATION
AS/NZS 2576: 1550-B7* *Nearest Classification

DESCRIPTION
McKAY Tubealloy 258-O is a fabricated type, open arc tubular flux cored wire depositing a Cr-Mo-W Martensitic steel alloy. It is designed for surfacing mild and low alloy steel components subject to moderate abrasive wear and impact under high compressive stresses and/or at temperatures up to 530C. Crack free deposits can be obtained by controlled heat input or the use of preheat.
OPERATIONAL DATA
Welding parameters shown below are for DC electrode positive. An electrode stick out length of 12-25mm is recommended for 1.2mm size, 25-35mm for 1.6mm.
WIRE SIZE (mm) 1.2 1.6 WELDING CURRENT RANGE (A) 120-230 225-350 ARC VOLTAGE RANGE *(V) 24-27 30-34*
80
CONTENTS
1G

0.45 C 1.40 Mn 0.80 Si 6.00 Cr 1.50 Mo 1.50 W Bal Fe

Number of Layers Hardness 1 2 3 As-deposited on 1020 Steel 49 Rc 53 Rc 57 Rc Mn Steel 51 Rc 54 Rc 57 Rc
Abrasion Resistance: Good Impact Resistance: Good Non-Machinable: Grinding only Flame Cutting: Difficult Deposit will Relief Check Cracks Thickness should be Limited to Five Layers Maximum
APPLICATIONS
Coupling Boxes Kiln Trunnions Spindles PACKAGING DATA

WIRE SIZE (mm) 1.2 1.6 PACK SIZE (KG) 11.3 11.3
Dragline Chains Mill Guides Wobbler Ends
PART NUMBER S605812-029 S605819-029
81
CONTENTS
McKAY TUBE-ALLOY A43-O

SUMMARY
Self Shielded or Open Arc Hard Surfacing Flux Cored Wire Niobium-Chromium Carbide Iron Weld Deposit Resistant to Severe High and Low Stress Abrasion Low to Moderate Impact Loading Weld deposits are to be Shaped by Grinding Only
CLASSIFICATION
AS/NZS 2576: 2460-B7

DESCRIPTION
McKAY Tube-Alloy A43-O is a fabricated type, self shielding tubular flux cored wire depositing a high chromium-niobium surfacing alloy which resists severe high and low stress abrasion and low to moderate impact. The weld deposit will check crack readily and out performs straight C-Cr hard surfacing alloys. It can also be used where high temperature (650C) wear resistance is required. Spatter level is low, slag cover is minimal and is easily removed.
OPERATIONAL DATA
The recommended operating parameters are for DC positive with an electrode stick out length of 20-35mm.
Welding Current DC + Other wire sizes and spool weights are available on indent only. *Voltage is determined by arc current and wire arc length. Welding currents and voltage shown are operational guides only.
82
CONTENTS
1G

5.50 C 0.20 Mn 1.0 Si 22.00 Cr 6.50 Nb Bal Fe

Number of Layers Hardness 1 2-3 As-deposited on 1020 Steel 56-60 Rc 60-64 Rc Mn Steel 45-50 Rc 54-58 Rc
Abrasion Resistance: Excellent Impact Resistance: Poor Non-Machinable: Grinding only Flame Cutting: Difficult Deposit will Relief Check Cracks Thickness should be Limited to Five Layers Maximum
Augers Coal Feeder Screws Coke Chutes Conveyer Screws Grizzly Bars and Fingers Muller Tires Pipeline Ball Joints Scraper Blades Sizing Screws Dredge Cutter Heads & Teeth Dredge Pump Inlet Nozzle and Side Plates PACKAGING DATA
WIRE SIZE (mm) 1.6 PACK SIZE (KG) 11.3
APPLICATIONS
Bucket Lips and Teeth Coal Pulverizer Rolls & Tables Coke Pusher Shoes Fan Blades Pipeline Ball Joints Paving Agitator Screws Pub Mill Paddles Sheepsfoot Tampers
PART NUMBER S607719-029
83
CONTENTS
McKAY VERTIWEAR-600
SUMMARY
Suites Out-of Position Applications Multi-Purpose Martensitic Steel Moderate Abrasive Wear and Medium to High Impact Weld Deposits - Machineable
CLASSIFICATION
AS/NZS 2576: 1855-B5* *Nearest Classification

DESCRIPTION
McKAY Vertiwear 600 is a gas shielded, all position, hard surfacing fluxcored wire designed to operate in a smooth semi-spray arc transfer. The weld metal control is superior to competitive gas shielded hard surfacing wires allowing higher deposition and greater productivity in out-of-position applications. Excellent operator appeal in all positions. McKAY Vertiwear 600 deposits a multi-purpose martensitic steel alloy and can be used to hard surface mild and low alloy steel components subject to moderate abrasion coupled with medium to high impact. It also exhibits excellent compressive strength and metal-to-metal wear resistance. The recommended shielding gas for Vertiwear 600 is 75% Argon - 25% CO.
OPERATIONAL DATA
The recommended operating parameters are for DC positive with an electrode stick out length of 20-35mm.
84
CONTENTS
1G
2G
3G
HARDFACING PRODUCTS - HARDFACING GAS SHIELDED FLUX CORED WIRES
4G

0.40 C 0.75 Mn 0.60 Si 6.50 Cr 1.00 Mo Bal Fe
TYPICAL MECHANICAL PROPERTIES (AS WELDED)

Number of Layers Hardness Hardness asdeposited 55 1 2 3-8 Time at Temp 10 Hours 20 Hours 80 Hours As-deposited on 1020 Steel 52 Rc 56 Rc 57 Rc Hardness after Tempering 535C 620C 54 46 49 40 47 40 Good Good Good Difficult
Abrasion Resistance: Impact Resistance: Machinability Flame Cutting: Magnetic
APPLICATIONS
Coupling Boxes Dredge Ladder Rolls Mill Guides Wobber Ends PACKAGING DATA
WIRE SIZE (mm) 1.2
Dragline Chain Kiln Trunnions Sliding Metal Parts
PACK SIZE (KG) 15
PART NUMBER S607112-029
85
CONTENTS
CONTENTS
The following pages cover a range of technical information and data tables pertaining to the field of welded fabrication and general engineering. This section is designed to provide a ready reference guide for welding engineers, design costing personnel, workshop supervisors and welding operators, and to foster higher quality, higher productivity welding. GLOSSARY........................................................... 88-105 OXY-ACETYLENE FLAME ADJUSTMENT..........106-107 WELDING SYMBOLS..........................................108-115 ELECTRODE CLASSIFICATIONS Manual Metal Arc Welding Electrodes.....................116-123 Gas Metal Arc Welding Ferritic Steel Electrodes....... 124-126 Flux Cored Arc Welding Electrodes........................ 127-129 Manual Metal Arc and Gas Metal Arc Welding for Aluminium and Stainless Steel Electrodes........... 130-131 Repair and Hardfacing .......................................... 132-133 Submerged Arc Welding Electrodes and Fluxes.... 134-135 Weld deposition and costing data Users Guide........................................................... 136-147 Mass of Weld Metal in Joint.................................... 148-153 Quantity of Consumables Required....................... 154-157 Deposition Rates.................................................... 158-165 Duty Cycles............................................................ 166-167 Electrode Consumption for Typical Butt Joints....... 168-169
CONTENTS
CONTENTS
WeldabilitY guide for steels..................170-193 Common weld TROUBLES ............................194-199 SI units and conversion data...................200-203 Table 1. Conversion from Inches to Millimetres...........................204 Table 2. Travel and Wire Feed Speeds........................................205 Table 3 C - F Temperature Conversions.......................... 206-209 Table 4. Comparison of Hardness Scales....................................210 Table 5. Stress and Energy Conversions..................................... 211 Table 6. Wire and Sheet Sizes............................................. 212-213 SYmbols for elements and geometric formulae......................................... 214
87
CONTENTS
GLOSSARY
The following is a selection of some of the more common welding terms and abbreviations in current Australian usage. Please refer to Australian Standard AS2812 (Welding, Brazing and Cutting of Metals - Glossary of Terms) for a more comprehensive list. AMPERAGE - The measurement of the amount of electricity flowing past a given point in a conductor per second. Current is another name for amperage. ANGLE OF BEVEL - The angle at which the edge of a joint is prepared for making a weld, refer to FIG 1. (A) - (F) for typical examples ARC BLOW - An uncontrolled deflection of a welding arc caused by an uneven distribution of magnetic field around the arc. ARC LENGTH - The distance from the end of the electrode to the parent material. ARC VOLTAGE - The voltage across the welding arc. ARC WELDING (AW) - Fusion welding in which heat for welding is obtained from an electric arc or arcs. ARC WELDING GUN - A device used in semi-automatic and automatic arc welding to transfer current, guide the consumable electrode and direct shielding gas when used. AS-WELDED - The condition of weld metal, welded joints or weldments after welding prior to any subsequent thermal or mechanical treatment. BACKING - A weld backing maybe incorporated in welded joint design to simplify the root pass. Backing of suitable material can be incorporated in the weldment, or alternativley removable temporary backing material can be used. e.g. ceramic tiles BACK-STEP WELDING - A welding technique wherein the increments of weld metal are deposited in a direction opposite to that of progression. BARE ELECTRODE - A filler metal electrode consisting of a single metal or alloy that has been produced into a wire, strip or bar form which has no flux coating or covering applied to it.
88
CONTENTS
GLOSSARY
BASE (PARENT) METAL - The metal to be welded or joined other than the filler metal. BASIC ELECTRODE - A flux coated electrode in which the covering contains a high proportion of basic materials, such as limestone and flurospar etc. BRAZE WELDING (BW) - The joining of metals using similar joint designs as for fusion welding. However, the parent metal is not melted as in fusion welding. A non-ferrous alloy with a melting point above approx. 500C and below that of the parent metal is normally used as the filler metal and is deposited without the aid of capillary action, as in brazing. BRAZING - A joining process in which, during heating, molten filler metal is made to flow by capillary action between a narrow joint preparation. In general, the melting point of the filler metal is above approx. 450C, but is always below the melting temperature of the parent metal. A fluxing agent is usually used to promote the flow of filler metal along and around the joint. BRONZE WELDING - Term used to describe Braze Welding using a Copper rich filler metal. BUTTERING - A material preparation process in which one or two layers of weld metal are deposited on the surfaces to be joined. The buttering provides a suitable transition weld deposit for subsequent completion of the joint. BUTT WELD - A weld in which the weld lies substantially within the extension of the planes of the surfaces of one or more of the pads joined, see Fig 1 for typical examples. CDT - Controlled Droplet Transfer CELLULOSE ELECTRODE - A flux coated electrode in which the covering contains at least 15 percent cellulose and up to 30 percent titania as rutile or titanium white. CO WELDING - Gas Metal-Arc welding using CO as the shielding gas, see preferred term - Gas Metal Arc Welding. CONSTANT VOLTAGE POWER SOURCE - An arc welding power source whose terminal voltage remains substantially constant between full load and no load conditions.
89
CONTENTS
GLOSSARY
CONSUMABLES - Materials directly consumed in the making of a weld, including electrodes, flux heating and shielding gas and filler wire etc. CORED ELECTRODE - A consumable electrode having a core of flux and/or alloying ingredients. COVERED ELECTRODE - A filler metal electrode, used in arc welding, consisting of a metal core wire with a relatively thick covering of flux which provides protection for the molten metal from the atmosphere, improves the properties of the weld metal and stabilises the arc. CRATER - A depression left in the weld where the arc is broken. CONSUMABLE GUIDE WELDING - see Electroslag Welding. DEFECT - One or more discontinuities that cause non compliance of a weld. DEPTH OF FUSION - The distance from the fusion face to that point within the joint at which fusion ceases, see Fig 2.(a) and (b). DEPOSITION EFFICIENCY (a) For manual metal arc welding electrodes, the ratio of the mass of deposited metal to the mass of the core wire consumed (excluding stubs); expressed as a percentage. (b) For continuous electrodes, the ratio of the mass of deposited metal to the mass of electrode consumed; expressed as a percentage. For 85% deposition efficiency means 85kg of weld metal was produced from 100kg of electrode metal. DEPOSITION RATE - The mass of metal deposited (excluding spatter) in a unit of time. DILUTION - The alteration of composition of the weld metal deposited from a filler metal or electrode due to mixing with the melted parent metal. It is expressed as a percentage of melted parent metal to the weld metal. DIP TRANSFER - see Short Circuiting Arc Transfer. DISCOUNTINUITY - a flaw in the weld which complies or may comply with the acceptance standard
90
CONTENTS
GLOSSARY
DROOPING CHARACTERISTIC POWER SOURCE - An arc welding power source whose terminal voltage drops to a value appreciably below the open circuit voltage (O.C.V.) after the arc has been initiated. DUTY CYCLE - (a) Power Source Duty Cycle is the amount of time a welding machine can be used at a given amperage, generally expressed as a percentage of a 5 min. period, eg. 60% at 300amps means the machine can be used at 300 amps for 3 mins in every 5 mins (b) Operator Duty Cycle is the ratio of welding or cutting time to the total work time expressed as a percentage. ELECTRODE - A component of the welding circuit through which current is immediately conducted to the arc, molten slag, or base metal. (a) Non-consumable electrode - an electrode which does not provide metal eg. a Tungsten electrode. (b) Consumable electrode - an electrode which provides filler metal. ELECTRODE NEGATIVE - Arc welding using direct current in which the electrode is connected to the negative pole of the welding power source. Also referred to as, straight polarity. ELECTRODE POSITIVE - Arc welding using direct current in which the electrode is connected to the positive pole of the welding power source. Also referred to as, reverse polarity. ELECTRODE STICKOUT - In automatic and semi-automatic arc welding, the length of the electrode projecting beyond the region of current pick-up / contact tip during welding. ELECTROSLAG WELDING (ESW) - A continuous wire electrode, vertical fusion welding process in which the molten pool of metal and covering slag are confined to the joint by copper shoes. The wire feeding nozzle progresses automatically up the joint or in the case of the consumable guide variant, is melted as the weld level rises. The heat for fusion is generated by the electrical resistance of the slag bath.
91
CONTENTS
GLOSSARY
FILLET WELD - A weld or series of welds of approximately triangular cross-section joining two surfaces approximately at right angles to each other in a lap joint, tee joint or corner joint. Note. The bulk of the weld metal is outside the planes made by the surfaces of the base metals, see Fig 2, (b) and (d) for typical examples. FLAT POSITION - The position in which welding is performed from the upper side of the joint and the weld face is approximately horizontal (Sometimes called downhand welding), see Fig 3, 1F and 1G positions. FLUID SLAG - A slag which flows freely during whilst molten during welding. FLUX - A substantially non-metallic material used during welding, brazing, braze welding or soldering to clean the surfaces of the joint chemically, to prevent atmospheric oxidation and to reduce impurities or float them to the surface in the form of a slag. FRIABLE SLAG - A slag that crumbles easily to aid removal. FUSION FACE - The portion of a surface, or an edge, which is to be fused (melted) in making a fusion weld, see Fig 2(a) and (b). FUSION ZONE - The area of parent metal melted as determined on the cross section of a weld, see Fig 2(a) and (b). FLUX CORED ARC WELDING (FCAW) - Arc welding using a continuous, consumable, flux cored wire (electrode) which provides the filler metal. Gas shielding, alloying addlions and slag coverage may be provided by the flux contained within the electrode. Gas shielding may or may not be required. FUSION WELDING - Welding in which similar parent metals are fused (melted) together with or without the use of a filler metal of similar composition. GAS METAL ARC WELDING (GMAW) - The preferred terminology for the process of arc welding using a continuous, consumable, solid wire (electrode) which provides the filler metal and in which shielding is obtained entirely from an externally supplied gas or gas mixture. The process is similar to and also known as MIG, MAG AND CO welding.
92
CONTENTS
GLOSSARY
GAS PORE - A weld cavity caused by entrapped gas. GAS TUNGSTEN ARC WELDING (GTAW) - The preferred terminology for the process of arc welding, with or without added filler metal, using a non-consumable electrode of pure or activated tungsten, shielded by an externally supplied gas or gas mixture. The process is similar to and also known as TIG, Heliarc or Argonarc welding. GAS WELDING - Welding in which the heat for welding is produced by the combustion of a gas mixture. Filler metal may or may not be used. The most popular gas combination is oxygen / acetylene however oxygen / LP gas, air / acetylene or air / LP gas are mixtures which may be used, depending on the joining process adopted. GLOBULAR TRANSFER - Metal transfer which takes place as globules of diameter substantially larger than that of the consumable electrode from which they are transferred. HARD SURFACING - Surfacing with a wear resistant material. The preferred term to hardfacing. HEAT AFFECTED ZONE (HAZ) - The portion of parent metal which has not been fused but has nevertheless been metallurgically affected by the heat of welding, brazing or cutting, Refer to Fig 2(a) and (b) for clarification. HERTZ - Hertz is often referred to as cycles per second. In Australia, the frequency or directional change of alternating current is usually 50 hertz. HIGH FREQUENCY - Covers the entire frequency spectrum above 50,000 Hz. Used in GTA welding for arc ignition and stabilization. HORIZONTAL POSITION - The position of welding wherein the line of the weld root is approximately horizontal, see Fig 3, 2F and 2G positions.
93
CONTENTS
GLOSSARY
HYDROGEN CONTROLLED ELECTRODE - An electrode depositing weld metal containing not more than a specified quantify of diffusible hydrogen in the deposited weld metal when assessed in accordance with the appropriate standard. The category of such electrodes may be sub-divided into classifications of medium hydrogen, low hydrogen and very low hydrogen, each having successively lower allowable levels of diffusible hydrogen. INCLUDED ANGLE - The angle between the planes of the fusion faces of the parts to be welded, see Fig 1 for typical examples. INDUCTANCE - Inductance comes from an inductor (stabilizer). The inductor slows down the changes in current, changing the machines rate of response and number of short circuits per second. An inductor helps limit the amount of spatter, and generally improves the wetting out of the weld puddle. INTERMITTENT WELD - A series of welds at specified intervals along a joint, see Fig 7 (c). INTERRUN TEMPERATURE - In a multi run weld, the temperature of the weld and adjacent parent metal immediately prior to the deposition of the next weld run. Also called INTERPASS TEMPERATURE. INVERTER - Power source which increases the frequency of the incoming primary power, thus providing for a smaller size machine and improved electrical characteristics for welding, such as faster response time and more control for pulse welding. IRON POWDER ELECTRODE - A flux coated electrode in which the covering contains a high percentage of iron in the form of powder to improve deposition efficiency typically 110-130%. JOINT PENETRATION - The minimum depth of fusion into a joint, excluding reinforcement. JOINT PREPARATION - Details of the edge preparations and set up of workpieces for welding. Refer to Fig 1, (A)-(F) for examples. Ksi - (kips) kilo (1000) pounds per square inch.
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GLOSSARY
LAND - The straight portion of a fusion face between the edge of the root face and: (a) the sloping face of a bevel preparation, or (b) the curved part of a J edge preparation, see Fig 1, (F). LANDING - See root face LAP JOINT - A joint between two overlapping members approximately in the same plane, see Fig 9, (C). LEG LENGTH - The distance between the root and the toe of a fillet weld. Leg length is the dimension used to size a fillet weld to AS1101.3. Leg length is known as the z dimension in ISO 2553, see Fig 2(d) and weld symbols section. LOW HYDROGEN ELECTRODE - see Hydrogen Controlled Electrode. MAG WELDING - Metal Active Gas, see Gas Metal Arc Welding. MANUAL METAL ARC WELDING (MMAW) - Arc welding with a flux covered electrode manually applied by the welder without automatic or semi-automatic replacement of the electrode. Shielding is provided only by decomposition of the electrode covering. In American terminology, known as, Shielded Metal Arc Welding (SMAW). MECHANISED WELDING - Welding with equipment which performs the welding operation under preset conditions under the constant control of a welding operator. MIG WELDING - Metal Inert Gas, see Gas Metal Arc Welding. MITRE FILLET WELD - A fillet weld of equal leg lengths in which the face of the weld is essentially flat. MULTIPLE ARC WELDING - Welding wherein a single process runs with more than one electrode from a single power source eg. twin arc, or a single process operates with more than one electrode from separate power sources and separate nozzles eg. tandem arc. Essentially a single weld pool is maintained throughout.
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GLOSSARY
NARROW GAP WELDING - A modification of conventional automatic arc Welding of thick sections where square preparations or V preparations with small included angles and narrow gaps are used. NON-TRANSFERRED ARC - A plasma arc struck between the tungsten electrode and the torch nozzle. OPEN-CIRCUIT VOLTAGE (OCV) - The voltage between the live output terminals of a welding power source when no current is flowing/no arc. OVERHEAD POSITION - The position in which welding is performed from the underside of the joint, see Fig 3, 4F and 4G positions. OVERLAP - Weld metal at the toe of a weld which covers the parent metal surface but is not fused to it. OXYGEN-ACETYLENE WELDING - Gas welding in which the heat for welding is produced by the combustion of an oxygenacetylene gas mixture. PARTIAL PENETRATION - A butt weld where, by design, fusion does not extend the full depth of the joint. PASS - see Weld Run. PEENING - The mechanical working of weld metal by means of hammer blows or bombardment with shot or pellets to reduce residual stress or distortion. PENETRATION BEAD - Weld metal protruding through the root of a fusion weld made from one side only. PLASMA ARC WELDING (PAW) - A process in which the electric arc generates a hot ionised gas stream that both shields and transfers heat to the joint. POROSITY - Clustered/grouped gas pores or voids in weld metal. POROUS SLAG - A slag that has a honeycomb structure. POSITIONER - A mechanical device manually or power operated to hold, tilt or rotate the work to the desired position for welding.
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GLOSSARY
POST WELD HEAT TREATMENT (PWHT) - Any thermal treatment carried out after welding. PREHEAT - The application of heat to the parent metal immediately prior to welding or cutting. PULSED ARC WELDING - Welding in which pulses of current are superimposed on a constant background current. In continuous electrode processes the pulses control metal transfer across the arc. Ideally, one pulse produces one droplet of molten metal across the arc. PULSING - Sequencing and controlling the amount of current, the polarity, and the duration of the welding arc. REINFORCEMENT - Weld metal lying outside the plane joining the weld toes. RESIDUAL WELDING STRESS - Stress remaining in a metal part of structure as a result of welding. RESISTANCE WELDING - A process in which two pieces of metal are joined by placing pressure on electrodes which are on opposite sides of the joint to be welded, maybe a spot or a continuous weld. There is no arc with this process, the resistance of the metal to the current flow is what causes fusion. RMS - Root Mean Square. The effective values of measured AC voltage or amperage. RMS equals 0.707 times the maximum, or peak value. ROOT FACE - The portion of a fusion face at the root which is not bevelled or grooved, Refer to Fig 1 for examples. ROOT GAP - The minimum distance at any cross-section between edges, ends or surfaces to be joined, Refer to Fig 1 for examples. ROOT OF WELD - The points as shown in cross-section, at which the back of the weld intersects the base metal surfaces, see Fig 2 (a) and (b) for examples.
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GLOSSARY
SHORT CIRCUITING ARC TRANSFER - Metal transfer in which fused parts of a consumable electrode are detached in rapid succession during repeated short circuiting contacts with the molten weld pool. Also called short arc or dip transfer. SILVER BRAZING - Brazing in which a silver alloy is used as the filler metal. SILVER SOLDERING - See Silver Brazing. SIZE OF WELD - (a) Equal leg fillet weld - the length of the equal sides of the largest isoceles triangle which can be inscribed within the fillet cross-section, see leg length. (b) Unequal leg fillet weld - the lengths of the sides containing the angle of the largest triangle which can be inscribed within the fillet cross section. (c) Butt weld - the minimum depth which a butt weld extends into a joint, exclusive of reinforcement. SLAG INCLUSION - Slag entrapped in weld metal or between weld metal and base metal. Only present with welding processes that use a flux eg. MMA and SAW. SOFT SOLDERING - see Soldering. SOLDERING - A low strength joining process in which, during heating, a molten Lead-Tin filler alloy is made to flow onto and around the joint preparation. In general, the melting point of the filler metal is less than 450C, but always below the melting temperature of the parent metal. A fluxing agent is often used to promote the flow of filler metal around the joint. SPATTER - Globules of weld metal which are expelled during welding and which do not form part of the weld. SUBMERGED ARC WELDING (SAW) - Arc welding in which a continuous, consumable, wire electrode (flux cored or solid) is used and the arc is submerged under a granular flux cover, some of which fuses to form a slag. Single or multiple electrodes in the form of solid or tubular wires or strip may be employed, attached to one or more power sources and feeding devices.
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GLOSSARY
TIG WELDING - Tungsten Inert Gas, see Gas Tungsten Arc Welding. SPRAY TRANSFER - Metal transfer which takes pace as a rapid projected stream of droplets of diameter not larger than that of the consumable electrode from which they are transferred. STRESS RELIEF HEAT TREATMENT - Heating to, and if necessary holding at, some temperature generally below the transformation range, usually followed by slow cooling, for the purpose of reducing internal stresses. STRINGER BEAD RUN - A bead or run made without intentional weaving motion. TACK WELD - A weld (generally short) made to hold parts of a weldment in alignment until final welds are deposited. THROAT THICKNESS - (a) Actual throat thickness the perpendicular distance between two lines (each parallel to a line joining the outer toes) one being a tangent at the weld face and the other being through the further most point of fusion penetration. Measured from the root to the weld face. Known as the a dimension in ISO 2553. (b) Design throat thickness - the minimum dimension of throat thickness used for design purposes, refer to Fig 4, (a) and (b) for examples. TINNING - The term as applied to brazing and braze welding defines the deposition of a thin layer of fluxed filler metal onto joint surfaces in order to provide a sound and strong interface between parent metal and weld deposit. T-JOINT - A joint between the end or edge of one part and the face of the other part, The parts making an angle to one another of more Than 5 degrees up to and including 90 degrees in the region of the joint, see Fig 1, (E) and (F) for examples. TOE - The junction between a weld face and the base metal or between weld faces, refer to Fig 2, (C) and (d) for examples.
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GLOSSARY
TOUCH OR SCRATCH START - An arc starting procedure for TIG (GTAW). The tungsten is touched or scratched on the workpiece; when the tungsten is lifted from the workpiece an arc is established TOUCH WELDING - Metal arc welding using a coated electrode, where, as a result of a characteristic of the coating, it can be kept in contact with the base metal during welding to facilitate control of arc length. TRANSFERRED ARC - A plasma arc which is struck between a tungsten electrode and the workpiece. UNDERCUT - A sharp groove at the toe of a weld flaw which is a run between the weld and the parent metal or in previously deposited weld metal caused by wastage of the underlying material, see Common Weld Defects section. VERTICAL POSITION - The position of welding wherein the line of the weld root is approximately vertical, see Fig 3, 3F and 3G positions. VISCOUS SLAG - A slag with characteristics which restrict the flow of molten slag into the weldpool during welding. VOLTAGE - The pressure or force that pushes the electrons through a conductor. Voltage does not flow, but causes amperage or current to flow. Voltage is sometimes termed electromotive force (EMP) or difference in potential. VOLTAGE REDUCTION DEVICE (VRD) - a device used to reduce the OCV of welding machines to lower and safer levels WEAVING - Transverse movement of the end of an electrode during deposition of weld metal. WELDING PROCEDURE - The detailed methods and practices involved in the making of a weld eg. amps, volts, travel speed, material and consumable type etc. WELD FACE - The exposed surface of a weld on the side from which welding was performed, refer to Fig 2, (C) and (d) for examples.
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GLOSSARY
WELD JUNCTION - The boundary between the fusion zone and the heat affected zone (HAZ) of a weld, see Fig 2, (a) and (b). WELD METAL - All metal melted during the making of a weld and retained in the weld, see Fig 2, (a) and (b). WELD RUN - The weld metal resulting from one passage of an electrode, torch or blowpipe, also called weld pass. WIRE FEED SPEED - Expressed in in/min or mm/s, and refers to the speed and amount of filler metal fed into a weld. Generally speaking the higher the wire feed speed, the higher the amperage. WORK - The material or object on which welding, brazing, soldering or cutting is carried out. Also called workpiece..
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GLOSSARY
Included angle Angle of bevel Root face Root gap Root face Root gap Root radius Included angle Angle of bevel
(A) SINGLE-V BUTT JOINT Included angle Angle of bevel Root face Root face Root gap (C) DOUBLE-V BUTT JOINT
(B) SINGLE-U BUTT JOINT Included angle Angle of bevel
Root radius Root gap
(D) DOUBLE-U BUTT JOINT
Included angle & angle of bevel Root face Root face Root gap (E) SIBGLE BEVEL-T BUTT JOINT Root gap
Included angle & angle of bevel
Root radius Land
(F) SIBGLE-J T-BUTT JOINT
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GLOSSARY
Weld zone Heataffected Zone Weld metal Parent metal Depth of fusion Fusion face Weld junction Root of weld
Weld zone
Weld metal
Fusion zone Root of weld
Fusion zone Heat affected zone
(A) BUTT WELD
(B) FILLET WELD
Weld width Toes Weld face Toe Toe Weld width Weld face
Leg (length) Toe Weld face (C) BUTT WELD
Toes
Leg (length) (D) FILLET WELD
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GLOSSARY
FILLET WELDS
FLAT POSITION 1F HORIZONTAL POSITION 2F VERTICAL POSITION 3F OVERHEAD POSITION 4F
Axis of Weld Horizontal
Axis of Weld Vertical
PIPE BUTT WELDS

FLAT 1G HORIZONTAL 2G POSITION 5G POSITION 6G
L
45 5
Pipe shall be turned or rolled while welding, Axis of Pipe Horizontal
Axis of pipe Vertical
Pipe shall NOT be turned or rolled while welding, Axis of Pipe Horizontal
Inclined Axis with Pipe Stationary
BUTT WELDS
FLAT POSITION 1G HORIZONTAL POSITION 2G VERTICAL POSITION 3G OVERHEAD POSITION 4G
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Plates Horizontal
Plates Vertical
Plates Vertical
Plates Horizontal
GLOSSARY
Design throat thickness Actual throat thickness (A) Actual throat thickness
Design throat thickness (B)
FIGURE 4 ACTUAL AND DESIGN THROAT THICKNESS OF TYPICAL WELDS
D D
D + 0.85 D
FIGURE 4A DEEP PENETRATION WELD AND DESIGN THROAT THICKNESS TO AS 1554.1
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CONTENTS
ADD
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OXY-ACETYLENE FLAME ADJUSTMENT

FLAME ADJUSTMENTS FOR OXYGEN ACETYLENE WELDING For oxy-acetylene welding there are essentially four main types of flame adjustments used for welding a wide variety of base metals. A neutral flame is the most common setting used for the majority of fusion welding and braze welding applications. The following diagrams are intended as a guide to the easy identification of these flame types and their use with specific base metals. (A) OXIDISING FLAME For welding Copper and certain Copper based alloys
Small inner cone
OXY-ACETYLENE FLAME ADJUSTMENT
(B) NEUTRAL FLAME
For welding Steel, Stainless Steel, Cast Iron, Aluminium and Copper etc.
Bright inner cone
(C) REDUCING FLAME For welding Aluminium and Low Alloy Steel etc.
Small pale green feather
(D) CARBURIZING FLAME Suitable for silver brazing, soldering and many hard surfacing applications.
Bright acetylene feather
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WELDING SYMBOLS
Welding symbols are the shorthand of welding, they provide a concise means of relaying information on engineering drawings. Detailed information such as the type, size, orientation and finishing requirements of the weld joint can be communicated. Welding symbols do not always contain all the information required for welding. Reference is often given on the welding symbol, to a specification, process, procedure or other document which provides the necessary data to complete the welding operation. The use of welding symbols result in the following benefits: 1.The complete translation of specific design requirements to the workshop; regarding such parameters as weld sizes, processes to be used, joint preparations etc thus allowing the welding task to be complete as per instruction. 2.The elimination of unnecessary and incomprehensible details on drawings-when such details specify weld type, size, length, pitch etc. 3.The establishment of a common understanding of design intent and welding prerequisites between designers, workshop welder/ inspectors, welding engineers, Q.A./Q.C personnel and code authorities etc. 4.Standardisation, within and across the welding, fabrication and construction industries. BASIC SYMBOLS There are different standards for welding symbols. The following pages are set out using the International Standard ISO2553 (Welded, brazed and soldered joints - Symbolic representation on drawings) and the Australian Standard AS1101.3 (Graphical Symbols for General Engineering - Welding and Non-Destructive Examination) which is based on the American Welding Society Standard. AWS A2.4 In AS1101.3, a clear distinction is made between the terms weld symbol and welding symbol. The term, weld symbol describes the type of weld to be deposited see FIGURE 6A for the basic weld symbols in common use. The welding symbol is a method of representing the weld symbol on drawings and includes all the relevant information and references necessary to complete the welded joint.
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WELDING SYMBOLS
ELEMENTS OF A WELDING SYMBOL TO AS1101.3 The major elements are: (a) Reference line (shown horizontally) (b) Arrow (c) Basic weld symbols (d) Dimensions and other data (e) Supplementary symbols (f) Finish symbol (g) Tail (h) Specification, process, or other references Refer to Figure 5 for the standard location of these elements on a welding symbol.
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110
Preparation angle; included angle of countersink for plug welds Length of weld Pitch (centre-to-centre spacing) of welds Site weld symbol
)
L P
BOTH SIDES
WELDING SYMBOLS
Basic weld symbol or detail reference
Number of spot, seam, stud, plug or protection welds
(N)
ARROW SIDE
Tail (Tail omitted when reference is not used)
)(
Specification, process, procedure or other reference
S (D)
OTHER SIDE
Depth of preparation; size or strength for certain welds
F A R
CONTENTS Arrow connecting reference line to arrow side member of joint Weld-all-around symbol Reference line NOTE: Reproduced with permission from SAI Global under Licence 1110-c075
Finish symbol
Contour symbol
Root gap; depth of filling for plug and slot welds
Design throat thickness
Elements in this area remain as shown when tail and arrow are reversed
FIGURE 4: LOCATION OF ELEMENTS ON A WELDING SYMBOL
WELDING SYMBOLS
BUTT WELD
Square Scarf V Bevel U J Flare V Flare Bevel
Fillet Weld
Plug Weld Or Slot Weld
Spot Weld Or Projection Weld
Seam Weld
Backing Run Or Backing Weld
Surfacing
Edge Weld
Stud Weld
FIGURE 6A BASIC WELD SYMBOLS

Complete Penetration From One Side
Weld All Around
Site Weld
Backing Or Spacer Material
Surfacing
Convex
Concave
FIGURE 6B SUPPLEMENTARY SYMBOLS
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CONTENTS
WELDING SYMBOLS
(A) SINGLE-FILLET WELD 8 Symbol (B) UNEQUAL DOUBLE-FILLET WELDS. 6 6 12 Desired weld 12 Symbol 6 12 8 Desired weld 8
(C) STAGGERED INTERMITTENT FILLET WELDS. 75 75 75 75 75-250 75-250 125 125
250
C Weld C Weld C Weld C Weld Desired welds
(D) COMBINED FILLET AND BUTT WELD IN T-JOINT WITH SPECIFIED ROOT GAP. (3) 2 3 5 Desired weld 5 Symbol (3) 2 5
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CONTENTS
WELDING SYMBOLS
(A) PARTIAL PENETRATION, SINGLE-V BUTT WELD 90 6 (10) 90
6 Desired Weld 90 (D=10)
Symbol 5 (12) 90 5 (12) 90 See Note
(B) FULL PENETRATION (D=12) 5 22 5 (D=12)
Note overlap Desired Weld
90
Symbol Note: The total design throat thickness (D)=22mm
(C) SINGLE BEVEL BUTT WELD WITH ROOT OPENING (4) 10 (4) 2 (7) 60 2 (7) Desired Weld 60 Symbol See Note
Note: The total design throat thickness cannot be greater than plate thickness (10mm)
14
70
(D) COMBINED FILLET AND BUTT WELDS 25 14 9 6 (14) Note 6 (14) overlap 9 70
70 70
Symbol 9 6 6 9
Desired Weld
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CONTENTS
WELDING SYMBOLS
(A) SURFACE WELD
Desired weld 3
Symbol
(B) PLUG WELD 45 12 See Note
12
45
Section of desired weld
Symbol NOTE: See drawing for dimensions and orientation
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CONTENTS
WELDING SYMBOLS
(C) SPOT WELD A 24 24 24 24 6 (5) 24 RSW
12
+
12
+
12 6
A Desired weld
Section A-A
Symbol RSW - Resistance spot welding
(D) SEAM WELD Min acceptable shear strength 35 N/mm
EBW 35 N/mm
Desired weld
Section A-A
Symbol EBW - Electronbeam welding
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ELECTRODE CLASSIFICATIONS
A GUIDE TO INTERPRETING THE AUSTRALIAN / NEW ZEALAND STANDARD CLASSIFICATION FOR LOW CARBON STEEL MMAW ELECTRODES The Australian/New Zealand Standard 4855 for Manual Metal Arc Welding of non-alloy and fine grain steel is identical to ISO 2560 standard, and is to supersede AS/NZS 1553.1. Under the new AS/NZS 4855 standard, covered electrode can be classified based upon either yield strength and 47J minimum impact energy known as method -A, or tensile strength and 27J minimum impact energy known as method -B, which the second method is widely accepted in Australian market. For details of the complete range of classifications, please consult AS/NZS 4855. Compulsory clalssification designators Specification number Classification by tensile strength and 27J CVN requirement Covered electrode Deposit metal tensile strength. 49 indicates minimum tensile strength of 490 N/mm , other designator like 43, 55 or 57 is often used Type of flux coating Condition of heat treatment. The symbols A and/or P are used to indicate the as-welded and/or heat treated condition/s Optional supplemental designators Diffusible hydrogen. H5, H10,H15 is used to indicate a maximum diffusible hydrogen content of 5,10, and 15 ml/100g of deposited metal, respectively
AS/NZS 4855-B - E49 16 A U H10

Optional supplemental designators 47J impact energy at the normal 27J test temperature has also been met.
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ELECTRODE CLASSIFICATIONS - MANUAL METAL ARC WELDING ELECTRODES
A GUIDE TO INTERPRETING THE AMERICAN ANSI / AWS SPECIFICATION FOR CARBON STEEL ELECTRODES FOR SHIELDED METAL ARC WELDING The ANSI/AWS A5.1 Specification for Shielded Metal Arc Welding details classifications covering general purpose, iron powder and low hydrogen electrodes. The classification system consists of an alphanumeric group followed by a group of optional designators. Please consult ANSI/AWS A5.1 for further details on the range. 1ST GROUP
Minimum Weld Metal Strength Tensile Yield Elongation ksi ksi % 60 48 22 70 58 22
2ND GROUP
Welding Position, Welding Current and Coating Type ie EXX12, EXX24 and EXX18 For details refer to the Usability Digits of Major Classifications on next page.
3RD GROUP
Optional Designator for Improved Impact Toughness E7016-1=20 ft.lb @ -50F av.min. E7018-1=20 ft.lb @ -50F av.min. E7024-1=20 ft.lb @ -0F av.min.
ELECTRODE
E XX XX
XHXR
3RD GROUP
3RD GROUP Optional designators
3RD GROUP
Optional Diffusible Hydrogen Designator indicates that the low hydrogen electrode meets the requirements of the diffusible hydrogen test. H4 <4mL/100g) of deposited weld metal H8 <8mL/100g) of deposited weld metal H16 <16mL/100g) of deposited weld metal
Optional Coating Absorbed MoistureDesignator indicates that the coating of a low hydrogen electrode is moisture resistant after being exposed to an environment of 80F and 80% relative humidity for a period of not less than 9 hours. Maximum specified moisturecontents are detailed in Table 10 of thespecifications.
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USABILITY DIGITS OF MAJOR CLASSIFICATIONS INDICATING TYPE OF POSITIONS AND CURRENT TYPE REQUIREMENTS
USABILITY WELDING TYPE OF CURRENT CLASSIFICATION POSITIONS AND POLARITY 10 11 12 13 14 15 16 18 19 20 24 27 28 46 48 99 F,V,OH,H F,V,OH,H F,V,OH,H F,V,OH,H F,V,OH,H F,V,OH,H F,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-down OH, H F,V-down OH, H As specified D.C. electrode positive A.C. or D.C. electrode positive A.C. or D.C electrode positive or negative A.C. or D.C electrode positive or negative A.C. or D.C electrode positive or negative D.C. electrode positive A.C. or D.C. electrode positive A.C. or D.C. electrode positive A.C. or D.C electrode positive or negative A.C. or D.C. electrode positive A.C. or D.C electrode positive or negative A.C. or D.C electrode positive or negative A.C. or D.C. electrode positive A.C. or D.C. electrode positive A.C. or D.C. electrode positive As Specified by manufacturer TYPE OF COVERING AND SLAG High cellulose High cellulose High titania viscous slag High titania viscous slag Low iron powder *Hydrogen controlled *Hydrogen controlled *Hydrogen controlled basic, low iron powder Limenite High iron oxide High iron oxide titania *Hydrogen controlled powder iron oxide *Hydrogen controlled low iron powder basic *Hydrogen controlled basic *Hydrogen controlled basic, low iron powder As Specified by
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CONTENTS
NOTE: The abbreviations, F, V, V-Down, OH, H, and H-FiIIet indicate the following welding positions: F-Flat, V-Vertical, V-down - Vertical down, OH-Overhead, H-Horizontal, H-fillet-Horizontal fillet. *Unless otherwise indicated the classification digits have wide usage amongst the Australian AS, USA (AWS), Canadian (CSA), Japanese (JIS) and the new draft ISO Standards. European Economic Community Standards (CEN). As national standards are subject to regular revision these situations could alter.

119
A GUIDE TO INTERPRETING THE AUSTRALIAN STANDARD CLASSIFICATION FOR HIGH STRENGTH STEEL MMAW The Australian/New Zealand Standard 4857 for Manual Metal Arc Welding of high-strength steesl is identical to ISO 18275 standard, and is to supersede AS/NZS 1553.2. Under the new AS/NZS 4857 standard, covered electrode can be classified based upon either yield strength and 47J minimum impact energy known as method -A, or tensile strength and 27J minimum impact energy known as method -B, which the second method is widely accepted in Australian market. For details of the complete range of classifications, please consult AS/NZS 4857. Compulsory clalssification designators Specification number Classification by tensile strength and 27J CVN requirement Covered electrode Deposit metal tensile strength. 62 indicates minimum tensile strength of 620 N/mm , other designator like 59, 69, 76, 78 or 83 is often used Type of flux coating Any other agreed chemical composition Condition of heat treatment. The symbols A and/or P are used to indicate AS/NZS 4857-B - E62 18-G A U H10 the as-welded and/or heat treated condition/s Optional supplemental Optional supplemental designators designators 47J impact energy Diffusible hydrogen. H5, H10,H15 is used to indicate at the normal a maximum diffusible 27J test temperature hydrogen content of 5,10, has also been met. and 15 ml/100g of deposited metal, respectively
CONTENTS
A selection of designators for nominal alloy weld metal compositions widely used in ISO, Australian (AS) European and American (AWS) systems of classification for electrodes and weld metal. See the appropriate Standard for the fully specified composition requirements and the location(s) of the designator in the classification.
ALLOY GROUP Carbon Molybdenum Chromium Molybdenum Steels DESIGNATOR A1 B1 B2 or B2L B3 or B3L B6 (5Cr)# B7, B7L (7Cr)# B8, B8L (9Cr)# Ni1, Ni3L or C3 Ni2, Ni2L or C1, C1L Ni3, Ni3L or C2, C2L NM D1 D2 M (eg. E7618-M) M1, M2, M3, M4 eg. F9A2ECM1-M12) EF1-EF6 series F1-F6 series K1-K7 series W, W1, W2 G, GS NOMINAL COMPOSITION REQUIREMENTS 0.40 - 0.65Mo 0.50Cr 0.5Mo 1.25Cr 0.5Mo 2.25Cr 0.5Mo 5Cr 1Mo 7Cr 5Mo 9Cr 1Mo 1 Ni 2.5 Ni 3.5 Ni 1 Ni 0.5Mo 1.5 Mn 0.35 Mo 1.8 Mn 0.35 Mo A series of Mn-Ni-Cr-Mo specified compositions for various strength levels Refer to standards SAW Electrodes SAW Weld metals FCAW Weld metals Refer to AWS Standards Ni-Cr-Cu steels typically 0.5Ni-0.5Cr 0.5Cu Composition exceeds minimum requirements in at least one specified element.
Nickel Steels Manganese Molybdenum Steels Mil. Spec. Type Low Alloy High Tensile Series, AS 1553.2 and AWS A5.23 Examples Other Low Alloy Steels of specified composition (SAW and FCAW standards Weathering Steels (Corten - Austen etc.) Alloy unspecified
L variants are a low carbon version (usually 0.05 % max) of the standard alloy carbon range # Alternative designators in some AWS standards.
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DESCRIPTION OF MMAW ELECTRODE TYPES AS CLASSIFIED BY NATIONAL AND INTERNATIONAL STANDARDS EXX10 AND EXX11 TYPES (AUSTARC 11) Electrodes of these classifications have thin coatings which contain at least 15% cellulose and up to 30% titania as rutile or titanium white. The group is characterised by a forceful, deeply penetrating, spray type arc with fairly high spatter. A voluminous gas shield is produced, as a result of decomposition of the cellulose materials in the arc region, which protects the weld metal from atmospheric contamination. High weld metal quality (including radiographic soundness) is achieved in all welding positions and the electrodes operate satisfactorily from AC or DC (electrode positive) power sources for EXX11 types and from DC (electrode positive) only for EXX10 types. EXX12 TYPE (AUSTARC 12P) Electrodes of this classification have thin coatings which contain a high proportion of titania as rutile, ilmenite or titanium white. The group is characterised by a quiet, medium penetrating arc with low spatter. The slag is viscous, full covering and easily removed when cool. General ease of handling in all welding positions and an ability to bridge gaps in work having poor fit-up are features common to this electrode type. Due to the viscous slag, many of these electrodes are suitable for use in the vertical down position. In Europe, rutile-cellulose is a common designation, while in the AWS classification sodium binders are specified. EXX13 TYPE (AUSTARC 13S) Electrodes of this classification are similar in formulation to the EXX12 group. However, basic materials are added to increase the fluidity of the slag. Similar to EXX12 electrodes, they operate with a quiet medium-penetrating arc with low spatter. The slag is fluid, full covering and easily removed when cool. The fluid slag makes this electrode ideal for fillet welding in the flat or horizontal, vertical-up and overhead welding positions. Potassium binders give improved arc stability and are specified for the AWS classification. (cont. over)
EXX14 TYPE Electrodes of the EXX14 type have medium thick coatings, containing a high proportion of titania and sufficient iron powder to ensure a deposition efficiency of 105 - 130%. They operate with a smooth, medium penetrating arc with low spatter. The slag is fairly viscous, full covering and easily removed when cool. These electrodes are suitable for both single-run and multiple-run welds in all positions and can be used to bridge gaps in work having poor fit-up. Due to the viscous slag, many of these electrodes are suitable for use in the vertical down position. EXX15 TYPE The original basic low hydrogen type is suitable for use on DC electrode positive only. Similar characteristics and application to EXX16 and EXX18. EXX16 TYPE (AUSTARC 16TC) These electrodes have a chemically basic slag, generally of the limestone-fluoride type similar to the EXX15 group but with the ability to run on AC as well as DCEP Higher arc stability is provided by the use of potassium silicate binders and other potassium bearing materials in the coating. Coating materials are inorganic, selected for minimal combined moisture and coverings are baked at a high temperature to provide low hydrogen in the arc atmosphere. Basic coated electrodes are noted for their tough low oxygen weld metals and suitability for welding a wide range of carbon and low alloy steels. The fluid full covering slag gives slight convex beads and excellent all position welding capabilities. EXX18 TYPE (AUSTARC 18TC AND AUSTARC 77) Similar coating type and operational characteristics to the EXX16, but the somewhat heavier coating contains sufficient iron powder to give increased deposition efficiency to 105-130%. This still permits all position welding on AC or DCEP but the presence of the iron powder also improves metal transfer and operational characteristics. The EXX18 group are widely used in a range of steels and critical applications where weld quality is the main requirement, particularly in all position welding. The group also serves as the major basic group for a wide range of low alloy high tensile electrodes.
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EXX19 TYPE The slag type is based on the titanium oxide-iron oxide mineral, ilmenite, and therefore has similarities to the EXX12 & 13 types but with some distinct differences. Characterised by fluid slag and forceful arc it gives Grade 1 radiographic standards, good ductility and toughness down to -20C. EXX20 TYPE A high iron oxide-manganese oxide/silicate type slag giving a spray type arc and smooth flat to concave welds. Easily removed honeycomb type brittle slag. EXX24 TYPE (AUSTARC 24) Similar slag type to EXXl2, 13 & 14 but with larger proportion of iron powder and heavier coating, approximating some 50% of electrode weight. High deposition rate, high speed runs and high efficiency in the 130 to 150% class. EXX27 TYPE Electrodes of this type have thick, heavy coatings which contain a high proportion of iron and manganese oxides and/or silicates, and sufficient iron powder to ensure a deposition efficiency greater than 130%. They operate with a vigorous, spray type arc with medium to deep penetration. The slag is fluid, voluminous, full covering and when cool well honeycombed on the underside, friable and easily removed. Electrodes of this type are suitable for high speed welding applications in the flat and horizontal-fillet positions where good penetration and easy deslagging are essential. EXX28 TYPE A heavy coated high iron powder version of the basic coated lime fluorspar EXX18 electrode. The coating usually contains approximately 50% of the weight of the electrode, restricting its use to the flat and horizontal fillet positions. EXX46 AND EXX48 TYPES Electrodes of the EXX46 and EXX48 classifications have respectively the same usability, composition and design characteristics as EXX18, except for excellent vertical-down performance.
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A GUIDE TO INTERPRETING THE AUSTRALIAN STANDARD CLASSIFICATION FOR FERRITIC STEEL GMAW ELECTRODES The standard AS/NZS 2717.1 for Gas Metal Arc Welding Ferritic Electrodes is the only AS/NZS standard for semi-automatic welding process that has not been superseded by ISO standards. Previous FCAW stand AS 2203.1 has been supersended by AN/NZS ISO 17632, 17634 and 18276. The system of classification consists of three alphanumeric groups separated by the hyphens, which may be summarised as follows. For full details of the complete range of classifications, testing, chemical, mechanical, radiographic and other requirements of the standard, please consult AS/NZS 2717.1.
2ND GROUP AS WELDED TENSILE PROPERTIES* Weld Metal Min. Tensile Min.Yield Classification Strength Strength W50XH W559H 500 MPa 550 MPa 360 MPa 470 MPa Min. Elongation on 5d 22% 19% Type of external shielding gas First digit is G for gas. C = shielding with welding grade carbon dioxide M= shielding with mixed gases. I = shielding with inert gas.
For complete details refer to AS / NZS 2717.1 3RD GROUP Weld metal properties. A indicates as-welded condition, or P after post weld heat treatment H indicates hydrogen controlled weld metal.
AS 2717.1 ES6 - GC - W 50 3 A H
FIRST GROUP - ES = Electrodes, Solid, followed by a numerical or alphanumerical code which define the chemical composition of the wire. For example Wire Class.
ES3 ES4 ES5 ES6 ES7 ESB2L ESNi2 ESD2 ESM3 ESMG ER70S-G
C
.06-.15 .07-.15 .06-.19 .06-.15 .07-.15
Mn
.90-1.40 1.00-1.50 .90-1.40 1.40-1.85 1.50-2.00
Si
.45-.75 .60-.85 .30-.60 .80-1.15 .50-.80
Other
.50-90AI-
The third digit, for carbon steel electrodes, indicates the Impact energy grade number as specified below. For low alloy, ferritic steel electrodes, the third digit is 9 and the minimum average CVN impact values are as stated in AS / NZS 2717.1. Impact Energy Grade # Z A 0 2 4 6 Min. Avrge Charpy V notch impact value Not required 47J at +20 47J at 0 47J at -20 47J at -40 47J at -60
Low carbon Cr-Mo Alloy 2.5 Ni Alloy Mn-Mo-Alloy Mn-Ni-Cr-Mil Spec Alloy o specified composition
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Refer AS / NZ 2717 for full range of classifications and compositions.
CONTENTS
A GUIDE TO INTERPRETING THE ANSI /AWS GAS SHIELDED ARC WELDING FILLER METAL SPECIFICATION The ANSI / AWS A5.18 specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding includes Metal Cored electrodes formerly classified in ANSI / AWS A5.20 and an example is illustrated to acquaint the user with information provided by the specification.While the full range of classifications can be employed with GMAW only solid rods should by used for GTAW (TIG) and PAW processes. For full details of all test requirements, radiographic standards, manufacturing tolerances, packaging etc refer to the latest edition of the standard.
LETTER DESIGNATORS AS WELDED TENSILE PROPERTIES* Min. Tensile Weld Metal Strength Classification psi MPa ER 70-X ER 70-XX 70,000 480 70,000 480 Min. Yield Strength psi Min. Elongation MPa % 22 22
ELECTRODE CLASSIFICATIONS - GAS METAL ARC WELDING FERRITIC STEEL ELECTRODES
E = Electrode R = Rod S = Solid Wire C = Composite Metal Cored Wire M = Mixed Shielding Gas C = Cabon Dioxide Shielding Gas
58,000 400 58,000 400
*Properties as detailed are appliccable for all classifications OPTIONAL DESIGNATORS Indicate diffusible weld metal hydrogen content
ER70S - 6 H4 ER70C - 6M H4
DEPOSITION PROCESS Class
ER70S-2 ER70S-3 ER70S-4 ER70S-5 ER70S-6 ER70S-7
H4 = <4mL/100g) H8 = <8mL/100g) H16 = <16mL/100g)
C
0.07 0.06-0.15 0.07-0.15 0.07-0.19 0.06-0.15 0.07-0.15
Mn
0.90-1.40 0.90-1.40 1.00-1.50 0.90-1.40 1.40-1.85 1.50-2.00
Si
0.40-0.70 0.45-0.75 0.60-0.85 0.30-0.60 0.80-1.15 0.50-0.80
Other
Ti, Zr, AI 0.50 Cu 0.50 Cu Cu, Al 0.50 Cu 0.50 Cu
DEPOSITION PROCESS Class

ER70S-2 ER70S-3 ER70S-4 ER70S-5 ER70S-6 ER70S-7 ER70S-G ER70S-3X ER70S-6X ER70SG(X) ER70SGS(X)
Ftlb
20 @ -20F 20 @ 0F N/A N/A 20 @ -20F 20 @ -20F As Agreed 20 @ 0F 20 @ -20F As Agreed N/A
J
27 @ -29F 27 @ -18F N/A N/A 27 @ -29F 27 @ -29F As Agreed 27 @ -18F 27 @ -29F As Agreed N/A
ER70S-G Agreed between the supplier & customer
WELD METAL ANALYSIS

E70C-3X 0.12 E70C-6X 0.12 1.75 1.75 0.90 0.90 0.50 Cu 0.50 Cu
E70C-G Agreed between the suppler & customer E70C-GS(X) Agreed between the suppler & customer Single figures are maximum G- general, GS = general, single pass only
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EXAMPLES: 1. AWS A5.18: ER70S-6 Indicates a solid wire electrode and filler rod. Mechanical testing of an all weld metal test plate, deposited under CO shieldng will give min. 72 ksi (500 MPa) tensile strength, 60 ksi (420 MPa) yield strength, min. 22% elongation on 4D and a charpy impact strength of 27J at - 29C. The weld will meet radiographic requirements. The wire meets a specffied chemical analysis, dimensional requirement and some additional testing where supplied as a filler rod only. 2. AWS AS.28: ER80S-B2 Indicates a solid wire electrode and filler rod. Mechanical testing of an all weld metal deposit, welded under Argon+1-5% O gas shielding is carried out after PWHT at 620C. The requirements are a min. tensile strength of 80 ksi (550 MPa) yield strength at 0.2% offset of 68 ksi (470 MPa) and an elongation 19% min. on 4D. It has to meet radiographic soundness but no impact properties are specified for this alloy. The wire, a nominal 1.25% Cr/0.5% Mo alloy must meet a specific composition analysis, dimensional requirements and some addtional requirements for supply as a filler rod only. 3. AWS A5.28: E80C-B2 A cored or composite electrode the dropping of the R indicates it meets the specification for an electrode only. It meets all the weld metal soundness and mechanical requirements specified in example 2 above but the B2 alloy specific composition is confirmed by anaysis of the deposited weld metal.
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A GUIDE TO INTERPRETING THE AS/NSZ ISO SPECIFICATIONS FOR FLUX CORED ARC WELDING The new AS/NZS ISO 17632 standard is a series of adopted ISO standards to cover Flux Cored Arc Welding (FCAW) electrodes for Non-alloy and fine grain steels. The following provides a brief introduction into the classification systems, and the standard series cover different electrode range. For full classification details, please consult the latest standards. AS/NZS ISO 18276: high strength Steels AS/NZS ISO 17634: creep resisting steels AS/NZS ISO 17633: Stainless steels. Compulsory clalssification designators Classification by tensile strength and 27J CVN requirement Tubular cored electrode Minimum tensile strength meets 550MPa Tested temperature @ -40C meets the minimum impact properties of 27J Usability designator. T5 indicates Lime-flouride flux, and generally referes to Basic flux system Welding position. 1 indicates all positional; and 0 - downhand only. Shielding gas M indicates mixed gases Indicates tested in the as welded condition chemical composition designator, N2 indicate AS/NZS ISO 17632-B - T 55 4 T5-1 M A-N2-U H5 2%Nil in deposited weld metal Optional supplemental designators
ELECTRODE CLASSIFICATIONS - FLUX CORED ARC WELDING ELECTRODES
47J impact energy at the normal 27J test temperature has also been met. Diffusible hydrogen. H5,H10,H15 is used to indicate a maximum diffusible hydrogen content of 5, 10 and 15 ml/100g of deposited metal, respectively.
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A GUIDE TO INTERPRETING THE ANSI / AWS SPECIFICATIONS FOR FLUX CORED ARC WELDING The ANSI / AWS A5.20 (Plain Carbon) and A5.29 (Low AlIoy) Electrode specifications have similar classification systems. They are shown in a combined form to acquaint the user with the information provided by the classification. For full details of all test requirements, radiographic standards, manufacturing tolerances, packaging, weld metal compositions etc., please consult the latest edition of the appropriate specification WELD METAL STRENGTH DIGITS WELD METAL COMPOSITION
The strength digits 6 and 7 in A5.20 and 6, 7, 8, 9, 10, 11 and 12 in A5.29 represent 0.1 of the min. tensile strength in ksi, eg. 8=80ksi (550MPa) 11=110ksi (760MPa) Each strength group has a min. yield strength, 12ksi (10ksi for 6 in A5.29) below the min. tensile strength and a min. elongation requirement.
Electrodes to A5.20 have a weld metal composition requirement that ensures they are plain carbon steels and do not employ an alloy suffix. Electrodes to A5.29 have specific compositions and employ the designations as shown in Table 4 of this section (Page 126). These include the A1, B2, B3, Ni1, Ni2, D1, D2, D3, K1 to K7: W types. For full details of the chemical compositions, refer to Table 1 of A5.29
TUBULAR
Flux Cored Electrode
ELECTRODE POSITIONAL CAPABILITIES
AWS A5.20 E X X T - X
AWS A5.29 E X X T X - X
0 = Flat and Horizontal 1 = All Positions
IMPACT STRENGTH USABILITY AND PERFORMANCE
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Note: A5.20 Classifications shown here are T-X, A5.29 as TX. For details of usability and performance refer to Page 135.
The A5.20 classification EXXT-1, T-5, T-6 & T-8 have min. impact requirements shown in the usability table. In A5.29 the requirement for impact testing on as-welded or PWHT specimens and the test temperature for min. 20ft-lb (27J) is specified in Table 4 against the complete classification eg. E81T1-Ni2 AW-40F (40C) E80T5-Ni2 PWHT - 75F (-60C)
ELECTRODE CLASSIFICATIONS - FLUX CORED ARC WELDING ELECTRODES

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USABILITY AND PERFORMANCE CAPABILITIES CLASSIFICATION T-1, T1 - Almost invariably a Rutile (Titania) based flux imparting smooth running, spray transfer, low spatter using CO shielding, electrode positive. Some designed for out of positioning welding when Argon/CO mixtures may be preferred. Most popular group. E7XT-1 - Has impact requirement of 20ft-lb (27J) at 0F. (-18C). T-2 - Essentially similar to T-1 but higher Mn and Si for improved single pass welding over mill scale, rust or on rimmed steel in the flat and horizontal fillet positions. T-3 - Self shielded, high speed single pass welds on sheet metal up to 5mm thick using DCEP. T-4, T4 - Self shielded, very high deposition rate with globular transfer on DCEP. Low penetration, desulphurised welds, resistant to cracking, can be used on poor fit up. Suitable single or multiple run in flat and horizontal positions. T-5, 15 - Lime Fluoride basic flux for high toughness and crack resistance using DCEP and CO shielding. Argon/CO mixtures may be preferred for some applications.Globular transfer, convex beads (similar E7016-18 electrodes) for critical flat and horizontal fillet welds. Impact requirement for EXXXT-5 is 20ft-lb. (27J) at -20F (-29C). T-6 - Self shielded, DCEP, spray type transfer for single or multiple pass welding in flat or horizontal positions. Provides good low temperature impact properties 20ft-lb (27J) at -20F (-29C) and root penetration, easy slag removal in flat and horizontal positions. Single or multipass welds, T-7 - Self shielded, DCEN, single and multipass pass welds with desulphurising slag giving crack resistant welds. Larger sizes give high deposition rates, small sizes provide all position welding. T-8, T8 - Self shielded, DCEN, all position welding, single and multipass. The slag system produces good impact properties (T8 min. 20ft-lb (27J) at -20F (-29C). and a desulphurised weld metal resistant to weld cracking. T-10 - Self shielded, DCEN, single pass welding at high travel speeds in the flat, horizontal, down slopes (to 20). T-11 - Self shielded, DCEN, with a smooth spray arc, General Purpose electrodes for single and multipass welding in all positions and high travel speed welding. T-G, TX-G - A classification for new multipass electrodes not covered by any of the above. T-GS - A classification for new single pass electrodes not covered by any of the presently defined classifications.
STANDARDS AUSTRALIA AND THE ANSI/AWS SPECIFICATION STANDARDS FOR STAINLESS STEEL AND ALUMINIUM ALLOY ELECTRODES The new AS/NZS standards offer two classification systems, which are according to nominal composition (-A) and alloy type (-B) respectively. In Australia market, the B system is widely accepted and substantially the same to AWS standards.The following provides a brief introduction into the classification systems employed and the information they provide to the user. These are: ANSI/AWS A5.4 - Stainless Steel MMAW ELECTRODES - AS/NZS 4854 ANSI/AWS A5.9 - Stainless Steel GMAW ELECT. - AS/NZS ISO 14343 ANSI/AWS A5.10 - Al./Al. Alloy GMAW - AS/NZS ISO 18273 For full details of the manufacturing tolerances, testing requirements, packaging, chemical composition and other aspects of the standard specifications, please consult the latest edition of the appropriate above standard. 1. CORROSION-RESISTING CHROMIUM AND CHROMIUMNICKEL STEEL ELECTRODES (a) MMAW COVERED ELECTRODES - AS/NZS 4854-B and ANSI/AWS A5.4 The basis of these classifications is the chemical composition and mechanical properties of the deposited metal, the coating type and current.The system of designation is as follows: ELECTRODE E
X X X - X
ALLOY DESIGNATION COATING TIME
An alphanumeric system of alloy designation almost universally employed. eg. 308, 316L, 309Mo, 310 etc.
-15 DC Electrode Positive Lime Type -16 AC or DCEP Lime or Rutile Type -17 AC or DCEP Acid Rutile Type -25 DC EP Heavy Coated Lime Type -26 AC or DCEP Heavy Coated Rutile Type
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The -17, -25, and -26 suffixes are recent additions to the classifications. The -17 is a more siliceous version of the -16. The -25 and -26 coatings are designed for flat and horizontal welding and are generally synthetic versions using lower alloyed or plain carbon core wires. (b) GMAW ELECTRODES The Standards Australia AS/NZS ISO 14343 for gas metal arc electrodes bases its classification of the electrode range on the composition of the solid wire. This is followed by the commonly employed alphanumeric designation of the chromium nickel steel, the actual composition of which is specified in the standard.
No mechanical properties are specified. The ANSI/AWS A5.9 Specification covers solid wires, and metal cored, stranded or composite wires and again bases its classification on the chemical composition of the solid wires or a fused sample of the cored or composite wires. This specification covers electrodes or filler metals for GMAW, GTAW or SAW processes. For this reason, no mechanical testing requirements are specified. The designations in the classifications differ slightly. 2. ALUMINIUM AND ITS ALLOYS GMAW ELECTRODES The AS/NZS ISO 18273 and ANSI / AWS A5.10 standards specifications for Aluminium and Aluminium alloys GMAW electrodes (and in the case of A5.10, filler rods) both base their classification on the chemical composition of the solid wire. The alloy is designated by an internationally accepted system involving a four digit number, the first indicating the aluminium content or the main alloying element, Of these, the following are employed in welding as electrodes or filler rods, viz. 1XXX = 2XXX = 4XXX = 5XXX = Aluminium content 99% min. Copper is main alloying element Silicon is main alloying element. Magnesium is main alloying element.
ELECTRODE CLASSIFICATIONS - MANUAL METAL ARC & GAS METAL ARC WELDING
The second digit indicates modifications to the basic alloy or impurity limits while the third and fourth digits identity the aluminium alloy or indicate the aluminium purity.
A prefix of E indicates an electrode wire in the Australian Standard and ER indicates Electrode/Filler Rod in the ANSI / AWS System.
Example:- E5356 and ER5356 are classifications for a popular 4.5-5.5% Mg aluminium alloy with minor additions of Mn, Cr and Ti and limits on Si,Fe,Cu,Zn and others.
Modifying the alloy designation to 5556 indicates mainly a rise in Mn level from approximately 0.1 to 0.5-1.0% and marginally higher aim value for Mg and Zn (0.1 max to 0.25 max.), which results in a higher tensile strength deposit. Alloy E5183 and ER5183 has become a popular filler metal used in the fabrication of marine passenger, car ferry and pleasure craft. It is a modification of the 5356 alloy with increases in Si, Mn and Zn and is particularly suitable for welding 5083 alloy in marine applications because of the higher tensile strength weld metal. The composition of the wires in both standards are almost identical with slightly narrow tolerance on Beryllium content from AWS standard and an electrode fully meeting the requirements of AWS A5.10 will be deemed to be qualied to the AS/NZS ISO 18273.
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A GUIDE TO INTERPRETING THE AUSTRALIAN ANDNEW ZEALAND SPECIFICATION FOR REPAIR AND HARDFACING CONSUMABLE The AS/NZS 2576 Welding Consumable for Build-Up and Wear Resistance is based on the Welding Technology Institute of Australia (WTIA) Technical Note 4. The standard classifies consumables by alloy type, deposit hardness, welding process and consumable type. For complete details of the consumable classifications please refer to the latest edition of AS/NZS 2576. 1ST = ALLOY GROUP
1 = Steels 2 = Chromium white irons 4 = Cobolt alloys 5 = Nickel alloys 3 = Tungsten carbide composites
ELECTRODE CLASSIFICATIONS - REPAIR AND HARDFACING
2ND DIGIT = ALLOY TYPE
In combination with the first digit it indicates the specific type of alloy whithin a group. 23XX = Austenitic chromium-carbide iron
6 = Copper alloys
2360 - A4
3RD & 4TH DIGIT = DEPOSIT HARDNESS

Indicates mean undiluted deposit hardness prior to any heat treatment or work in service. Hardness is expressed in Rockwell C (HRC) units. ie. XX60 = 60-65 HRC
DEPOSITION PROCESS
The letter indicates the welding process. A = Manual Metal Arc Welding C = Gas Welding
B = Submerged Arc Welding and Flux Cored Arc Welding
5TH DIGIT = CONSUMABLE TYPE A1 = Tubular electrode no alloy contribution from the flux coating. A4 = Low carbon steel core wire alloy additive flux coating. B1 = Tubular wire no alloy. contribution from the flux coating. B5 = Gas shielded tubular flux core wire. B7 = Self shielded tubular flux core wire. C1 = Filler Rod. C3 = Powder.
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A GUIDE TO INTERPRETING THE AUSTRALIAN STANDARD CLASSIFICATION FOR SUBMERGED ARC WELDING ELECTRODES AND FLUXES The Australian Standard for electrodes and fluxes for SAW, AS 1858.1 (C and C-Mn Steels) published by Standards Australia and its classification system has strong similarities with the ANSI / AWS SAW specifications, particularly in relation to electrode and alloy weld metal designations and compositions. The following provides a guide to the designations and layout of the classification systems (shown in combined form) to acquaint the user with the information provided by the classifications. For full details of the complete range of classification testing requirements, chemical, mechanical, radiographic and other requirements of the standard, consult AS 1858.1. EXAMPLE: AS1858.1 EL12-FMM-W404 is a complete designation. It refers to a flux and wire combination that will produce weld metal which in the as-welded condition, will have a tensile strength no lower than 430 MPa and Charpy V-notch impact strength of a minimum of 35J at -40C when deposited with an EMK12 electrode under the conditions called for in this specification.
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ELECTRODE CLASSIFICATIONS - SUBMERGED ARC WELDING ELECTRODES AND FLUXES
A GUIDE TO INTERPRETING THE AUSTRALIAN STANDARD CLASSIFICATION FOR SUBMERGED ARC WELDING ELECTRODES AND FLUXES
ELECTRODE AND WELD METAL DESIGNATIONS AND COMPOSITIONS Electrode
EL8 EL12 EM12K
Mn
Si
0.10max 0.25/0.60 .0.07max 0.05-0.15 0.25/0.60 0.07max 0.05-0.15 0.80/1.25 0.10/0.35
FLUX APPLICATION S = Single Run M = Multi Run B = Basic Flux G = General Purpose
HYDROGEN A suffix indicating hydrogen controlled weld metal may be added when max. H2 level is established. (AS 3752 - 1996) H15 <15mL/100g H10 <10mL/100g H5 <5mL/100g of deposits of metal
Note: A small selection only of carbon steel electrodes. For full list and details refer tothe appropriate part of the standard FLUX CONTRIBUTION TO WELD ANALYSIS L = Low Mn & Si A = Alloys other than M = Medium Mn & Si Mn & Si and added to L, H = High Mn & Si M or H eg.LA, MA or HA
E or EC XXX - F X X - W XX X X
ELECTRODE (SOLID) FLUX WELD METAL
X HX
ELECTRODE COMPOSITE (CORED)
HEAT TREATMENT A+ Tested As Welded P=Tested Post Weld heat treated
WELD METAL STRENGTH DIGITS The strength digits 40 and 50 in part 1 of AS 1858 represent one-tenth of the approximate min. tensile strength in MPa of the tensile range. Each strength level also has a min. Proof Stress (0.2% Offset) and Elongation requirements specified by this standard.
IMPACT ENERGY NUMBER 0 = No impact required 1-5 = test temperature of +20C to -60C in 20 intervals. Energy Requirement W40X = 35J W50X = 40J WXXX = 27J
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WELD DEPOSITION AND COSTING DATA

Weld costing systems differ throughout the world and between companies in similar operations but with different methods of cost accounting. Some variations in systems are due to variations in methods of selling consumables. For example, MMAW consumables may be sold by the number, length or mass of the electrodes. However, all systems invariably rely on a basic philosophy of determining the quantity (in kg.lb, m etc) of consumable required to produce a given volume of joint. From this, the labour time for joint completion, based on the deposition rate and duty cycle estimates for the welding consumables/processes, welding positions and workshop/site situations, in question, can be determined. The costs of joint preparation and finishing must also be considered, and like the other factors mentioned can be substantially influenced at the design stage. The lowest welding costs are achieved when full use is made of the high productivity welding processes and when joints are designed specifically for these processes. Australia sells all major solid (and some gas) welding consumables by mass (kg), and all requirements can be related back to the mass of added weld metal required to produce a unit length of joint. Most well equipped welding shops have a range of processes, particularly MMAW, GMAW and SAW machines, and the following approach to weld costing is based on a system which can integrate the various methods and allow for substitution as desired. THE WIA APPROACH TO WELD COSTS DETERMINATIONS TO ASSIST YOU IN ESTIMATING WELDING COSTS WE HAVE PUT TOGETHER THE FOLLOWING GUIDE IN FOUR SECTIONS. A COMPREHENSIVE GUIDE TO USING SECTIONS 1-4 The mass of weld metal in a length of joint is a product of its volume (cross-sectional area x length) and its density. Most weld joint cross-sections can be broken up into basic shapes as detailed below and illustrated in Figure 10
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WELD DEPOSITION AND COSTING DATA - USERS GUIDE
RECTANGULAR CROSS SECTIONS TRIANGULAR CROSS-SECTIONS REINFORCMENT CROSS-SECTIONS
Major area of the square, vee and U joints and roof gap components. Major areas of vee and bevel joints, fillet sections 1 Semi-elliptical shapes of predictable or measurable heights and widths reinforcing the weld face. Part circle segments associated with U and J joints The carbon arc electrode selected Or gas nozzle) determines the width, while the rate of travel and angle determines the depth of gouge. Areas of predicable contours are covered. A range of fillet sizes and shapes including convexity and concavity allowances.
TABLE 1.0 TABLE 1.1 TABLE 1.2
RADIUS CROSS-SECTIONS
TABLE 1.3
BACK GOUGED CROSS-SECTIONS
TABLE 1.4
FILLET WELD SECTIONS
TABLE 1.5
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Side A fA hA 1/2 L
W=2r
Side b
d2
hB fB
Figure 10
TABLES 1.0-1.5 of SECTION 1 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 you can calculate the area. 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 mm 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 mm, and multiplying by .00785 will give the mass of weld metal per metre of joint, in kg/m.
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A COMPREHENSIVE GUIDE TO USING SECTIONS 1-4 CONT. Quantity of consumables data, tabled in section 2, allows the quantity of consumable(s) required to weld a given joint, to be calculated. Further to this, the DEPOSITION RATE and Duty Cycle data of sections 3 & 4 enable realistic estimates of actual welding speeds and times to be determined for specific consumables/welding processes, welding positions and workshop/site situations. Detailed practical examples, illustrating the use of information contained in Sections 2-4 are featured respectively in Guides 2-4. BY FOLLOWING THE GUIDES THROUGH FROM 1-4 THE USER IS GIVEN A STEP-BY-STEP METHOD FOR DETERMINING: 1. the mass of weld metal required per metre of joint 2. the quantity of consumable(s) required per metre of joint 3. the continuous (100% duty cycle) welding speed/time for one metre of joint 4. a realistic estimate of the actual welding speed/time to complete one metre of joint. GUIDE 1 - DETERMINE MASS OF WELD PER METRE USING TABLES 1.0 - 1.5 OF SECTION 1 (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 = 10 (therefore, included angle is 20) r (root radius) = 10 mm d (root face) = 8 mm With a root face (d) of 8 mm and a root radius (r) of 10 mm, the depth of the rectangular and triangular sections (d) will be, d = T - (d + r) = 60 - 18 = 42 mm. The width of the rectangle (w) is of course equal to 2r = 20 mm. Side A Rectangular, Triangular and Radius Cross-Sections
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 20 and a depth of 42 mm will need a mass of weld metal per meter 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.. ................................................................................1.23 kg/m (D).
GUIDE 1 CONT. SIDE A REINFORCEMENT CROSS-SECTION The reinforcement width of Side A (fA ) will be the addition of 2r (20mm) and L (15mm, taken from TABLE 1.1) plus whatever overlap onto the parent metal is considered desirable practice. For this example, assume an average overlap of 3mm 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).
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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 electrode 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 .......................................................... 0.86kg/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 (f8) 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
GUIDE 2 - DETERMINE QUANTITY OF CONSUMABLES REQUIRED PER METRE USING TABLES 2.0 - 2.3 OF SECTION 2 Given the mass of weld metal required to Fill a metre of joint, the next step is to determine the mass of consumable(s) initially required. The weld metal yield achieved from welding with a consumable electrode or filler wire largely depends on the efficiency of the welding process / consumable in question. This efficiency is influenced by such inherent wastage factors as, weld metal spatter, slag coverage and gas plume production. The Quantity of consumables figures listed in tables 2.0-2.3 are for a weld metal yield of 1 kg and take account of these inherent losses. An additional percentage (listed in the EXTRA FOR WASTAGE column) is usually added to allow for typical shop wastage such as stub ends & wire snips etc.

PRACTICAL EXAMPLE 1 CONTINUED For the U-joint discussed in EXAMPLE 1 of GUIDE 1 let us assume that 1.6 mm Austfil 71T with CO shielding gas is used for the single root pass weld on Side A and for welding the entire back gouged section on Side B; and a SAW process using 4.0mm wire is used for the remainder of the joint. AUSTFIL 71T REQUIREMENTS (NOT INCLUDING ALLOWANCE FOR SHOP WASTAGE) Side A. Allow .25 kg of weld metal/metre of joint for the root pass deposit (assuming that a single pass with a 1.6 mm Austfil 71T is comparable in size to an 8 mm fillet weld). Side B. From Guide 1, the mass of weld metal per metre of joint for the back gouged cross-section (including reinforcement) is 1.05 kg/m. (0.86 +0.19)Therefore, the total weld metal required from Austfil 71T is 1.05 + 0.25 = 1.30 kg/m. From table 2.2 type A, 1.20 kg of Austfil 71T will produce 1 kg of weld metal. Therefore, 1.20 x 1.30 = 1.56kg of Austfil 71T will produce 1.30 kg of weld metal per metre of joint. CO Shielding Gas Consumption To estimate CO gas consumption let us assume, the 1.6mm Austfil 71T is deposited at 350 Amps and 29 Volts, which will produce a weld metal deposition rate of approx 5.4 kg/hr (see table 3.2 part B of section 3). GUIDE 2 CONT. For a CO flow rate of 12 L/min approximately 0.13m (or .24kg) of CO gas will be consumed per kg of weld metal deposited (see table 2.2). Therefore, 1.30 x 0.13 = 0.17 m3 (or .32 kg) of CO will be used to deposit 1.30 kg of weld metal per metre of joint. SAW FILLER METAL AND FLUX REQUIREMENTS (NOT INCLUDING ALLOWANCE FOR SHOP WASTAGE) The wire/flux submerged arc combination is required to produce 12.12 - 1.30 = 10.82 kg of weld metal per metre of joint. From table 2.3 approximately 1.02 kg of wire will produce 1 kg of weld metal. Therefore, 1.02 x 10.82 = 11.04 kg of wire will produce 10.82 kg of weld metal per metre of joint. Also from table 2.3 approximately 1.1 kg of flux is required to produce 1 kg of weld metal. Therefore, 1.1 x 10.82 11.90 kg of flux will be consumed to produce 10.82 kg of weld metal per metre of joint.In the summary, the quantity of consumables required to complete one metre of joint are:
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1.6 kg of 1.6 mm Austfil 71T wire 0.2 m (0.3 kg) of CO shielding gas 11.0kg of wire 11.9 kg flux not including allowances for shop wastage. GUIDE 3 - DETERMINE 100% DUTY CYCLE WELDING SPEED TIME USING TABLES 3.0 - 3.6 of SECTION 3 From the Deposition Rate data in tables 3.0 - 3.6 of section 3 for the selected consumables and arc processes, the continuous welding speed (in m/hr) and welding time (in hr/m) can be determined. Where deposition conditions are substantially varied for different sections of a joint - for example narrow root passes versus wide weave capping passes, the welding speed should be calculated separately rather than an average taken. PRACTICAL EXAMPLE 1 CONTINUED For the U-joint discussed in example 1 of guides 1 and 2 let us assume the 1.6 mm Austfil 71T (used for the single root pass weld on Side A and for welding the entire back gouged section on Side B) is deposited at 350 amps and 29 volts under CO shielding gas with an electrode stickout of 25 mm. From table 3.2, part B, the typical deposition rate is 5.4 kg/hr. As calculated in guide 2, the wire requirements is 1.30 kg of weld metal per metre of joint. Therefore the welding speed for Austfil 71T will be 5.4 1.30 = 4.15 metres of joint/hour or the welding time will be 0.24 hours/metre of joint. For welding the remainder of the joint with SAW process, assume a welding current of 700 amps and voltage of 34 volts for the 4 mm wire nominated. From table 3.3 the typical deposition rate is approximately 8.3 kg/hr. As determined in guide 2, the wire/flux combination is required to produce 10.82 kg of weld metal per metre of joint. Therefore, the welding speed will be: 8.3 10.82 = 0.77 metres of joint/hour or the welding time will be 1.30 hours/metre of joint. 10.82From the calculated welding time for continuous welding of the Austfil 71T /CO and SAW process combinations, the total welding time is .24 + 1.30 = 1.54 hours/ metre of joint. In summary, given a duty cycle of 100%, (that is continuous, uninterrupted, welding of the consumables detailed in this example) one metre of joint will be completed in 1.54 hours.

GUIDE 4 DETERMINE REALISTIC ESTIMATE OF WELDING SPEED/TIME USING THE DUTY CYCLE DATA OF SECTION 4 The continuous welding speeds and welding times, (That is for a Duty Cycle of 100%) calculated in practical example 1 of guide 3 serve as a starting point for determining realistic welding speeds and welding times for joint completion.
As stated in section 4, Duty Cycle is a measure of the arc on time as a percentage of the total time elapsed. The total elapsed time must take into account all additional non-arc operations, such as materials handling, weld deslagging, electrode changes overs etc and personal allowances, as well as the total arc-on time. In order to arrive at realistic welding speeds and times which will approach the actual figures achieved, it is important to use duty cycle estimates which are realistic for the consumable/arc process combinations and workshop/site in question. The choice of a satisfactory duty cycle may be determined by referring to past records for workshop or site projects undertaken using similar welding consumables and arc processes under similar working conditions. Since detailed information of this nature is often unavailable, a suitable duty cycle figure may be arrived at by using published data and/or by educated guessing.
section 4 entitled Duty Cycles details a range of achievable duty cycles for the main arc welding processes used. The duty cycles given under each heading are generally accepted as maintainable by most reasonably equipped workshops or welding sites. To continue practical example 1 from guide 3, let us assume from the information in parts (b) and (c) of SECTION 4; a duty cycle of 30% for the FCAW process a duty cycle of 40% for the SAW process
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Therefore, a realistic estimate of the welding speed for Austfil 71T/CO is 4.15 x .30 = 1.25 metres of joint/hour, and the welding time is 0.80 hours/metre of joint; and a realistic estimate of the welding speed for SAW process is 0.77 x .40 = 0.31 metres of joint/hour, and the welding time is 3.25 hours/metre of joint.
FROM THE CALCULATED WELDING TIMES FOR THE FCAW AND SAW COMBINATIONS THE TOTAL WELDING TIME TO COMPLETE ONE METRE OF JOINT IS 0.80 + 3.25 = 4.05 HRS. This welding time will be a good approximation of the actual time to complete one metre of join given that the duty cycle estimates used are realistic for the welding task involved.
PRACTICAL EXAMPLE 2 If, for the joint described in example 1, the initial two passes on Side A and all of Side B is welded with MMAW electrodes, Austarc 77 and Austarc 24 -instead of Austarc 71T; and the remainder of the joint is welded with SAW process, the following variations could take place.
Side A. The initial two passes with 4 mm Austarc 18TC will deposit 2 x .14 = .28 kg of weld metal per metre of joint (assuming, a single pass with 4 mm Austarc 18TC is comparable to a 5 mm fillet, see section 1, Table1.5). The remainder of Side A is to be welded with SAW process. Side. The first pass welded with 4 mm Austarc 18TC will deposit .14 kg of weld metal per metre of joint. The remainder of Side B is to be complete with 5 mm Austarc 24.
GUIDE 4 CONT. 4 MM AUSTARC 18TC REQUIREMENT The total mass of weld metal required from 4 mm Austarc 18TC is .28 + .14 = .42 kg per metre of joint. At a typical current setting of 170 amps, the deposition rate (at 100% duty cycle) is 170 x .01 = 1.70 kg/hr (see section 3 table 3.0) Therefore, the continuous welding time to deposit .45 kg of weld metal with 4 mm Austarc 18TC is. .42 = 0.25 hours/metre of joint 170
Assuming a duty cycle of 25% (see section 4), a realistic estimate of the actual welding time is .25 = 1,00 hours/metre of joint .25
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5 MM AUSTARC 24 REQUIREMENT The remainder of Side B requires 1.05 - 0.14 = 0.91 kg of weld metal per metre of joint, deposited with 5 mm Austarc 24. At a typical current setting of 300 amps, the deposition rate (at 100% duty cycle) is 300 x 0.135 = 4.05 kg/hr (see section 3, table 3.0) Therefore, the continuous welding time to deposit 0.92 kg of weld metal with 5 mm Austarc 24 is 0.91 = 0.22 hours/metre of joint 4.05 Assuming a duty cycle of 30% (see section 4), a realistic estimate of the actual welding time is .22 = 0.73 hours/metre of joint .30 SAW CONSUMABLE The remainder of Side A requires 11.07 - .28 = 10.79 kg of weld metal per metre of joint. A typical current and voltage setting of 700 amps and 34 volts, for the 5 mm SAW wire nominated will produce a typical deposition rate (at 100% duty cycle) of 8.3 kg/hr (see section 3, table 3.3) Therefore, the continuous welding time to deposit 10.72 kg of weld metal with 5 mm wire is 10.79 = 1.30 hours/metre of joint 8.3 Assuming a duty cycle of 40% (see SECTION 4), a realistic estimate of the actual time is
For Example 2, The Total Welding Time To Complete One Metre Of Joint May Be Summarised As Follows: 4mm Austarc 18TC (at 25% duty cycle) - 1.00 hrs/metre of joint 5mm Austarc 24 (at 30% duty cycle) - 0.73 hrs/metre of joint 5mm wire/flux combination (at 40% duty cycle) - 3.25 hrs/metre of joint Estimate of actual welding time to complete joint 4.98 hrs/metre of joint
1.30 = 3.25 hours/metre of joint .40
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SIMPLY, MULTIPLY D X W FOR CROSS-SECTIONAL AREA (MM ) AND READ DIRECTLY FROM THE TABLE. WHERE A SECTIONAL OR TOTAL JOINT AREA IS ALREADY KNOWN IN SQUARE INCHES, MULTIPLY BY 645.2 FOR MM AND USE THIS TABLE. This table provides the mass of steel weld metal per metre of joint (kg/in) for known cross-sectional areas.Simply, multiply d x w for cross-sectional area (mm ) and read directly from the table. Where a sectional or total joint area is w already known in square inches, multiply by 645.2 for mm and use this table.
50 0.39 1.18 1.96 2.75 3.53 4.32 5.10 5.89 6.67 7.46 8.24 8.32 8.40 7.54 7.61 7.69 8.48 6.75 6.83 6.91 5.97 6.04 6.12 6.20 6.99 7.77 8.56 d d w 5.18 5.26 5.34 5.42 w 4.40 4.47 4.55 4.63 3.61 3.69 3.77 3.85 2.83 2.90 2.98 3.06 d w 2.04 2.12 2.20 2.28 1.26 1.33 1.41 1.49 0.47 0.55 0.63 0.71 60 70 80 90 d
AREA (mm )
10
20
30
40
0.08
0.16
0.24
0.31
100
0.79
0.86
0.94
1.02
1.10
200
1.57
1.65
1.73
1.81
1.88
300
2.36
4.43
2.51
2.59
2.67
400
3.14
3.22
3.30
3.38
3.45
500
3.93
4.00
4.08
4.16
4.24
600
4.71
4.79
4.87
4.95
5.02
700
5.50
5.57
5.65
5.73
5.81
RECTANGULAR WELD CROSS-SECTIONS TABLE
800
6.28
6.36
6.44
6.52
6.59
900
7.07
7.14
7.22
7.30
7.38
1000
7.85
7.93
8.01
8.09
Where increments of less than 10 mm are considered necessary, add to the above, on the basis of .008 kg/in for every 1 mm .
8.16
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MASS OF WELD METAL IN JOINT

TABLE 1.1 TRIANGULAR WELD CROSS-SECTIONS SECTION SHAPES AND ANGLES
30 L 45 L d 20 L 30 L
MASS OF STEEL WELD METAL PER METRE OF JOINT (kg/m) Depth d (mm) 6 8 10 12 14 16 20 22 24 26 28 30 35 40 45 50 55 60 70 75 80 Width L (mm) 3.5 4.6 5.8 6.9 8.1 9.2 11.5 12.7 13.9 15.0 16.2 17.3 20.2 23.1 26.0 28.9 31.8 34.6 40.4 43.3 46.2 kg/m 008 0.14 0.23 0.32 0.45 0.58 0.90 1.10 1.31 1.53 1.78 2.04 2.77 3.63 4.59 5.67 6.86 8.15 11.10 12.75 14.51 Width L (mm) 6.0 8.0 10.0 12.0 14.0 16.0 20.0 22.0 24.0 26.0 28.0 30.0 35.0 40.0 45.0 50.0 55.0 60.0 70.0 75.0 80.0 kg/m 0.14 0.25 0.39 0.57 0.77 1.00 1.57 1.90 2.26 2.65 3.08 3.53 4.81 6.28 7.95 9.81 11.87 14.13 19.23 22.08 25.12 Width L (mm) 2.1 2.8 3.5 4.2 4.9 5.6 7.1 7.8 8.5 9.5 9.9 10.6 12.3 14.1 15.9 17.6 9.4 21.2 24.7 26.4 28.2 kg/m 005 0.09 0.14 0.20 0.27 0.35 0056 0.67 0.80 0.94 1.09 1.25 1.69 2.21 2.81 3.45 4.19 5.99 6.79 7.77 8.85 Width L (mm) 3.2 4.3 5.4 6.4 7.5 8.6 10.7 11.8 12.9 13.9 15.0 16.1 18.8 21.4 24.1 26.8 29.5 32.2 37.5 40.2 42.9 kg/m 0.08 0.14 0.21 0.30 0.41 0.54 0.84 1.02 1.22 1.42 1.65 1.90 2.58 3.36 4.26 5.26 6.37 7.58 10.30 11.83 13.47
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WELD DEPOSITION & COSTING DATA - MASS OF WELD METAL IN JOINT
TABLE 1.1 TRIANGULAR WELD CROSS-SECTIONS CONT. SECTION SHAPES AND ANGLES
50 L 60 L 70 L d 90 L d MASS OF STEEL WELD METAL PER METRE OF JOINT (kg/m) Depth d (mm) 6 7.5 10 12 14 16 20 22 24 26 28 30 35 40 45 50 55 60 70 75 80 Width L (mm) 5.6 7.5 9.3 11.2 13.1 14.9 18.7 20.5 22.4 24.2 26.1 28.0 32.6 37.3 42.0 46.6 51.3 56.0 65.3 69.9 74.6 kg/m 0.13 0.24 0.37 0.53 0.72 0.94 1.47 1.77 2.11 2.47 2.87 3.30 4.48 5.86 7.42 9.15 11.07 13.19 17.94 20.58 23.42 Width L (mm) 6.9 9.2 11.5 13.9 16.2 18.5 23.1 25.4 27.7 30.0 32.3 34.6 40.4 46.2 52.0 57.7 63.5 69.3 80.8 86.6 92.4 kg/m 0.16 0.29 0.45 0.65 0.89 1.16 1.81 2.19 2.61 3.06 3.55 4.07 5.55 7.25 9.18 11.32 13.71 16.32 22.20 25.49 29.01 Width L (mm) 8.4 11.2 14.0 16.8 19.6 22.4 28.0 30.8 33.6 36.4 39.2 42.0 49.0 56.0 63.0 70.0 77.0 84.0 98.0 105.0 112.0 kg/m 0.20 0.35 0.55 0.79 1.08 1.41 2.20 2.66 3.17 3.71 4.31 4.95 6.73 8.79 11.13 13.74 16.62 19.78 26.93 30.91 35.7 Width L (mm) 12.0 16.0 20.0 24.0 28.0 32.0 40.0 44.0 48.0 52.0 56.0 60.0 70.0 80.0 90.0 100.0 110.0 120.0 140.0 150.0 160.0 kg/m 0.28 0.50 0.79 1.13 1.54 2.01 3.14 3.80 5.42 5.31 6.15 7.07 9.62 12.56 15.90 19.63 23.75 28.26 38.47 44.16 50.24 d
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TABLE 1.2 WELD REINFORCEMENT CROSS-SECTIONS
F
Depth, d (mm) 6 8 10 12 14 16 20 22 24 26 28 30 35 40 45 50 h=1.0mm 0.04 0.05 0.06 0.07 0.09 0.10 0.12 0.14 0.15 0.16 0.17 0.18 0.22 0.25 0.28 0.31 h=1.5mm 0.06 0.07 0.09 0.11 0.13 0.15 0.18 0.20 0.22 0.24 0.26 0.28 0.32 0.37 0.42 0.46 h=3.0mm
MASS OF STEEL WELD METAL PER METRE OF JOINT (kg/m) REINFORCEMENT HEIGHT, h. h=4.5mm h=6.0mm
0.18 0.22 0.26 0.30 0.37 0.41 0.44 0.48 0.52 0.55 0.65 0.74 0.83 0.92
0.28 0.33 0.39 0.44 0.55 0.61 0.67 0.72 0.78 0.83 0.97 1.11 1.25 1.39
0.74 0.81 0.89 0.96 1.04 1.11 1.29 1.48 1.66 1.85
Note. For face widths in excess of 50 mm, estimate average height of reinforcement and calculate as for a rectangle, referring to table 1.0
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TABLE 1.3 RADIUS WELD CROSS-SECTIONS
Radius r (mm) 3 4 5 6 7 8 9 10 11 12 13 14 15 MASS OF WELD METAL PER METRE OF JOINT (kg/m) 0.11 0.20 0.31 0.44 0.60 0.79 1.00 1.23 1.49 1.18 2.08 2.42 2.77 U 0.06 0.10 0.15 0.22 0.30 0.39 0.50 0.62 0.75 0.89 1.04 1.21 1.39 MASS OF WELD METLEL PER METRE OF JOINT (kg/m) 0.06 0.12 0.15 0.30 0.31 0.52 0.94 0.96 1.36 1.48 2.77 depth J
U J r
Depth r (mm) 1.5 2.5 3.5 4 5 7 8 10 10 12 15
Width (mm) 6 8 7 12 10 12 19 14 22 20 30
Area (mm) 7.07 15.71 19.24 37.70 37.27 65.97 119.38 109.96 172.79 188.50 353.43
1/2 width
Note. Note: Appropriate reinforcement additions, selected from table 1.2, will generally be required to be added to the above figures.
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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 a typical concave profile. The figures are based on actual leg length being maintained. Note that the leg lengths shown are not applicable to the concave welds which are designated in this table by throat thickness.
WELD SIZE Leg Length, L (mm) 3.2 3.5 4.0 4.8 5.0 5.6 6.0 6.4 7.0 8.0 9.5 10.0 12.7 15.9 19.0 22.2 24.4 (inch) 1/8 5/32 3/16 7/32 1/4 ~5/16 3/8 Throat Thickness T (mm) 2.3 2.5 2.8 3.4 3.5 4.0 4.2 4.5 4.9 5.7 6.7 7.1 7.1 11.2 13.4 15.7 18.0 Cross- sectional Area (mm) 5.1 6.1 8.0 11.5 12.5 15.7 18.0 20.5 24.5 32.0 45.1 65.0 50.0 126.4 180.5 246.4 322.6
5/8 ~3/4 7/8 1.0
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h L
Flat and Convex Welds h=0 (There.) .04 .05 . 06 .09 .10 .12 .14 .16 .19 .25 .36 .39 .63 .99 1.42 1.93 2.53 h=1.0mm .07 .08 .09 .13 .14 .17 .19 .22 .25 .32 .44 .48 .74 1.13 1.59 2.13 2.75 h=1.5mm .08 .10 .11 .15 .17 .19 .22 .24 .28 .35 .48 .52 .80 1.20 1.67 2.23 2.86 h=2.5mm .57 .61 .91 1.34 1.84 2.42 3.08
MASS OF WELD METAL PER METRE (kg/m) Throat Thickness T (mm) 2.3 2.5 2.8 3.4 3.5 4.0 4.2 4.5 4.9 5.7 7.7 7.1 9.0 11.2 13.4 15.7 18.0 Convex Welds Typical Concave Weld 0.05 0.06 0.07 0.10 0.11 0.13 0.15 0.17 0.21 0.27 0.39 0.42 0.68 1.06 1.52 20.6 2.70
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QUANTITY OF CONSUMABLES REQUIRED

The QUANTITY OF CONSUMABLE figures listed in TABLES 2.0 - 2.3 are for a weld metal production of 1kg and to take into account inherent wastage losses such as weld metal spatter, slag coverage, and gas plume production. An additional percentage (listed in the EXTRA FOR WASTAGE column) is usually added to allow for typical shop wastage such as stub ends and wire snips etc.To obtain the quantity of consumable required to produce 1kg of weld metal read directly from tables 2.0 - 2.3 for the appropriate consumable, shielding gas, arc transfer mode etc. TABLE 2.0 MANUAL METAL-ARC WELDING (MMAW)
CONSUMABLES TYPE High Efficiency (150%), Iron Type Electrodes EXX24, 27 & 28 to AS/NZS 4855 ELECTRODE LENGTH (mm) 450 380 450 380 380 QUANTITY OF CONSUMABLES EXTRA FOR WASTAGE 10% 10% 10% 10% 10%
50mm Stub Length 1.60 1.63 1.63 1.66 1.73
75mm Stub Length 1.66 1.75 1.73 1.73 1.87
Conventional, Low Iron Powder or Hydrogen Controlled Electrodes EXX12, 13, 14, 16 &18 Types to AS/NZS 4855 Cellulose Type Electrodes (EXX10 & 11 Types to AS/NZS 4855)
TABLE 2.3 SUBMERGED-ARC WELDING (SAW)

CONSUMABLES TYPE, CONDITIONS ECT. Mild and Low Alloy Steel Welding Wire Flux Consumption - For any given wire size under the following conditions Low Voltage, Normal Amperage Low Amperage, Normal Voltage Normal Voltage, Normal Amperage High Voltage, Normal Amerpage Hight Amperage, Normal Voltage QUANTITY OF CONSUMABLE 1.02 EXTRA FOR WASTAGE 2%
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Note. For Aluminium weld metal divide the steel weld metal mass per metre by 2.9
0.8 kg 1.6 kg 1.1 kg 1.6 kg 0.8 kg
15% 15% 15% 15% 15%
WELD DEPOSITION & COSTING DATA - QUANTITY OF CONSUMABLES REQUIRED
TABLE 2.1 GAS METAL-ARC WELDING (GMAW) AND PULSED ARC WELDING
CONSUMABLES TYPE, SHIELDING GAS, ARC TRANSFER MODE ECT. QUANTITY OF CONSUMABLE EXTRA FOR WASTAGE
TYPE A MILD ALLOY STEEL WELDING WIRES (AUSTMIG ES6, ESD2 ECT)
USED WITH (i) CO SHIELDING GAS Short Arc Transfer (95%) Globular Transfer (90%) Globular Free Flight Transfer (93%) (ii) Ar + 15 - 25% CO SHIELDING GAS Short Arc Transfer (97%) Globular Transfer (94%) (iii) Pulsed Arc Transfer (:Syncro-Pulse CDT) and Programmed Shielding Gas (98%) TYPE B STAINLESS STEEL WELDING WIRES (eg. AUSTMIG 308LSI, 316SI ect): USED WITH Ar or Ar/He Based Shielding Gases and all Arc Transfer Modes, including Pulsed Arc Transfer (98%) 1.02 kg Streaming Spray Transfer (96%) 1.05 kg 1.11 kg 1.08 kg 1.03 kg 1.06 kg 1.04 kg 1.02 kg
2% 2% 2% 2% 2% 2%
SHIELDING GAS CONSUMPTION FOR MILD, LOW ALLOY AND STAINLESS STEEL WIRES
TYPICAL CONDITIONS Short Arc Transfer or Pulsed Arc Transfer with a Typical Gas Flow rate of 15L/min Globular, FreeFlight or Streaming Spray Transfer with a typical Gas Flow Rate of 20L/min DEPOSITION CONSUMPTION PER RATE OF: KG OF WELD METAL 1.0 kg/hr; 2.8 kg/hr 3.0 kg/hr 7.0 kg/hr .90m (1.68kg of CO+) .32m (.60kg of CO+) .40m (.75kg of CO+) .17m (32kg of CO+) EXTRA FOR WASTAGE 10% 10% 10% 10%
(%) Typical Electrode Efficiency for wire type, shielding gas and transfer mode Indicated. + Where appropriate, the mass of CO shielding gas required.NB. 1m of CO at 15.6C and 1 atmosphere has a mass of 1.87 kg. 1m = 1000 Litres.
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QUANTITY OF CONSUMABLES REQUIRED

TABLE 2.1 GAS METAL-ARC WELDING (GMAW) AND PULSED ARC WELDING
CONSUMABLES TYPE, SHIELDING GAS, ARC TRANSFER MODE ECT. QUANTITY OF CONSUMABLE EXTRA FOR WASTAGE TYPE D ALUMINIUM WELDING WIRES (eg. AUSTMIG 5356, 4043, 5183 etc.) 1.05 kg 1.02 kg
Pulsed Arc Transfer (Syncro-Pulse CDT) (98%)
Spray Arc Transfer (95%)
1% 1%
SHIELDING GAS CONSUMPTION FOR FOR ALUMINIUM WIRES:

TYPICAL CONDITIONS Spray Arc Transfer with a Inert Gas Flow Rate Pulsed Arc Transfer with a Inert Gas Flow Rate of 18L/min of 28L/min DEPOSITION RATE OF: 1.0kg/hr 2.0kg/hr 0.5kg/hr 2.0kg/hr QUANTITY OF CONSUMABLE 1.68m3 0.84m3 2.16m3 0.54m3 EXTRA FOR WASTAGE 10% 10% 10% 10%
(%) Typical Electrode Efficiency for arc transfer mode Indicated.
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WELD DEPOSITION & COSTING DATA - QUANTITY OF CONSUMABLES REQUIRED
TABLE 2.2 FLUX CORED ARC WELDING (FCAW)

CONSUMABLES TYPE, TYPICAL DEPOSITION EFFICIENCY ECT. TYPE A GAS SHIELDED, DOWNHAND AND POSITIONAL, DCEP WIRES OF 83% EFFICIENCY: (E70T-1, E71T-5 TYPES TO AWS A5.20) QUANTITY OF CONSUMABLE 1.20 kg EXTRA FOR WASTAGE 2%
TYPE B SELF SHIELDED, DOWNHAND DCEP WIRES OF 83% EFFICIENCY: (E70T-4, E70T-6 TYPES TO AWS A5.20) TYPE C GAS SHIELDED, DOWNHAND METAL CORED WIRES OF 95% EFFICIENCY:
1.20 kg 1.05 kg 1.20 kg
2% 2% 2%
TYPE D SELF SHIELDED, POSITIONAL DCEN WIRES OF 75% EFFICIENCY: (E61T-8, E71T-8 TYPES TO AWS A5.20)
TABLE 2.2 FLUX CORED ARC WELDING (FCAW)

CONSUMPTION PER KG OF WELD METAL Assuming a gas flow rate of 12 L/minfor a weld deposition rate of: 4 kg/hr; 6 kg/hr; 8 kg/hr; 2 kg/hr; .36m (.67kg of CO*) .32m (.18kg of CO*) .40m (.12kg of CO*) .17m (.09kg of CO*) EXTRA FOR WASTAGE 10% 10% 10% 10%
* Where appropriate, the mass of CO shielding gas required. NB. 1 m3 of CO at 15.6C and 1 atmosphere has a mass of 1.87 kg. 1 m3 = 1000 Litres.
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DEPOSITION RATES
TABLES 3.0-3.5 provide a comprehensive range of typical deposition rates for the continuous operation of various arc welding consumables and arc processes. The tables are designed as an easy-to-read guide to show typical deposition rates achievable tor the electrode/wire types, sizes, welding parameters and shielding gases shown. The tables also give useful information on suitable welding parameters such as welding current, voltage and modes of operation. It should be emphasised that the deposition rates tabulated are for continuous operation (100% duty cycle) of the consumable/arc process in question. Refer to SECTION 4 for further information on typical duty cycle estimates for the welding task involved. The typical deposition rates given for each current setting may vary with changes in arc voltage, electrode stickout and shielding gas composition - refer to the information given below each Table.
For accurate deposition rate calculations for continuous wires, measure wire feed speed (in m/min) during welding and use the appropriate Mass/Length figures from table 3.6 and Quantity of Consumables data from tables 2.1-2.3. TABLE 3.0 TYPICAL DEPOSITION RATES USING MMAW
ELECTRODE TYPE, CLALSSIFICATION TO AS/NZS 4855 E4110/11 E4112/13 E4814 E4824 E4127 E4816 E4818 / E4846 WIA ELECTRODES 11 12P, 13S 24 16TC 18TC, 77 TYPICAL (F) FACTOR kg/amp/ hr .009 .008 .01 .0135 .0135 .009 .01 DEPOSITION F X A = kg/hr TYPICAL CURRENT, A( ) 5mm 1.7(190) 1.8(220) 2.4(240) 4.1(300) 4.1(300) 2.0(220) 2.0(200) 4mm 1.4(150) 1.4(170) 1.9(190) 2.7(200) 2.8(210) 1.5(170) 1.6(160) 3.2mm 1.0(110) 1.0(130) 1.4(135) 2.0(150) 2.0(150) 1.2(130) 1.2(115)
The factors (F) are typical for those low carbon steel electrodes, as classified to AS/NZS 4855 in popular use throughout Australia. Multiplying the FACTOR (F) by the CURRENT (A) selected for the electrode size (within its normal current range) will provide typical deposition rates (kg/hr) at 100% duty cycle.
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WELD DEPOSITION & COSTING DATA - DEPOSITION RATES
TABLE 3.1A TYPICAL DEPOSITION RATES USING GMAW WITH LOW CARBON AND LOW ALLOY STEEL WIRES (EG AUSTMIG ES6, ESD2 OR SIMILAR WIRES)
WIRE SIZE (mm) 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.9 0.9 0.9 0.9 0.9 0.9 0.9 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.6 1.6 1.6 1.6 1.6 1.6 + WELDING CURRENT (AMPS) 60+ 80+ 100+ 120+ 140+ 160+ 180 70+ 100+ 120+ 150+ 180+ 180 200 90+ 100+ 150+ 100+ 220 250 280 120+ 150+ 170+ 220 250 310 340 140+ 200+ 250+ 300 350 400 ARC VOLTAGE (VOLTS) 16+ 17+ 18.5+ 20+ 20+ 22+ 30 15+ 19+ 19+ 20+ 21+ 29 31 19+ 19+ 20+ 20+ 28 32 34 18+ 18+ 19+ 30 32 34 36 19+ 19+ 21+ 30 34 34 WIRE FEED SPEED (M/ MIN) 3.3 4.4 5.9 7.0 9.9 12.4 14.3 3.7 6.0 6.9 8.7 11.5 12.0 14.0 3.3 3.6 5.6 7.0 14.6 15.7 16.8 2.7 3.5 3.9 6.2 9.1 11.3 12.9 1.7 1.7 3.1 4.9 6.2 7.5 DEPOSITION RATE (kg/hr) 0.7 1.0 1.3 1.6 2.2 2.8 3.2 1.1 1.7 2.0 2.5 3.3 3.4 4.0 1.2 1.3 2.0 2.5 5.2 5.6 6.0 1.4 1.8 2.0 3.2 4.7 5.8 6.6 1.6 1.6 2.8 4.5 6.7 6.8
Short arc transfer conditions. Note: Deposition rate data determined using: DC+ (reverse polarity) with a conventional constant power source. Ar - 16/18% CO2 shielding gas An electrode stickout length at 8-10 mm for short arc transfer conditions and 15 mm for spray arc transfer conditions. Deposition efficiency at 96% for both short arc transfer & spray arc transtor conditions
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DEPOSITION RATES
TABLES 3.1B TYPICAL DEPOSITION RATES USING PULSED ARC WELDING WITH LOW CARBON AND LOW ALLOY STEEL WIRES (EG AUSTMIG ES6)
WIRE SIZE (mm) 0.8 0.8 0.8 0.8 0.8 0.9 0.9 0.9 0.9 0.9 0.9 1.0 1.0 1.0 1.0 1.2 1.2 1.2 1.2 1.2 1.2 1.6 1.6 1.6 1.6 1.6 WELDING CURRENT (AMPS) 35 70 105 140 175 40 45 90 135 180 230 110 170 230 290 40 100 160 220 280 350 70 165 260 355 450 ARC VOLTAGE (VOLTS) 17.0 20.0 23.0 25.0 28.0 18.0 17.0 21.0 24.0 27.0 30.0 21.0 24.0 28.0 31.0 19.0 21.5 24.0 26.5 29.0 32.0 20.0 24.0 28.0 31.0 35.0 WIRE FEED SPEED (M/MIN) 2.0 5.3 8.6 11.9 15.2 2.5 1.9 6.1 9.3 12.5 16.0 5.3 8.4 11.5 14.6 1.5 3.5 5.5 7.4 94 11.7 1.3 2.8 4.4 5.9 7.5 DEPOSITION RATE (kg/hr) 0.5 1.2 2.9 2.7 3.5 0.7 0.7 1.8 2.7 3.7 4.7 1.9 3.1 4.2 5.3 0.8 1.8 2.9 3.9 4.9 6.1 1.2 2.6 4.1 5.5 7.0
Note: Deposition rate data obtained using: Ar + 16-18% CO2 shielding gas A deposition efficiency of 98% for pulsed arc transfer TABLE 3.3 TYPICAL DEPOSITION RATES USING SUBMERGED-ARC WELDING (SAW) WITH LOW CARBON AND LOW ALLOY STEEL WIRES WIRE SIZE (mm) 2.0 2.4 3.2 4.0 4.8 DEPOSITION RATE (kg/hr) - WELDING CURRENT (AMPS) 300 3.1 2.9 2.6 400 4.8 4.1 3.9 3.6 500 5.5 5.3 5.1 600 7.5 6.8 6.7 5.0 700 8.7 8.3 7.4 800 10.1 10.0 8.9 900 11.9 10.4
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Deposition rate data achieved using DC+ (reverse polarity) with, normal voltage settings for the wire sizes listed. An electrode stickout of 25mm is used with all wire sizes & current settings. Note: Deposition rates may be increased by 30-50% using DC(Straight Polarity) & approximately 15-25% using AC. The use of an electrode stickout longer than 25mm with the same welding current increases deposition rate significantly.
CONTENTS
TABLE 3.2A TYPICAL DEPOSITION RATES USING FCAW

WIRE SIZE (mm) WELDING CURRENT (AMPS) ARC VOLTAGE (VOLTS) WIRE FEED SPEED (M/MIN) 3.4 5.3 7.4 9.8 3.7 5.1 6.7 8.2 10.8 11.5 2.4 3.0 3.7 4.3 5.0 5.5 3.4 5.3 7.4 9.8 3.7 5.1 6.7 8.2 9.4 2.4 3.0 3.7 4.3 4.7 DEPOSITION RATE (kg/hr) 1.4 2.2 3.3 4.5 2.4 3.4 4.4 5.4 7.1 7.6 3.4 4.3 5.2 6.1 7.1 7.8 1.4 2.2 3.3 4.5 2.4 3.4 4.4 5.4 6.1 3.4 4.3 5.2 6.1 6.6
PART A. T1 TYPE OF CORED WIRE 1.2 130 23 1.2 150 24 1.2 200 26 1.2 250 28 1.6 200 26 1.6 250 28 1.6 300 30 1.6 350 32 1.6 400 34 1.6 425 36 2.4 300 27 2.4 350 28 2.4 400 32 2.4 450 32 2.4 500 34 2.4 525 35 PART B. T5 TYPE OF CORED WIRE 1.2 130 22 1.2 150 23 1.2 200 24 1.2 250 26 1.6 200 25 1.6 250 27 1.6 300 28 1.6 350 29 1.6 375 30 2.4 300 25 2.4 350 26 2.4 400 28 2.4 450 29 2.4 475 30
Note. Deposition rate data determined using: DC+ (reverse polarity) with a conventional Constant Potential power source Welding grade CO shielding gas An electrode stickout length of, 15mm for 1.2mm, 25mm for 1.6mm & 2.4mm wire sizes A deposition efficiency of 84% for globular transfer Voltage figures are typical machine meter readings-actual arc voltage will be 1-3 volts lower than meter reading due to voltage drop across welding leads. Reduce arc voltage by 2-3 volts when using mixed gas.
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DEPOSITION RATES
TABLES 3.4A TYPICAL DEPOSITION RATES USING GMAW WITH 300 SERIES STAINLESS STEEL SOLID WIRES
WIRE WELDING ARC WIRE FEED DEPOSITION SIZE CURRENT VOLTAGE SPEED RATE (kg/hr) (mm) (AMPS) (VOLTS) (m/min) 0.9 80+ 17+ 4.2 .3 0.9 100+ 18+ 5.1 1.5 0.9 150 20 8.4 2.5 0.9 200 23 12.5 3.7 1.2 125+ 18+ 3.1 1.6 1.2 200 20 5.9 3.1 1.2 250 27 8.1 4.3 1.2 300 29 10.9 5.8 Short arc transfer conditions Note: Deposition rate data determined using: DC+ (reverse polarity) with a conventional constant potential power source Ar+ 1-2% O2 shielding gas An electrode stickout length of, 8-10mm for short arc transfer conditions and 15mm for spray arc transfer conditions A deposition efficiency of 98% for both short arc transfer and spray arc transfer conditions
TABLE 3.4B TYPICAL DEPOSITION RATES USING PULSED ARC WELDING WITH 300 SERIES STAINLESS STEEL SOLID WIRES
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WIRE WELDING ARC WIRE FEED DEPOSITION SIZE CURRENT VOLTAGE SPEED RATE (kg/hr) (mm) (AMPS) (VOLTS) (m/min) 0.8 30 17.0 2.4 0.6 0.8 60 19.0 5.8 1.4 0.8 90 21.0 9.2 22 0.8 120 230 12.6 3.0 0.8 150 25.0 16.0 3.9 0.9 35 17.0 2.5 0.8 0.9 75 20.0 5.6 1.7 0.9 120 235 9.1 2.7 0.9 165 26.5 12.5 3.8 0.9 210 30.0 16.0 4.8 1.0 35 16.0 1.5 0.6 1.0 80 18.0 4.2 1.6 1.0 130 21.0 7.1 2.6 1.0 180 24.0 10.1 3.7 1.0 225 26.0 12.7 4.7 1.2 50 17.0 1.5 0.8 1.2 100 19.5 2.8 1.5 1.2 150 22.0 4.1 2.2 1.2 200 24.5 5.3 2.8 1.2 250 27.0 6.6 3.5 1.2 300 295 7.9 4.2 1.2 350 32.0 9.1 4.8 Note: Deposition rate data obtained using: A deposition efficiency of 98% for pulsed arc transfer Ar + He + 1.5% CO
TABLES 3.5A TYPICAL DEPOSITION RATES USING GMAW WITH AUSTMIG ALUMINIUM ALLOY WIRES (EG. AUSTMIG 5183)
WIRE SIZE (mm) 0.9 0.9 0.9 0.9 1.2 1.2 1.2 1.2 WELDING CURRENT (AMPS) 100 125 175 200 150 175 225 250 ARC VOLTAGE (VOLTS) 17 18 21 22 22 23 05 25 WIRE FEED SPEED (m/min) 9.2 10.9 15.0 18.0 7.8 9.0 13.8 13.8 DEPOSITION RATE (kg/hr) 0.9 1.1 1.5 1.7 1.4 1.6 2.4 2.4
TABLE 3.5B TYPICAL DEPOSITION RATES USING PULSED ARC WELDING WITH AUSTMIG ALUMINIUM ALLOY WIRES (EG. AUSTMIG 5183)
WIRE WELDING ARC WIRE FEED SIZE CURRENT VOLTAGE SPEED (mm) (AMPS) (VOLTS) (m/min) 0.9 25 14.0 2.8 0.9 50 16.0 5.6 0.9 70 17.0 7.9 0.9 90 18.0 10.1 0.9 115 20.0 13.0 1.0 35 15.0 3.6 1.0 70 17.0 6.5 1.0 110 19.0 10.0 1.0 140 21.0 12.6 1.0 180 23.0 16.0 1.2 35 15.0 2.8 1.2 85 18.0 6.1 1.2 135 21.0 9.4 1.2 185 24.0 12.7 1.2 235 27.0 16.0 1.6 80 15.0 2.5 1.6 140 17.5 4.6 1.6 200 20.0 6.7 1.6 265 22.5 8.8 1.6 325 25.0 10.9 Note: Deposition rate data determined using: Welding grade Ar shielding gas A deposition efficiency of 98% for pulsed arc transfer
Note: Deposition rate data determined using: DC+ (reverse polarity) with a conventional constant potential power source. Welding grade Ar shielding gas An electrode stickout length of 20mm A deposition efficiency of 95%
DEPOSITION RATE (kg/hr) 0.3 0.6 0.8 1.0 1.3 0.5 0.8 1.3 1.6 2.1 0.5 1.1 1.7 2.3 2.9 0.8 1.5 2.1 2.8 3.5
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DEPOSITION RATES
TABLES 3.6 MASS / LENGTH TABLES PART A. LOW CARBON AND LOW ALLOY STEEL GMAW WIRES
WIRE SIZE (mm) GRAM OF WIRE PER METRE METRES OF WIRE PER KG 0.6 2.2 450.5 0.8 3.9 253.7 0.9 5.0 200.4 1.0 6.2 161.3 1.2 8.9 112.7 1.6 15.8 63.4
PART B. FCAW WIRES

WIRE SIZE (mm) GRAM OF WIRE PER METRE METRES OF WIRE PER KG 1.2 7.6 131.6 1.6 13.0 76.9 2.0 20.0 50.0 2.4 28.0 34.7 3.2 50.1 20.0
PART C. LOW CARBON AND LOW ALLOY STEEL SAW WIRES

WIRE SIZE (mm) GRAM OF WIRE PER METRE METRES OF WIRE PER KG 2.0 24.6 40.6 2.4 35.5 28.2 3.2 63.1 15.9 4.0 98.6 10.1 4.8 141.0 7.0
PART D. STAINLESS STEEL WELDING WIRES

WIRE SIZE (mm) GRAM OF WIRE PER METRE METRES OF WIRE PER KG 0.8 4.1 245 0.9 5.1 197.7 1.0 6.3 158 1.2 9.0 111.2 1.6 16.0 62.6
PART E. ALUMINIUM WELDING WIRES

WIRE SIZE (mm) GRAM OF WIRE PER METRE METRES OF WIRE PER KG 0.8 1.4 712 0.9 1.7 528.2 1.0 2.2 455 1.2 3.1 327.5 1.6 5.4 184.2
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DUTY CYCLES
The deposition rates tabled in SECTION 3, are for a duty cycle of 100% - that is continuous (uninterrupted) welding of the consumable/arc process in question. DUTY CYCLE IS, BY DEFINITION, A MEASURE OF THE ARC ON TIME EXPRESSED AS A PERCENTAGE OF THE TOTAL ELAPSED TIME, IE arc time x 100 Duty Cycle = (%) total elapsed time This parameter indicates the proportion of the operating time during which weld metal is actually being deposited. The duty cycle can vary considerably according to a number of factors including: the welding process the type of consumable operating conditions the application involved the degree of mechanisation general workshop efficiency a variety of human factors or personal allowances such as putting gloves and helmet on, putting aside and picking up electrode holder etc. Figure 4.0 summarizes the potential range of duty cycles for various arc welding processes and modes of operation. 100 80 Duty Cycle % 60 40 20 0
Surfacing Operations SAW Automatic Welding
Machine or Mechanised Welding MMAW
GW
Manual Welding
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Figure 4.0
GMAW FCAW
RW
WELD DEPOSITION & COSTING DATA - DUTY CYCLES

167
(a) Manual Metal-Arc Welding (MMAW) The maximum obtainable duty cycle for MMAW is of the order of 65% but most applications will not permit a duty cycle greater than 50% to be achieved over a days production. The duty cycle for MMAW operations varies widely with the type of application and operating conditions. Electrode changes, slag removal, intermittent welding and changing positions etc all play a part in reducing the actual arc on time. With added delays, such as personal allowances and materials handling, most welding workshops are capable of maintaining duty cycles of 15-30%
(b) Gas Metal-Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW) Semi-automatic Arc Processes For semi-automatic surfacing operations a duty cycle approaching 80% is possible. However, most GMAW and FCAW operates between 30-60%; with mechanised semi-automatic welding yielding duty cycles of 45-60% and conventional (or manual) semi-automatic processes producing duty cycles of typically 30-40%. (c) Submerged-Arc Welding (SAW) For fully automatic hard surfacing operations, a 95% duty cycle is possible with the submerged-arc process; however most submerged-arc welding operates between 40-60% duty cycle due to essential setting up, deslagging, loading / positioning and other handling operations.
CONTENTS
ELECTRODE CONSUMPTION FOR TYPICAL BUTT JOINTS

ELECTRODE CONSUMPTION FOR SOME COMMON BUTT JOINTS The following Tables provide useful data on the mass of weld metal and MMAW electrodes required to complete some common butt joints. Electrode consumption is calculated using the following simple equation: D M= 1-P where 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.
OPEN SQUARE GROOVE BUTT JOINT - WELDED BOTH SIDES Reinforcement height, r = 2 mm.
W T R
JOINT DIMENSIONS (MM) T R W 3 0 7 3 1 7 6 1.5 10 6 3 10
Mass of steel weld metal per metre. (D) (kg/m) 0.17 0.20 0.32 0.39
Mass of MMAW** electrodes required per metre (M) (kg/m) 0.28 0.33 0.53 0.64
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WELD DEPOSITION & COSTING DATA - ELECTRODE CONSUMPTION FOR BUTT JOINTS
60 W r L R JOINT DIMENSIONS (MM) R L W 3.5 1.5 3.5 3.5 3.0 3.0 3.0 1.5 1.5 3.0 3.0 3.0 Mass of steel weld metal per metre. (D) (kg/m) 0.26 0.57 0.79 0.83 1.38 2.06 60 W r Mass of MMAW** electrodes required per metre (M) (kg/m) 0.43 0.95 1.31 1.39 2.29 3.43 T
SINGLE V BUT JOINT Reinforcement height, r = 2mm
T 6 8
10.0 13.0 15.0 15.0 19.0 23.0
10 12 16 20
Single V But Joint Reinforcement height, r = 2mm
L R
JOINT DIMENSIONS (MM) T R L W 12 3.0 3.0 10.0 16 20 25 50 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 12.0 15.0 18.0 32.0
Mass of steel weld metal per metre. (D) (kg/m) 0.71 1.06 1.50 2.13 6.97
Mass of MMAW** electrodes required per metre (M) (kg/m) 1.18 1.75 2.48 3.53 11.58
For 380mm long EXX12, 13, 14, 16 & 18 type MMAW electrodes to AS/NZS 4855, P is typically 0.4. This figure assumes a stub end length of 50mm. (See table 2.0 for further details.)
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WELDABILITY GUIDE FOR STEELS

The majority of steels in general use are considered Weldable using most arc welding processes. The degree to which they are rated as weldable is indicated by an imprecise term, Weldability which is (as yet) not fully assessable by a laboratory test or series of tests. We have included two different weldability guides to assist you in determining preheat of materials. The first guide is the same as that used in Australian Standards and WTIA technical notes the second guide is a method adopted by WIA and known as the WIA Welability Guide Furthermore, what is considered to be a satisfactory joint for one set of service conditions, possibly, steel sections embedded in concrete under static loading, may not be acceptable for another set of service conditions, such as in the tension member of a flexing structure or under corrosive conditions. For this reason, no economically acceptable hard and fast rules can be provided in a Guide such as this and the recommendations should always be tempered in their translation into practice with a knowledge of the intended application and other factors relevant to the situation. Arc welding is a process of intense localised heating and rapid cooling, providing a sudden heating-quenching heat treatment effect on both the weld metal and the adjacent parent metal (HAZ). As a general rule the tendency of a steel to strengthen and harden, following this heat treatment, increases as the carbon and alloy content increases. Its composition is therefore an important factor in assessing weldability. CARBON EQUIVALENT Carbon is the most effective of the commonly used alloying elements in achieving increased strength and hardness (increased hardenability) and is present in all steels. Over many years, researchers have established numerous rating systems to compare the hardening potential of other common elements such as manganese and chromium against that of carbon. This has led to the concept of calculating Carbon Equivalent (CE) from the chemical composition of the steel as a means of assessing its weldability. The following is the IIW formula used for determining Carbon Equivalent from the percentage of elements present:
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CE = C +
Mn 6
Cr + Mo + V 5
Ni + Cu 15
The Weldability Reference Numbers used in this guide, relate to the following carbon equivalents:
CE below 0.30 0.30 to below 0.35 0.35 to below 0.40 0.40 to below 0.45 0.45 to below 0.50 0.50 to below 0.55 REFERENCE NUMBER 1 2 3 4 5 6 CE 0.55 to below 0.60 0.60 to below 0.65 0.65 to below 0.70 0.70 to below 0.75 0.75 to below 0.80 0.80 and above REFERENCE NUMBER 7 8 9 10 11 12
NOTE: Reference numbers above 12 are not related to CE. In instances where the ladle analysis is given for a steel, the maximum specification limits have been used to calculate CE. For steels containing multiple alloy additions, the use of maximum specification limits to calculate CE give conservative results; because the possibility of all alloying elements simultaneously achieving their maximum limit is remote. In these circumstances, it is recommended that the CE be calculated using 80-85% of the ladle analysis maximum specification limits. OTHER FACTORS INFLUENCING WELDABILITY Composition, although important, is not the only criterion used to assess the weldability, of a given steel, in a given joint situation. Other influences can be broadly related either to their effect on the heat treatment or the stress level of the joint.
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OTHER FACTORS INFLUENCING WELDABILITY Factors which can have an effect on the heat treatment and hence (with composition) the microstructure include; the mass of the section, its initial temperature, the heat input per unit length and the interpass temperature in multipass welds. Factors which relate generally to the stress level include; the degree of restraint imposed on the joint by its own mass and from external sources, base metal strength (rigidity, hardness) and geometry, uneven heating and cooling conditions and geometrical considerations such as joint preparation and alignment, notches due to weld contour, weld nugget shape and the presence of non-metallic inclusions, etc. The tendency towards weld and base metal cracking is further influenced by the inherent toughness and strength of the weld metal, the effect of base metal dilution on these properties and the presence of hydroge in the arc atmosphere. NOTES ON USING THE GUIDE The following pages list recommendations for welding some of the more commonly available steels in Australia. Based primarily on the steel composition, they assume moderate conditions of restraint and joint complexity. Where low hydrogen or hydrogen controlled conditions are nominated, electrodes should be dried accordingly to meet the required level. For MMAW, the use of 4mm electrodes (minimum size) has been assumed, although the user is expected to use the largest size practicable. The use of higher and lower heat inputs by other electrode sizes or processes can respectively lower and raise the recommended preheat temperature. Silicon levels are not listed for steels unless their content, within a particular group, exceeds the normal maximum limit of .35%, for other steels, typical Silicon figures have been quoted for interest sake. For further details regarding the Sulphur, Phosphorus and Silicon levels in a particular steel, refer to the manufacturers specification.
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The term Combined Joint Thickness (CJT) is used in many instances in conjunction with recommended preheat temperatures as a measure of the quenching severity of the joint. For simple butt and corner joints the CJT is the sum of each plate thickness, whilst for more complex joints, such as T joints, the CJT can be calculated as shown in figure 11.
t t CJT = t + 2t t t
t 75mm t t t t
t = average thickness over 75mm CJT = t + t
If t is already welded to t then: CJT = t + 2t + t
If t is already welded to t as shown then: CJT = t + t + t
FIGURE 11 Combined Joint Thickness (CJT) calculations for welds shown in black.
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CONTENTS

HYDROGEN CONTROL The term low hydrogen or hydrogen controlled is not indicative of no hydrogen, but of products and processes which have controlled limits on moisture or hydrogen producing materials. The fact that a product can meet the specified requirements of a code is not necessarily indicative of its ability to meet requirements in more critical situations. Some codes have maximum permissible moisture levels for lower strength electrodes and more stringent requirements for higher strength. As a general rule, as the retainability of the base material and weld metal increase, the allowable maximum limit for hydrogen is reduced. This situation is further complicated when restrictions are placed on preheat temperature and heat input - which normally help to increase the diffusion rate of hydrogen; such as for the welding of quenched and tempered steels. Flux coated hydrogen controlled electrodes when used in critical applications should be thoroughly dry prior to use. If any doubt exists, electrodes should be rebaked and used from a hot box. WIA WELDABILITY REFERENCE NUMBERS AND RECOMMENDATIONS
1&2 Readily weldable with any low carbon steel electrodes (for example, Austarc 11, 12P, 13S, 24) or arc welding process without special precautions. 1A 2A Rimmed steels welded with the GTAW Process (TIG) without added filler metal will give porous welds, due to gas evolution, caused by resumption of the rimming process. Use double deoxidised filler wire for sound joints.
174
CONTENTS
The sulphur or lead content of these steels can lead to hot shortness during welding and sulphur can also cause porosity. Welding is therefore not generally recommended except for non-critical applications. Basic coated, MMAW electrodes such as Austarc 16TC, 18TC, 77 should be used or specially formulated electrodes for welding sulphurised steels. The use of an intermediate buffer pad is recommended in extreme cases and through thickness joints are preferred to fillet welds. No preheat required.
3&4 3A 3B 4B 5
Readily weldable with any low carbon steel electrode, such as Austarc, 11, 12P, 13S, 24. For CJTs of 50mm or greater a preheat temperature of 50-75C is recommended, depending on the degree of restraint. Alternatively hydrogen controlled electrode such as Austarc 16TC, 18TC or 77 may be used with a preheat temperature of only 25C. As for 2A, but use 50C preheat on heavy sections. Check if Shipping Society approval and specific CVN impact gradings are required for electrode,then as for 3 Check if Shipping Society approval and specific CVN gradings are required for electrode, then as for 4. Conventional low carbon electrodes, such as Austarc 13S & 24 are still acceptable however,special notch toughness requirements etc. may dictate a preference for basic electrodes, particularly for butt welding applications. The use of hydrogen controlled basic electrodes, such as Austarc 16TC, 18TC & 77, reduce the preheat temperature necessaryto prevent HAZ weld metal cracking in highly restrained, heavy sections. No preheat is generally required for CJTs up to 40mm, welded with hydrogen controlled electrodes or CJTs up to 30mm, welded with conventional low carbon electrodes. When using conventional low carbon electrodes, preheat joint to 50C for CJTs of 40mm, and 125C for CJTs of 80mm. Using hydrogen controlled electrodes, preheat joint to 50C for CJTs of 55mm and 100C for CJTs of 80mm and above. For welding with semi automatic solid or flux cored wire like the Formula XL-525, Austmig ES6 or Austmig 70C-6M etc. at a heat input of 2.2kJ/mm, use a preheat temperature of 50C for CJTs of 80mm and above.
175
CONTENTS

WIA WELDABILITY REFERENCE NUMBERS AND RECOMMENDATIONS 6A 6B 6 7 As for 5, except when matching colour and corrosion resistance are required, an electrode depositing a Ni-Cu weld metal is recommended.
Hydrogen controlled electrodes of matching weld metal analysis and strength are normally recommended. For minimum preheat temperatures, refer to 5.
Hydrogen controlled electrodes are generally considered essential for the deposition of sound welds use a preheat temperature of 70C for CJTs of 40mm. 100C preheat for CJTs of 60mm and 150C preheat for CJTs of 110 mm and above. When using semi automatic solid or flux cored wire like the Formula XL-525, Austmig ES6 or Austmig 70C-6M etc., at approximately 2.2kJ/mm, a preheat temperature of 50C is recommended for CJTs of 60mm and 125C for CJTs of 110mm and above. Hydrogen controlled electrodes must be used with a preheat temperature of 70C for CJTs of 28mm, 100C for CJTs of 40mm and 170C for CJTs of 110mm and above. For welding with appropriate solid or flux cored wires, at approximately 2.2kJ/mm, a minimum preheat of 70C is required for CJTs of 45mm and 125C for CJTs of 80mm. Slow cooling from interpass temperature is required and critical weldments should be stress relieved.
7A 7B
Follow the general advice of 2A The welding of sulphur bearing steels is not generally recommended, except for non-critical applications. For general preheat requirements refer to 7. Hydrogen controlled electrodes of matching chemical analysis and strength are recommended. The service requirements of weldments employing this type of alloy demand high integrity welding. A minimum preheat temperature of 150C is generally recommended, for CJTs of 30-60mm, followed by slow cooling. A stress relieving heat treatment to 650C is common practice, following welding.
176
CONTENTS
8 9
Use hydrogen controlled electrodes with a preheat temperature of 75C for CJTs of 20mm. 120C for CJTs of 40mm and 170C for CJTs of 80mm. For semi- automatic welding with appropriate solid or flux cored wires, at approximately 2.2kJ/mm, use a preheat of 100C for CJTs of 40mm, and 200C for CJTs of 100mm. Slow cooling is essential, followed by a stress relieving heat treatment for critical joints.
9A
Use hydrogen controlled electrodes such as Austarc 16TC, 18TC or 77 with a minimum preheat of 90C for CJTs of 20mm, 150C for CJTs of 40mm and 200C for CJTs of 80mm. For semi-automatic welding with appropriate solid or flux cored wires, at approximately 2.2kJ/mm, a minimum preheat of 50C is recommended or CJTs of 20mm, 120C for CJTs of 40mm and 180C for CJTs of 80mm. Follow the general advice of 2A. The welding of sulphur bearing steels is not generally recommended, except for non-critical applications. For general preheat requirements, refer to 9.
10&11 Use hydrogen controlled electrodes such as Austarc 16TC, 18TC or 77 which have been thoroughly dried, with the following minimum preheat temperatures.
CJT 20 mm 120C 140C 40 mm 170C 190C 80mm 220C 230C WIA WELDABILITY REF: NUMBER 10 11
Alternatively use austenitic, stainless steel electrodes such as Unicord 312 with preheat temperatures approximately 50C less than those recommended above for hydrogen controlled electrodes. The use of dry electrodes is essential, as is slow cooling after welding. A post weld heat treatment is considered good welding practice.
177
CONTENTS

WIA WELDABILITY REFERENCE NUMBERS AND RECOMMENDATIONS 11A Following the general advice of 2A. The welding of higher carbon, sulphur bearing steels is not generally recommended, except for non-critical applications For general preheating requirements, refer to 11.
9C, 11C For high strength butt and filet welding of these steels, use Hydrogen controlled electrode & 12C of matching chemical analysis or strength. Refer to the minimum preheat temperatures and welding details described in 9,11 and 12 respectively. When welding these steels in the heat treated (hardened and tempered) condition check that the post weld heat treatment temperature chosen does not exceed the tempering temperature of the base material. 10B, 11B The welding of alloy spring steels in the heat treated (hardened and tempered) condition & 12B can be carried out using preheat and interpass temperatures of 200-300C, with extra slow cooling in insulating powder, a lime bath or a thermal blanket etc. Austarc 16TC, 18TC and 77 is recommended for root pass welding whilst subsequent higher strength passes may be made with high strength electrode eg. AWS A5.5: E110XX. Thoroughly dried electrodes are essential and post weld heat treatment is generally not recommended. 12 Use hydrogen controlled electrodes-in thoroughly dry condition, with the following minimum preheat temperatures:
CJT 20 mm 170C 40 mm 220C 80mm 260C WIA WELDABILITY REF: NUMBER 12
178
CONTENTS
Welding on these steels is preferred in the annealed condition and low dilution techniques should be employed. Under higher degrees of restraint a further 50C of preheat is recommended to avoid cracking. In some applications, the use of Unicord 312 is acceptable, especially where high preheats are difficult to achieve. Dry electrodes and clean joints are essential. Slow cooling followed by a PWHT immediately after welding is a compulsory practice. 13 14 14A Arc welding of these steels should be avoided if possible. Welding is best carried out on tool steels in the annealed condition, however, repair work on heat treated (hardened and tempered) material or minor attachments can be welded with Unicord 312. A preheat temperature of 150-500C is required as is a Post Weld Heat Treatment (PWHT) of 150-650C for exact heat treatment details refer to manufacturers data on the tool steel being welded. It is important that the PWHT temperature chosen does not exceed the tempering temperature of the tool or mould steel being welded. Hydrogen controlled ferritic electrodes, such as Austarc 16TC, 18TC and 77, should only be used on annealed tool steels, with accordingly higher preheat temperatures. Should be welded with hydrogen controlled electrodes or wires of matching chemical analysis and strength. Low hydrogen conditions are essential. Preheat and interpass temperatures of the order of 250C-300C are recommended followed by retarded cooling and a stress relieving heat treatment of 650-700C. As for 14, except that a matching 5% Cr - 1/2 Mo hydrogen controlled electrode is essential for matching strength and corrosion. An alternative approach of using Unicord 312 is acceptable for joints not subject to thermal fatigue conditions and allows the use of lower preheat temperatures and higher interpass temperatures.
179
CONTENTS

WIA WELDABILITY REFERENCE NUMBERS AND RECOMMENDATIONS 15 16 17 Should be welded with a type 420 filler metal for matching chemical analysis and mechanical properties. However, Staincord 309Mo-16, Unicord 312 are suitable austenitic, stainless steel electrodes for repair welds. A preheat and interpass temperature of 200C is recommended, immediately followed by a post weld heat treatment of 370C. Allow component to cool to 40C and post heat a second time, to ensure optimum properties. This class of alloy is best treated by water quenching during welding and remains a tough austenitic structure, unless reheated above 400C. Use 1220-A4 type electrode, for build-up or reclamation and Unicord 312 for butt and fillet welds. The base metal should be kept cool during welding by intermittent quenching, skip welding etc. The use of hydrogen controlled consumables is compulsory for welding Quenched and Tempered (Q & T) steels. Electrodes and wires providing matching strength to the structural grades are recommended for butt welding, however, consumables of under-matching strength such as Austarc 18TC, 77 may be suitable for fillet welding applications on both structural and abrasion resistant grades.
Because of the risk of stress relief cracking, post weld heat treatment of Q & T steels should not be undertaken, unless absolutely necessary. If so stress relieving temperatures should not exceed the tempering temperature of the Q & T steel being welded. Refer to WTIA Technical Note 15 for complete details on the welding of Q & T steels. The following minimum pre-heat temperatures, maximum interpass temperatures and maximum arc heat input energies should be used as a guide for welding both structural and abrasion resistant grades of Q & T steels.
180
CONTENTS
GRADE OF Q & T STEEL
<13
13 ~15
25 ~50
<50
HIGH STRENGTH GRADES 450 MPa min. Yield Stress 620 MPa min. Yield Stress 680 MPa min. Yield Stress ABRASION RESISTANT GRADES 320 HB (3000/10) 360 HB (3000/10) 500 HB (3000/10) ALL GRADES ALL GRADES
MINIMUM PREHEAT TEMPERATURES (C) (HIGH RESISTANT) 10 50 50 50 50 100 25 100 100 100 100 100 75 125 125 125 125 150 10 150 150 150 15 -
MAXIMUN ARC HEAT INPUT (kj/mm) 2.5 3.5 4.5 5.0
150
MAXIMUM INTERPASS TEMPERATURES (C) 175 200
220
181
CONTENTS

STEEL TYPES
STEEL DESIGNATION CHEMICAL ANALYSIS (%) C Mn WIA WELDABILITY REF: NUMBER 1,1A 3 4 4 5 6 8 7 7 10 11 11 12 LOW CARBON AND MILD STEELS .10 max .20-.50 .18-23 .30.60 .18-23 .70-1.00 .22-28 .30-60 MEDIUM CARBON STEELS .28-.34 .60-.90 .32-.38 .60-.90 .35-.42 .70-1.00 .37-.44 .60-.90 .43-.50 .60-.90 HIGH CARBON STEELS .48-55 .60-.90 .50-.60 .60-.90 .55-.60 .60-.90 .65-.75 .60-.90
1008 1020 1022 1025 1030 1035 X 1038 1040 1045 1050 1055 1060 1070
FREE MACHINING STEELS

STEEL DESIGNATION CHEMICAL ANALYSIS (%) C Mn S Pd WIA WELDABILITY REF: NUMBER
RESULPHURISED AND RESULPHERISED-REPHOSPHORISED GRADES 1110 .06-.11 .30-.60 .05-1.0 2A X1112 .08-.15 1.10-1.40 .20-.30 3A 1214 .15 max .80-1.20 .25-.35 3A 1137 .32-.39 1.35-1.65 .08-.13 9A 1144 .40-.48 1.35-1.65 .08-.13 11A 1146 .42-.49 .701-.00 0.089-.13 9A X1147 .40-.47 1.60-1.90 .10-.35 11A RESULPHURISED AND RESULPHERISED-REPHOSPHORISED GRADES 12L14 .15 max .80-1.20 .25-.35
182
CONTENTS
.15 -.35
2A
STEEL TYPES
STEEL DESIGNATION CHEMICAL ANALYSIS (%) C Mn WIA WELDABILITY REF: NUMBER 5 6 8 10 WIA WELDABILITY REF: NUMBER
X1320 X1325 X1330 X1340 STEEL DESIGNATION
CARBON-MANGANESE STEELS .18-.23 1.40-1.70 .23-.28 1.40-1.70 .28-.33 1.40-1.70 .38-.43 1.40-1.70 CHEMICAL ANALYSIS (%) C Mn Si Cr
SPRING STEELS XK 55S .50-.60 .70-1.00 .10-.35 .70-.90 11B XK 5160S .50-.65 .70-1.00 .10-.35 .70-.90 12B XK 9258S .50-.65 .70-1.05 1.60-2.20 12B XK 9261S .50-.65 .70-1.00 1.80-2.20 1 12B ALLOY STEELS (FOR OTHER THAN SPRING APPLICATIONS) 5155 .50-.60 .70-1.00 .10-.35 .70-.90 11 5160 .55-.65 .70-1.00 .10-.35 .70-.90 12 9255 .50-.60 .70-1.05 1.60-2.20 12 9261 .50-.65 .70-1.00 1.80-2.20 .10-.25 12 STEEL DESIGNATION CHEMICAL ANALYSIS (%) C .40 .50 .40 .30 .40 Mn Si Ni Cr Mo Other
4140 XK 4150 4340 XX9931(en 26) XX9940 (en 26)
ALLOY CONSTRUCTION STEELS .60 .25 .90 .20 1.30 .25 .65 .18 5.08 .60 .25 1.50 1.0 .25 .60 .25 2.50 .50 .20 .60 .25 2.50 .50 .20 -
WIA WELDABILITY REF: NUMBER 12C 12C 12C 11C 12C
183
CONTENTS

STEEL TYPES
STEEL DESIGNATION CHEMICAL ANALYSIS (%) C .20 .20 .12 .15 Mn Si Ni Cr Mo WIA WELDABILITY REF: Other NUMBER 6 5 9C 12 CASE HARDENING STEELS .50 .25 1.75 .25 .80 .25 .50 .50 .20 .50 .25 3.20 .90 .50 .25 4.20 1.20 .20 CHEMICAL ANALYSIS (%) C Mn SI Cr
4620 8620 En 36A XK9315 (en 398)
STEEL DESIGNATION
WIA WELDABILITY REF: NUMBER 7B 7B 7B 14 14A
Mn-Mo 1/2Cr - 1/2Mo 1Cr - 1/2Mo 2 1/4Cr - 1Mo 5Cr - 1/2Mo
FERRITIC CREEP RESISTANT STEELS .20 1.40 .45 .15 .50 .50 .50 .12 .50 1.10 .50 .12 .50 2.30 1.0 .12 .50 5.00 .60
184
CONTENTS
STEEL TYPES
STEEL DESIGNATION Mn Si Cr Ni Mo S Other
CHEMICAL ANALYSIS (%) WIA WELDABILITY REF: NUMBER
718 STAVAX IMPAX SUPREME 12C 12 12C 12 15 12C 12C 12C 11 12C 15 12
.33 .38 .33
V.30 12 15 12
M200
.40
CSM2
.30
HOLDER BLOCK
.50
CSM2 MAXEL H.B 420 MFQ
.30 .50 .35
THYRODUR 2767 THYROPLAST 2311 THYROPLAST 2312 THYROPLAST 2162 THYROPLAST 2399S THYROPLAST 2083
.45 .40 .40 .21 .40 .42
PLASTIC MOULD STEEL ASSAB .80 .30 1.80 .90 .20 .07 .50 .80 13.60 1.40 .30 1.80 .80 .20 .008 BOHLER STEEL 1..50 .40 1.90 .20 COMMONWEALTH STEEL .75 1.70 .40 MAXEL 1.0 .0 13.0 STEEL MARK - EAGLE GLOBE .80 .50 1.65 .40 1.25 .65 .18 .08 1.0 1.0 13.0 THYSSEN 1.40 4.0 .30 1.50 1.90 .20 1.50 1.90 .20 1.30 1.20 1.30 1.65 .15 .08 1.30 -
CONTENTS
185
186
CHEMICAL ANALYSIS (%) Si Cr Ni Mo S Other WIA WELDABILITY REF: NUMBER
CONTENTS
STEEL TYPES
STEEL DESIGNATION
Mn
8407 SUPREME QRO 90 13 13 13
.37 .04
1.0 .75
13 13
VEW W302 VEW W320 VEW W321 V.50 V1.0 V1.0 CO V.5 V1.0
.39 .31 .39
V1.0 V.5 V5.CO
NU - DIE V
.40
.40
13 13 13 13 12C
ADIC
.40
THYROTHERM 2344 THYROTHERM 2885 THYROTHERM 2713
.40 .32 .55
HOT WORK TOOL STEELS ASSAB .40 1.40 5.30 1.0 2.60 2.25 BOHLER STEEL 1.0 5.0 1.30 0 2.90 2.80 2.90 2.80 COMMONWEALTH STEEL 5.0 1.30 STEEL MARK - EAGLE GLOBE 1.0 5.0 1.30 THYSSENN 1.0 5.30 1.40 .30 2.80 .70 1.70 .30
STEEL TYPES
STEEL DESIGNATION Cr Ni Mo S Other
Mn
Si
XW10 XW41 XW5 +W DF2 V.2 W.5 W.70 W.10 W.20 V.2 W2 V.2 W2 V.1 W.5 V.10 V.10 V.10 13 13 13 13 13 13 13 13 13 13 13 3 13
1.0 1.55 2.50 .90
.60 .30 .80 1.20
V.20 V.80 W1.3 W.51V.1
13 13 13 13
K100 K105 K107 K110 K245 K305 K450 K455 K460 K510 K605 K630 K720
2.0 1.60 2.10 1.55 .63 .98 .48 .63 .95 1.18 .52 .85 .90
1.10 1.10 .30 .20
COLD WORK TOOL STEELS ASSAB .20 5.30 1.0 .30 12.0 .80 .30 12.50 .50 BOHLER STEEL 11.50 11.50 .60 11.50 11.50 .70 1.10 .60 5.10 1.0 .90 1.0 1.10 .50 .25 .70 1.0 3.10 .20 .80 .40 -
187
CONTENTS
188
CHEMICAL ANALYSIS (%) Cr Ni Mo S Other WIA WELDABILITY REF: NUMBER
CONTENTS
STEEL TYPES
STEEL DESIGNATION
Mn
Si
SC 23 SC 25 TOH NSS6 SRS V1.0 V1.0 W.2 V.2 13 13 13 3 13
2.0 1.50 .93 .70 .60
2.0 .20 1.20 1.90 .80
Z.25 W.5 V.1 V.15
13 13 13 13 13
THYRODUR 2379 THYRODUR 2842 THYRODUR 2250 THYRODUR 2767 THYRODUR 2101
1.55 .90 .60 .45 .65
2.0 .80
COLD WORK TOOL STEELS - CONT. STEEL MARK - EAGLE GLOBE .30 12.0 .30 12.0 .75 .20 .50 .30 1.0 1.35 1.60 .35 .40 THYSSEN 12.0 .70 .40 .60 1.10 1.40 4.0 .30 .90 -
STEEL TYPES
STEEL DESIGNATION Si 1 4 5 5 5 5 6 12 12 Ni Cr Mo Cu
Mn
200 250 or L15 350 or L15
WR350/1 or L0
7-460 R,N,A,T 5-490 N or A 7-490 R,N,A,T
31kg or 41kg 50kg or 60kg
AS 3678, STRUCTURAL STEELS - ORDINARY WELDABLE GRADE .15 .60 .35 .22 1.70 .55 .22 1.70 .55 AS 3678, STRUCTURAL STEELS - WEATHET RESISTANT WELDABLE GRADES .14 1.70 .55 AS 1548, STEEL PLATES FOR BOILERS AND PRESSURE VESSELS .20 .90-1.70 .60 .30 .25 .10 .30 .24 .90-1.70 .60 .30 .25 .10 .20 .24 .90-1.70 .60 .30 .25 .10 .30 AS 1085.1, RAIL STEELS .53-.69 .60-.95 .15-.35 .66-.82 .70-1.00 .15-.15 -
CONTENTS
189

STEELS TO SHIPPING CLASSIFICATION SOCIETY RULES
STEEL DESIGNATION CHEMICAL ANALYSIS (5) C Mn WIA WELDABILITY REF: NUMBER 3B 3B 4B 4B 3B 4B 3B 3B 4B 4B 3B 4B 4B 3B 3B 4B 4B LLOYDS REGISTER OF SHIPPING .23 .21 .80 min .21 .60 min .18 .70 min AMERICAN BUREAU OF SHIPPING CLASS A .23 CLASS B .21 .80-1.10 CLASS CS .16 1.00-1.35 CLASS DS .16 1.00-1.35 CLASS D .21 .70-1.35 CLASS E .18 .70-1.35 DET NORSKE VERITAS GRADE NVA .23 GRADE NVD .21 .60 min GRADE NVE .18 .70 min BUREAU VERTITAS GRADE A GRADE B .21 .80-1.40 GRADE D .21 .60-1.40 GRADE E .18 .70-1.50 GRADE A GRADE B GRADE D GRADE E Single values unless otherwise stated are maxima.
190
CONTENTS
CHEMICAL ANALYSIS (%) (DEPENDING ON PLATEN THICKNESS) Si 0.20 .25 .25 .45 .22 2.80 2.80 1.60 1.60 .17 .79 .40 .40 .40 .45 17 17 14 17 0.90 17 0.20 to 0.003 0.20 0.02 B. 0010 17 17 Ni Cr S Mo Ti Other WIA WELDABILITY REF: NUMBER
MIN STEEL YIELD DESIGNATION STRESs (MPa)
Mn
BISPLATE 60 BISPLATE 70
0.16 to
1.10 to
80 & 80PV
0.18
1.40
HY 80 HY 100 WEL-TEN 60 WEL-TEN 80C
500 600 620690 550 690 450 690
.14 .14 .11 .10
.30 .30 1.22 .85
WEL-TEN 80E .30 .90 .57 .50 -
686
.18
.18
.90
.23
.10
.40
V. 04 B. 001 V. 04 Cu. 28 V. 03 B. 004
USS T1
690
.16
.85
B. 004 V. 04 Cu .30 .02 B. 001 V 04
17 17
STEEL TYPES - QUENCHED AND TEMPERED STEELS (A) (A) HIGH STRENGTH STRUCTURAL STEELS
USS T1 TYPE A .30 .55 -
690
.18
.90
.20
CONTENTS
191
192
CONTENTS
STEEL DESIGNATION Si .40 .40 .35 .25 17 17 17 7 .25 .25 .40 B .003 .60 .10 .002 Cu .28 .40 .002 B .001 .90 .35 . .002 Cu .35 .70 .35 .002 17 .85 .85 .95 .20 .20 .15 .03 .03 .04 .002 .002 .002 17 17 17 Ni Cr S Mo Ti Other
TYPICAL CHEMICAL ANALYSIS RANGE (%) (DEPENDING ON PLATEN THICKNESS) WIA WELDABILITY REF: NUMBER
BRINDAL HARDNESS (HB)
Mn
320-360 360-400 400-460
.18 .28 .18
1.15 1.15 .50
BISPLATE 320 BISPLATE 360 BISPLATE 400 WEL-TEN AR 320
321 min
.18
1.10
361 min
.18
1.10
361 min
.18
1.10
STEEL TYPES - QUENCHED AND TEMPERED STEELS (B) ABRASION RESISTANT GRADES
WEL-TEN AR 360C WEL-TEN AR 360E WEL-TEN AR 500E
477 min
.18
1.20
193
CONTENTS
COMMON WELDING TROUBLES

1 UNDERCUTTING
2 CRACKED
WELDS
3 POROUS
WELDS
4 POOR
PENETRATION
194
CONTENTS
8 SPATTER
7 OVERLAPPING
6 INCLUSIONS 5 LACK OF
FUSION
195
CONTENTS

WHY
UNDERCUTTING
WHAT TO DO
1. Pause at each side of the weld bead when using a weaving technique 2. Use proper electrode angles 3. Use proper welding current for electrode size and welding position 4. Reduce arc length 5. Reduce travel speed
1. Faulty electrode manipulation 2. Welding current too high 3. Too long an arc length 4. Too fast travel speed 5. Arc blow
6. Reduce effects of arc blow
WHY
CRACKED WELDS
WHAT TO DO
1. Adjust weld size to part thickness 2. Reduce joint restraint through proper design 3. Select the proper joint design 4. Use more ductile filler 5. Reduce cooling rate through preheat 6. Properly clean base metal prior to welding
1. Insufficient weld size 2. Excessive joint restraint 3. Poor joint design and/or preparation 4. Filler metal does not match base metal 5. Rapid cooling rate 6. Base metal surface covered with oil, grease, moisture, rust, dirt or mill scale
196
CONTENTS
1. Excessively long or short arc length 2. Welding current too high 3. Insufficient or damp shielding gas 4. Too fast travel speed 5. Base metal surface covered with oil, grease, moisture, rust, mill scale, etc
WHY
POROUS WELDS
WHAT TO DO
1. Maintain proper arc length 2. Use proper welding current 3. Increase gas flowrate and check gas purity 4. Reduce travel speed 5. Properly clean base metal prior to welding 6. Properly maintain and store electrode
WHY
POOR PENETRATION
WHAT TO DO
1. Decrease travel speed 2. Increase welding current 3. Increase root opening or decrease root face 4. Use smaller electrode 5. Use electrode with deeper penetration characteristics 6. Reduce arc length
1. Travel speed too fast 2. Welding current too low 3. Poor joint design and/or preparation 4. Electrode diameter too large 5. Wrong type of electrode 6. Excessively long arc length
197
CONTENTS

WHY
LACK OF FUSION
WHAT TO DO
1. Reduce travel speed 2. Increase welding current 3. Weld design should allow electrode accessibility to all surfaces within the joint 4. Reduce electrode diameter 5. Reduce effects of magnetic arc blow 6. Use proper electrode angles
1. Improper travel speed 2. Welding current too low 3. Faulty joint preparation 4. Too large an electrode diameter 5. Magnetic arc blow 6. Wrong electrode angle
WHY
INCLUSIONS
WHAT TO DO
1. Completely remove slag between passes 2. Use a uniform travel speed 3. Reduce width of weaving technique 4. Use a smaller electrode size for better access to joint 5. Increase travel speed or change electrode angle or reduce arc length 6. Properly prepare tungsten and use proper current
1. Incomplete slag removal between passes 2. Erratic travel speed 3. Too wide a weaving motion 4. Too large an electrode 5. Letting slag run ahead of arc 6. Tungsten spitting or sticking
198
CONTENTS
WHY
OVERLAPPING
WHAT TO DO
1. Increase travel speed 2. Use proper electrode angles 3. Use a smaller electrode size
1. Too slow travel speed 2. Incorrect electrode angle 3. Too large an electrode
WHY
SPATTER
WHAT TO DO
1. Attempt to reduce the effect of arc blow 2. Reduce welding current 3. Reduce arc length 4. Properly maintain and store electrodes
1. Arc blow 2. Welding current too high 3. Too long an arch length 4. Wet, unclean or damaged electrode
199
CONTENTS
SI UNITS AND CONVERSION DATA

AUSTRALIAN INDUSTRY IS NOW FULLY CONVERTED TO THE S.I. (SYSTEME INTERNATIONAL) SYSTEM OF UNITS. In the S.I. system there are seven base units, from which other units are derived: QUANTITY length mass time electric current Thermodynamic temperature luminous intensity amount of substance NAME SYMBOL metre m kilogram kg second s ampere A kelvin K candela cd mole mol
In the S.I. system the use of factor notations, such as 10 or 10 , are avoided by the use of S.I. prefixes to indicate submultiples and multiples. The prefixes used to denote these, together with their appropriate symbols are shown as follows:
PREFIX deca hecto mega giga kilo X 10 10 10 SYMBOL da h M G k PREFIX deci cent micra nano milli X 10 10 10 10 10 SYMBOL d c
10 10
m u n
Therefore, for example, one millionth of a metre of .000001 m is expressed as one micrometre or 1 um. Some countries employ different unit systems, such as the U.S.A. which uses the imperial system. The following data is provided to assist the user in converting to locally accepted units. LENGTH: 1mm = .03937 in = 39 thousandths of an inch 1 m = 39.3701 in 1 in = 25.4mm 1 m = 3.2808 ft 1 ft = 0.3048m 1 m = 1.0936 yd 1 yd = 0.9144 m 1 km = 49.7097 chain 1 chain = 20.1168 m 1 km = 0.6214 mile 1 mile = 1.6093 km
200
CONTENTS
AREA:
1 mm =. 00155 in 1 m = 1,550 in 1 m = 10.7639 ft 1 m = 1.19599 yd 1 ha = 2.4710 acre 1 km = .3861 sq mile
1 in = 645.16 mm 1 ft = .0929 m 1 yd = .8361 m 1 acre = .4047 ha 1 sq mile = 2.5899 km 1 in = 16.3871 cm 1 ft = .0282 m 1 yd = .7646 m 1000 litres = 1m 1 gal = 4.5461 dm 1 qt = 1.1365 dm 1 pt = 0.5683 dm 1 US gal = 3.7854 dm 1 oz = 28.3495 g 1 lb = 0.4536 kg 1 stone = 6.3503 kg 1 cwt = 50.8023 kg 1 ton = 1.01605 t 1 ton = 22040 lb
VOLUME: 1 cm = .06102 in 1 m = 35.3147 ft 1 m = 1.3080 yd 1 dm = 1 litre = 61.0237 in 1 dm = .2200 gal 1 dm = 0.8799 qt 1 dm = 1.7598 pt 1 dm = 0.2642 US gal MASS:
1 kg = 35.2740 oz 1 kg = 2.2046 lb 1 kg = 0.1575 stone 1,000 kg = 1t = 19.6841 cwt 1t = 0.9842 ton 1t = 2204.6 lb
SPEED: 1 in/min = 25.4 mm/min 1 rn/hr = 16.7 mm/min 1 mm/min = 0.20 ft/hr 1 in/min = 5.0 ft/hr see table 2 tor Travel and Wire Speed Conversion Tables FLOW RATE: 1 L/min = 2.119 ft /hr 1 L/min = 0.264 gal/min 1 ft /hr = 0.125 US gal/min 1 ft /hr = 0.472 L/min 1 US gal/min = 3.785 L/min 1 US gal/min = 8.021 ft /hr
201
CONTENTS

TEMPERATURE The S.I. units of temperature is strictly speaking the Kelvin, K. The temperature unit used widely in Australia and recognised for use in the S.I. system, is however, the degree Celsius - C. Degree Celsius (C) is related to Kelvin (K) by the following formula: Temperature in Kelvin (K) = Temperature in degrees Celsius (C) + 273.15. Therefore, the zero point for Celsius temperature, 0C, is exactly equal to 273.15K. Another temperature unit still used in some countries is the degree Fahrenheit. F - refer to table 3 for 0C F Temperature Conversions. HARDNESS Refer to table 4 for a comparison of Hardness Scales STRESS In the S.I. system, the unit of stress is the newton per square metre, N/m , more popularly known as the pascal (symbol Pa). One pascal represents only a very small unit of stress, so the multiples, kN/m2 or kPa and MN/m or MPa, are frequently used. In the metric system the unit of stress is the kgf/mm whilst the imperial system uses both ton f/in (TSI) and lbf/in (psi) to define stress. NB. 1 MPa = 1 MN/m = 1 N/mm -1,000 kPa 1 MPa = 0.0647 ton f/in (TSI) 1TSI = 15.456 MPa 1 MPa = 145.038 lb f/in (psi) 1 psi = .0069 MPa 1 MPa = 0.1020 kgf/ mm N.B. (70 MPa equivalent to 10,000 psi) 1 kgf/ mm = 9.804 MPa
Refer to table 5 for conversion to various Stress units.
202
CONTENTS
PRESSURE The units of Stress and Pressure are, of course, interchangeable however some of the more popular units used for defining gas and atmospheric pressure are: 1 lbft/in (psi) = 6,895 Pa N.B. (14.5 psi equivalent to 100 kPa) 1 ksi = 1000 psi 1 kPa = 10-2 b (bar) lb = 105 Pa 1 kPa = 9.869 x 10-3atm 1 atm = 1.013 x l05 Pa 1 kPa = 7.501 mmHg 1 mm Hg - 133.3 Pa IMPACT ENERGY In the S.I. system the unit of energy is the joule, J. In the widely employed Charpy-Vee Notch Impact Test the joule is the unit used. One joule, J, is equivalent to 1 newton (force) x 1 metre (distance) in the S.I. system.In metric countries the energy figure commonly quoted is the kilogram metre, kgfm, whilst the imperial system commonly uses the foot pound, ft lbf. 1 J = 0.7376 ft lbf 1 J = 0.1020 kgfm 1 ft lbf = 1.3558J 1 kgfm = 9.8066
Refer to the Impact Energy Conversion table 5 DENSITY The S.I. unit of density is the kilogram per cubic metre, kg/in . In the metric system the unit of density is the gram per cubic centimetre, g/cm . The pound per cubic inch, lb/in , and the pound per cubic foot, lb/ft are units frequently used in the imperial system. 1 kg/m = 10-3 g/cm 1 g/cm = 1,000 kg/m 1 kg/m = 36.1273 x 10-6 lb/in 1 lb/in = 27,679.9 kg/m 1 kg/m = .0624 lb/ft 1 lb/ft = 16.0185 kg/m Some weld metal densities worth noting are: Mild Steel 7.85 x 10 kg/m Stainless Steel 7.95 x 10 kg/m Aluminium 2.7 x lO kg/m Tin Bronze 8.9 x 10 kg/m
203
CONTENTS
204
INCH (Fraction) MM MM 17.4625 17.0656 9.1281 9.9219 47/64 49/64 3/4 0.7656 0.7812 0.7969 0.8125 0.8281 27/32 55/64 57/64 15.0812 14.6844 59/64 15.4781 16.2719 0.6562 16.6687 15.875 0.6406 29/32 15/16 61/64 31/32 63/64 7/8 0.8437 0.8594 0.8906 0.9062 0.9219 0.9375 0.9531 0.9687 0.9844 0.875 0.750 0.7344 9.525 23/32 0.7187 45/64 0.7031 17.8594 18.2562 18.6532 19.4469 19.8433 20.2402 20.6375 21.0344 21.4312 22.2250 21.8281 22.6219 19.050 8.7312 11/16 0.6875 43/64 0.6719 23/64 25/64 13/32 27/64 29/64 15/32 31/62 33/64 17/32 35/64 37/64 0.5937 0.6094 0.625 9/16 0.5781 0.5625 0.5469 14.2875 13.8906 0.5312 13.4937 1/2 0.5156 13.0968 0.500 12.700 53/64 0.4844 12.331 13/16 0.4687 11.9062 51/64 7/16 0.4531 11.5094 25/32 0.4375 11.1125 0.4219 10.7156 0.4062 10.3187 3/8 0.3906 0.375 11/32 0.3594 0.3437 INCH (Fraction) INCH (Decimal) INCH (Decimal)
CONTENTS
INCH (Fraction)
1/16
3/64
1/32
1/64
INCH (Decimal)
MM
0.0469
0.0312
0.0158
0.3969
5/64
0.0625
3/32
0.0781
1.5875
1.1906
0.7937
7/64
9/64
1/8
0.1094
0.0937
1.9844
11/64
5/32
0.1406
0.125
2.7781
2.3812
0.1562
3.5719
3.175
CONVERSION FROM INCHES TO MM
13/64
3/16
0.1719
3.9687
0.1875
4.3656
15/64 19/32 39/64 41/64 21/32 5/8
7/32
0.2031
4.7625
17/64
1/4
0.2344
0.2187
5.1594
5.5562
19/64
9/32
0.2656
0.25
5.9531
0.2812
6.7469
6.35
23.0187 23.4156 23.8125 24.2094 24.6062 25.0031
21/64
5/16
0.2969
7.1437
0.3125
7.5406
0.3281
7.9375
8.3344
TRAVEL AND WIRE FEED SPEEDS

INCHES PER MIN 3 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 45 50 55 60 65 70 75 80 85 90 95 100 INCHES/ MIN 110 120 130 140 150 160 170 180 190 FEET PER HR 15 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 225 250 275 300 325 350 375 400 425 450 475 500 M/MIN 2.79 3.05 3.30 3.56 3.81 4.06 4.32 4.57 4.83 MM PER MIN 76 102 127 152 203 254 305 356 406 457 508 559 610 660 711 762 813 864 914 965 1016 1143 1270 1397 1524 1651 1778 1905 2032 2159 2286 2413 2540 INCHES/ MIN 200 225 250 275 300 325 350 375 400 CM PER MIN 7.6 10.2 12.7 15.2 20.3 25.4 30.5 35.6 40.6 45.7 50.8 55.9 61.0 66.0 71.1 76.2 81.3 86.4 91.4 96.5 101.6 114.3 127.0 139.7 152.4 165.1 177.8 190.5 203.2 215.9 228.6 241.3 254.0 M/MIN 5.08 5.72 6.35 6.99 7.62 8.26 8.89 9.53 10.16
M PER MIN .08 .10 .13 .15 .20 .25 .30 .36 .41 .46 0.51 .56 .61 .66 .71 .76 .81 .86 .91 .97 1.02 1.14 1.27 1.40 1.52 1.65 1.78 1.91 2.03 2.16 2.29 2.41 2.54 INCHES/ MIN 425 450 475 500 525 550 575 600 625
M PER HR 4.6 6.1 7.6 9.1 12.2 15.2 18.3 21.3 24.4 27.4 30.5 33.5 36.6 39.6 42.7 45.7 48.8 51.8 54.9 57.9 61.0 68.6 76.2 83.8 91.4 99.1 106.7 114.3 121.9 129.5 137.2 144.8 152.4 M/MIN 10.80 11.43 12.07 12.70 13.34 13.97 14.61 15.24 15.88
205
CONTENTS
C - F TEMPERATURE CONVERSIONS
The numbers in bold face type refer to the temperatures, either in degrees Celsius (C) or degrees Fahrenheit (F). For example, reading from centre to left, -150F is equivalent to -101C or from centre to right -150C is equivalent to -238F and so on.
C F C -101 -95.6 -90.0 -84.4 -78.9 -73.3 -67.8 -62.2 -56.7 -51.1 -45.6 -40.0 -34.4 -28.9 -23.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2 -11.7 -11.1 -10.6 -10.0 -9.44 -8.89 -8.33 -7.78 -150 -140 -130 -120 -110 -100 -90 -80 .70 -60 -50 -40 -30 -20 -10 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 F -238 -220 -202 -184 -166 -148 -130 -112 -94 -76 -58 -40 -22 -4 14 32 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 5.00 5.56 6.11 6.67 7.22 7.78 8.33 8.89 9.44 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 C F C 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 F 105.8 107.6 109.4 111.2 113.0 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2
206
CONTENTS
F C F 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 69.8 98.6 100.4 102.2 104.0
F C F 167.0 168.8 170.6 170.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8
-7.22 -6.67 -6.11 -5.56 -5.00 -4.44 -3.89 -3.33 -2.78 -2.22 -1.67 -1.11 -0.56 0 0.56 1.11 1.67 2.22 2.78 3.33 3.89 4.44
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
23.9 24.4 25.0 25.6 26.1 26.7 27.2 27.8 28.3 29.4 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6
75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
TEMPERATURE CONVERSION FORMULAE: C = 5 x (F - 32) F = 9 x C + 32 9 5
207
CONTENTS
C - F TEMPERATURE CONVERSIONS
The numbers in bold face type refer to the temperatures, either in degrees Celsius (C) or degrees Fahrenheit (F). For example, reading from centre to left, -100F is equivalent to -38C or from centre to right -100C is equivalent to -212F and so on.
C F C 36.1 36.7 37.2 38 43 49 54 60 66 71 77 82 88 93 99 100 104 110 116 121 127 132 138 143 149 154 160 166 171 177 182 188 193 199 97 98 99 100 110 120 130 140 150 160 170 180 190 200 210 212 220 230 240 250 260 270 280 290 300 310 320 330 340 350 380 370 380 390 F 206.6 208.4 210.2 212 230 248 266 284 302 320 338 356 374 392 410 413 428 446 464 482 500 518 536 554 572 590 608 626 644 662 680 698 716 734 277 382 288 293 299 304 310 316 321 327 332 338 343 349 354 360 366 371 377 382 388 393 399 404 410 416 421 427 432 438 443 449 454 460 C F C 530 540 550 560 570 580 590 600 610 620 630 640 650 660 670 680 690 700 710 720 730 740 750 760 770 760 790 800 810 820 830 840 850 860 F 986 1004 1022 1040 1058 1076 1094 1112 1130 1148 1166 1184 1202 1220 1238 1256 1274 1292 1310 1328 1346 1364 1382 1400 1418 1436 1454 1472 1490 1508 1526 1544 1562 1580
208
CONTENTS
F C F 752 770 788 806 824 842 860 878 896 914 932 950 968
F C F 1598 1616 1634 1652 1670 1688 1706 1424 1742 1760 1778 1796 1814 1832
204 210 216 221 227 232 238 243 249 254 260 266 271
400 410 420 430 440 450 460 470 480 490 500 510 520
466 471 477 482 488 493 499 504 510 516 521 527 532 538
870 880 890 900 910 920 930 940 950 960 970 980 990 1000
TEMPERATURE CONVERSION FORMULAE: C = 5 x (F - 32) F = 9 x C + 32 9 5
209
CONTENTS
COMPARISON OF HARDNESS SCALES

Figures are approx. Actual values to be substantiated by measurement.
ROCKWELL Hardness No. C Scale (HRc) 68.0 66.4 64.0 62.5 60.0 58.8 57.3 55.6 53.5 52.1 50.3 49.6 47.1 45.7 44.5 41.8 40.4 37.9 36.6 35.5 34.3 33.1 32.1 30.9 29.9 28.8 26.6 24.2 22.8 20.5 (18.8) (15.2) (10.0) (6.4) (0.9) VICKERS Hardness No. (Diamond Pyramid) (HV 30) 940 880 800 760 697 670 640 607 569 547 516 508 472 455 440 410 396 372 360 350 339 328 319 309 301 292 276 261 253 241 234 218 196 182 163 143 122 117 MM PER MIN Hardness No. (3000kg/10mm WC ball) (HB) 767 722 698 653 630 601 570 534 541 485 477 444 429 415 388 375 352 341 331 321 311 302 293 285 277 262 248 241 229 223 207 187 174 156 137 116 111 APPROXIMATE TENSILE STRENGTH (MPa) 2,239 2,131 2,020 1,887 1,813 1,703 1,675 1,544 1,496 1,447 1,351 1,294 1,214 1,172 1,144 1,102 1,068 1,034 999 971 945 889 841 814 766 745 689 621 585 523 462 400 386
210
CONTENTS
Value in brackets are beyond normal range.
STRESS AND ENERGY CONVERSIONS

STRESS CONVERSIONS tonf/in
90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0
MPa
1400 1350 1300 1250 1200 1150 1100 1050 1000 950 900 850 800 750 700 650 600 550 500 450 400 350 300 250 200 150 100 50 0
lbf/in (x 1000)
200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0
kgf/mm
140 135 130 125 120 115 110 105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0
kgfm
17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
IMPACT ENERGY CONVERSIONS Joules

160 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0
ft lb
120
110
100
90
80
70
60
50
40
30
20
10
211
CONTENTS
212
CONTENTS
THICKNESS OF DIAMETER, X BIRMINGHAM GAUGE (B/G.) 28 26 25 24 22 20 18 16 14 12 10 3.1 3.9 4.4 4.9 5.6 6.2 7.2 7.8 7.9 9.3 9.6 9.9 11.8 12.5 12.8 15.6 15.7 15.9 19.6 19.8 20.7 23.6 24.9 25.5 27.5 .049 .076 .096 .122 .156 .194 .258 .302 .308 .437 .459 .489 .694 .777 .819 1.22 1.23 1.27 1.93 1.96 2.15 2.77 3.11 3.26 3.78 SHEET OR PLATE OF THICKNESS, X. kg/in WIRE OR ROD DIAMETER, X Kg/50m
WIRE AND SHEET SIZES
INCHES (Decimal)
INCHES (Fractions)
MM
Figures are approx. Actual values to be substantiated by measurement.
0.015625 0.0196 0.0220 0.0247 0.028 0.03125 0.036 0.0392 0.03937 0.046875 0.048 0.495 0.059 0.0625 0.064 0.0785 0.0787 0.080 0.0984 0.0991 0.104 0.118 0.1250 0.128 0.138
1/64 1/32 3/64 1/6 1/8 -
0.397 0.498 0.559 0.628 0.711 0.794 0.914 0.996 1.0 1.191 1.22 1.26 1.5 1.588 1.63 1.99 2.0 2.03 2.5 2.52 2.64 3.0 3.175 3.25 3.5
IMPERIAL STANDARD OF WIRE GAUGE (SWG) 24 22 20 18 16 14 12 10 -
THICKNESS OF DIAMETER, X BIRMINGHAM GAUGE (B/G.) 8 31.4 31.9 35.3 37.4 38.3 39.3 46.2 47.1 49.8 55.0 59.8 62.3 62.3 64.6 70.7 74.8 78.5 99.7 124.6 149.5 174.5 199.4 4.93 5.11 6.24 6.99 7.34 7.71 10.69 11.10 12.43 15.11 17.90 19.42 19.42 20.88 24.97 27.97 30.83 49.72 77.69 111.87 152.34 198.88 SHEET OR PLATE OF THICKNESS, X. kg/in WIRE OR ROD DIAMETER, X Kg/50m
INCHES (Decimal)
INCHES (Fractions)
MM
0.157 0.160 0.177 0.1875 0.192 0.1969 0.232 0.2362 0.25 0.2756 0.300 0.3125 0.3150 0.324 0.3543 0.375 0.3937 0.5 0.625 0.75 0.875 1.0
5/32 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 -
4.0 4.07 4.5 4.762 4.88 5.0 5.89 6.0 6.35 7.0 7.62 7.938 8.0 8.23 9.0 9.525 10.0 12.700 15.875 19.050 22.230 25.400
IMPERIAL STANDARD OF WIRE GAUGE (SWG) 8 6 4 2 1 0 -
NOTE: The Birmingham Gauge is generally employed for uncoated plain carbon steel sheet. The Imperial Standard Wire Gauge (SWG) is commonly used for all steel (inc. stainless) & aluminium wires. It is also used for stainless steel, aluminium and other non ferrous sheets and tubes.
213
CONTENTS
SYMBOLS FOR ELEMENTS AND GEOMETRIC FORMULAE

SYMBOL FOR ELEMENTS Al Aluminium B Boron C Carbon Cb Columbium Cd Cadmium Co Cobalt Cr Chromium Sn Tin V Vanadium Cu Copper H Hydrogen Fe Iron Mg Magnesium Mn Manganese Mo Molybdenum N Nitrogen Ta Tantalum W Tungsten Nb Niobium Ni Nickel O Oxygen P Phosphorus Pb Lead S Sulphur Si Silicon Ti Titanium Zn Zinc
Columbium (Cb) is commonly know as Niobium (Nb). GEOMETRIC FORMULAE LENGTHS: Circumference of a circle = x diameter of circle Arc of a circle = .01745 x angle of arc, in degrees. AREAS: Triangle = 1/2 base x perpendicular height Circle = .7854 x square of diameter = x square of radius Ellipse = .7854 x long axis x short axis Parabola = 2/3 base x height Square = square of the side Rhomboid or Rhombus = base x height Parallelogram = base x height Sector of a circle = 1/2 radius x length of arc Polygon (regular) = 1/2 radius of inscribed circle x length of one side x number of sides VOLUMES:Cone = 1/3 area of circle x perpendicular height Cylinder = area of circle x height Prism = area of base x height Pyramid = 1/3 area of base x perpendicular height Sphere = 4.1783 x radius cubed
214
CONTENTS
NOTES
CONTENTS
SYMBOLS FOR ELEMENTS AND GEOMETRIC FORMULAE
215
NOTES
216
CONTENTS
217
CONTENTS
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WELDING INDUSTRIES OF AUSTRALIA

Hardfacing Gas Shielded Flux Cored Wires

AS/NZS 4855-B - E43 13 A AWS A5.1: E6013

ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

APPROX NO. OF RODS PER KG 103 67 31 20 11

PART NUMBER 12P20 12P25 12P32 12P40 12P50

Coating - Blue/White Stripe Tip - Plain Imprint - WIA 4313A

AS/NZS 4855-B - E43 13 A AWS A5.1: E6013

ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

APPROX NO. OF RODS PER KG 99 63 29 10 6 6

PART NUMBER 13S20 13S25 13S32 13S40 13S50 13S60

Coating - Light Grey Tip - Bronze Imprint - WIA 4916A

AS/NZS 4855-B - E49 16-A U H10 AWS A5.1: E7116-1 H8

ELECTRODES - HYDROGEN CONTROLLED ELECTRODES

LRS 4Ym H10

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

Coating - Light Grey Tip - Blue Imprint - WIA 4918-1A

AS/NZS 4855-B - E49 18-A U H5 AWS A5. 1: E7018-1

ELECTRODES - HYDROGEN CONTROLLED ELECTRODES

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

Coating - Light Grey Tip - Black Imprint - WIA 4918-1A

AS/NZS 4855-B - E49 18-1 U H5 AWS A5.1: E7018-1

ELECTRODES - HYDROGEN CONTROLLED ELECTRODES

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

PACKAGING (KG) Packet 2.2 5.0 5.0 5.0 Carton 11 15 15 15

APPROX NO. OF RODS PER KG 45 26 17 9

PART NUMBER 7725 7732 7740 7750

AS/NZS 4855-B - E49 24 A AWS A5.1: E7024

ELECTRODES - IRON POWDER ELECTRODES

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

PACKAGING (KG) Packet 5.0 5.0 5.0 Carton 15 15 15

APPROX NO. OF RODS PER KG 18 12 6

PART NUMBER 2432 2440 2450

AS/NZS 4855-B - E4311A AWS A5.1: E6011

ELECTRODES - CELLULOSE ELECTRODES

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

PACKAGING (KG) Packet 2.5 5.0 5.0 5.0 Carton 12.5 15 15 15

APPROX NO. OF RODS PER KG 66 33 21 14

PART NUMBER 1125 1132 1140 1150

Coating - Grey Tip - Black Imprint - WIA 309MO-16

AS/NZS 4854-B - E309LMo-16 AWS A5.4: E309MoL-16

ELECTRODES - STAINLESS STEEL ELECTRODES

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

PACKAGING (KG) Packet 2.5 2.5 Carton 12.5 12.5

APPROX NO. OF RODS PER KG 86 55

PART NUMBER SC309MO25 SC309MO32

Coating - Pink Tip - Green Imprint - WIA 316L-16

AS/NZS 4854-B - ES316L-16 AWS A5.4: E316L-16

ELECTRODES - STAINLESS STEEL ELECTRODES

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

APPROX NO. OF RODS PER KG 86 55 27

PART NUMBER SC31620 SC31625 SC31632

Coating - Grey Tip - Red Imprint - Unicord 312

AS/NZS 4854-B - ES312-16 AWS A5.4: E312-16